Integrated Melting System Shows its Mettle
One of the latest equipment systems developed by Pyrotek’s Metaullics division encompasses the vital industrial process area of aluminum scrap melting, using recycled chips. This complete Integrated Melting System (IMS), as it is known, then converts the recovered metal into a reusable product, and most important, at a fraction of the cost to the customer.
Chips are fed into the receiving hopper of the IMS equipment, and are conveyed whilst being dried towards the LOTUSS® Vortex. Fines are removed via a screen, magnets, cyclones and an airlock, and the purest chips are left to reach 300°C (572°F) in the thermal dryer. While using the heat retained in these chips for melting, they are submerged by the LOTUSS and melted below the molten metal surface to minimise the formation of oxides.
A Metaullics T-35SD circulation pump transfers the liquid aluminum into the skim well where oxides can float to the surface for removal. This operation maximises both recovery rates and energy efficiency since the hot exhausted flue gases are recycled back into the chip dryer.
The essential key elements of the IMS equipment and process are:
• Wet chips are received from the customer’s remote machining processes and the cutting fluid from the chips is separated and reclaimed for reuse.
• The chip drying equipment is designed to evaporate water and process material at rates determined by moisture, temperature and particle size. The material is fed at constant rates.
• The type of light-gauge scrap fed into the melting furnace by means of the LOTUSS does have an impact on the yield. By “pulling” dry light scrap material below the surface of the molten metal through the powerful “vortex” created by the LOTUSS system, oxidation of the material is minimised regardless of scrap type. The increases in recovery rate that are realized with the IMS are typically 1-5%, depending on the existing method. For maximum recovery, salt flux may be required.
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