Aluminium chips melting furnace

Aluminium chips melting furnace

Aluminum chips and UBC melting furnace with side well vortex stirring melting

What is aluminum chips melting furnace?

An aluminum chips melting furnace is a specialized furnace designed to melt aluminum chips, which are small, irregular pieces of aluminum often produced as waste from machining, cutting, or other aluminum processing activities.

These furnaces are engineered to address the unique challenges associated with melting aluminum chips, such as their high surface area-to-volume ratio, tendency to oxidize rapidly, and potential contamination from oils and lubricants.

Aim at the difficulty in aluminum chips recycling and melting, easy burn loss and floating on the liquid surface, not go down for the melting, we developed a new aluminum chips double chamber melting furnace.   

The liquid aluminum pump will be set up in outside, which will pump out molten aluminum from the reverberatory furnace and send them to the melting chamber; the melting liquid will flow into the reverberatory furnace for heating.

Aluminum chips will be conveyed and dry in the pipe, and thrown into the feeding room.

The aluminum chips will be melted through a special flow channel design (side well model), a whirlpool will be formed in the side well, aluminum chips will be drawn into aluminum liquid by the vortex.  

The chips will melt very fast in high-temperature liquid aluminum and be molten in aluminum liquid.  

More than a 95% recovery rate can be got through an oxygen protection dissolved state.  

Side well aluminum chips melting furnace is the most popular aluminum chips melting equipment in the world, also the new technology for aluminum chips melting.

It is widely used for aluminum chips, UBC, aluminum turnings factory and aluminum chips and scraps recycling industry.

Key Features and Components

1. Design and Construction:

Twin chamber melting furnace with vortex system: Commonly used,  The design helps to minimize oxidation by reducing direct contact with flames.  

2. Loading Mechanism:

Automatic Feed Systems: Many aluminum chips melting furnaces have automated feed systems to efficiently and safely load the chips into the furnace, minimizing exposure to the high-temperature environment and reducing manual labor.

Pre-treatment: Chips may go through pre-treatment steps like drying to remove moisture and cleaning to eliminate oils and contaminants before being fed into the furnace.

3. Heat Source:

Gas Burners: Often used due to their efficiency and ability to provide consistent heat.

Electric Resistance Heating: Sometimes used for its precise temperature control and cleaner operation.

4. Temperature Control:

Precise temperature control systems are essential to prevent overheating, which can lead to excessive oxidation and dross formation.

5. Fluxing Agents:

Fluxing agents may be added to the molten aluminum to help remove impurities and reduce dross formation. Common fluxes include chlorides and fluorides.

6.Degassing Systems:

Degassing systems are used to remove hydrogen and other gases from the molten aluminum, which can cause porosity and other defects in the final cast product.

7. Dross Management:

Systems for effectively skimming and removing dross, the oxidized layer that forms on the surface of the molten aluminum, are critical to maintaining the quality of the melt.

Aluminium chips melting furnace with vortex stirring melting system

Equipment structure description 

Aluminum chips and turnings conveying and drying system, side well stirring melting system, double chamber aluminum melting furnace, power control cabinet, pipe, etc.

Key Features

1. Specialized Design:

Aluminum chips twin chamber melting furnace with vortex system: These furnaces are designed to maximize heat distribution and minimize oxidation. 

Automated Feed Systems: Many furnaces feature automatic feeding mechanisms to handle the small, lightweight chips efficiently, reducing manual labor and exposure to high temperatures.

2. Advanced Heating Systems:

Efficient Heat Source: Gas/oil burners or electric resistance heating systems are commonly used to provide consistent and efficient heat.

Temperature Control: Precise temperature control systems ensure the aluminum chips are heated to the optimal melting point without overheating, which can lead to excessive oxidation.

3.Pre-Treatment Systems:

Chip Cleaning and Drying: Integrated systems to clean and dry the chips before melting, removing oils, lubricants, and moisture that could affect the melting process and quality of the molten aluminum.

4. Fluxing and Degassing:

Fluxing Systems: Addition of fluxing agents to the molten aluminum to remove impurities and reduce dross formation.

Degassing Systems: Equipment to remove hydrogen and other gases from the molten aluminum, preventing porosity and defects in the final product.

5. Dross Management:

Efficient Skimming Systems: Mechanisms to skim and remove dross from the surface of the molten aluminum, ensuring higher quality and reducing waste.

6. Energy Efficiency:

Insulation: High-quality insulation materials to minimize heat loss and improve energy efficiency.

Energy Recovery Systems: Some furnaces incorporate systems to recover and reuse heat, further enhancing energy efficiency.

aluminum chips melting furnaces are specially designed to handle the unique properties and challenges of melting aluminum chips, incorporating advanced features to ensure efficient, clean, and high-quality melting processes.

Benefits

1. Cost-Effectiveness:

Utilization of Waste Material: Aluminum chips are often a by-product of machining processes, and using them as a raw material can reduce overall material costs.

Lower Energy Consumption: Specialized furnaces designed for aluminum chips can melt them more efficiently, potentially using less energy compared to melting larger pieces of aluminum.

2. Environmental Impact:

Waste Reduction: By recycling aluminum chips, these furnaces help reduce industrial waste and the environmental footprint of aluminum processing operations.

Efficient Resource Use: Improved melting efficiency and energy recovery systems contribute to a lower overall environmental impact.

3. Improved Quality Control:

Cleaner Melt: Advanced cleaning, fluxing, and degassing systems ensure that the molten aluminum is of high quality, with fewer impurities and gases.

Consistent Quality: Automated systems and precise temperature control help maintain consistent melting conditions, leading to uniform quality in the final product.

4. Operational Efficiency:

Automation: Automated feeding and dross removal systems reduce the need for manual labor, improving safety and efficiency.

Faster Melting: The high surface area of aluminum chips allows for quicker melting, speeding up production cycles.

5. Versatility:

Handling Various Chip Sizes: The furnace can handle a wide range of chip sizes and shapes, providing flexibility in processing different types of aluminum waste.

Adaptability: Can be adapted for various production scales, from small workshops to large industrial operations.

6. Safety:

Reduced Manual Handling: Automated systems reduce the need for workers to handle hot materials directly, enhancing workplace safety.

Controlled Environment: Precise control over the melting process reduces the risk of accidents and improves overall operational safety.

Technical features of aluminium chips melting furnace

Low energy consumption, equipment power consumption 5-15KW;

Net recovery rate more than 92%;

Achieve aluminum chips and turnings online recovery, save aluminum chips remelting energy consumption, save cost about 100.00USD per ton

The continual operation, simple operation and environmentally friendly

Improve furnace temperature uniformity, extend refractory materials using life.

Aluminum Chips melting furnace with side well vortex stirring.

Contact us to obtain a reliable No-obligation quote, turnkey project and package deal!

In summary, aluminum chips melting furnaces offer specialized features that make them well-suited for efficiently and effectively melting aluminum chips.

They provide significant cost, environmental, and operational benefits, making them an attractive option for aluminum recycling and processing operations.