We design and deliver delacquering drum furnaces to increase the scrap share in the aluminium melting process. Delacquering furnaces reduce the annual energy consumption as well as the metal loss during heating and melting processes significantly. The circulation fan system in ST delacqering drum furnaces is designed to maximize energy efficiency. The heat from the cyclone is pressed into the after burner and the volatile organic components are burned together with the heat and used as fuel here. There are many benefits to this thermal cycle, such as reduced costs, energy saving, and a decrease in the emission of greenhouse gases. The use of waste heat from melting furnaces in the de-coating process allows for waste heat recovery, which benefits both the economy and the environment. Post-consumer scraps are permitted to enter the recycling cycle, preventing large amounts of carbon emissions and energy loss.

Sistem Teknik builds scrap charging cars for aluminium melting furnaces in order to optimize the aluminium recycling and production processes. With an innovative camera system, these charging cars use machine learning and IoT solutions in order to provide safe and efficient operations in casthouses.

Here is a recap of what we have been doing the past few years! To learn more about our R&D projects towards making the aluminium industry more eco-friendly, visit our website.

In aluminum melting and holding furnaces, temperature homogeneity and chemical composition are crucial for the quality of the end product. To prevent oxidation and dross formation, we provide electromagnetic stirrers. Homogenous temperature and chemical distribution are ensured by this electromagnetic stirring process. In addition to material efficiency, the melting rate of the furnace is increased significantly due to the preservation of the difference between the temperature of the surface and the bottom of the aluminium bath.

Sistem Teknik builds scrap charging cars for #aluminium melting furnaces in order to optimize the aluminium #recycling and #production processes. With an #innovative camera system, these charging cars use machine learning and #IoT solutions to provide safe and efficient operations in #casthouses. As a result of the wireless communication system with furnaces, the furnace door can be opened and closed over the car. The car can charge 2 to 20 tons of #scrap, #ingot bundles or T-bars due to their heavy construction structure and are available with diesel or electric motor-driven options. It can be designed in two distinct types according to the following purposes: 1- charging scrap to the melting furnace ramp (charging table is retracted – usually used in multi-chamber melting furnaces), 2- charging scrap into the melting furnace’s metal bath through the pusher plate. There are several features that make the charging car designs user-friendly such as the option of exchangeable charging boxes. In addition, the trolley hood that is made upon request prevents the release of gases from the melting furnace door into the foundry atmosphere during loading.

Sistem Teknik designs and produces furnaces for the rapid heating of aluminium logs/billets before the extrusion process. These furnaces are direct gas-heated and have pre-mix jet type nozzle burners that are controlled by the PLC. Through the special arrangement of the burners, the logs/billets are heatedswiftly with low gas consumption (18 Nm3/ton Al.). The temperature is measured within a range that is determined by the surface thermocouples which can be moved back and forth. After the heating process, material surface remains within a range of ± 10 °C. Heating efficiency is maximised by reusing flue gases that generate in the preheating zone. These furnaces are equipped with low thermal mass insulation materials and easily replaceable refractory blocks for insulation. The use of insulating materials with low heat retention capacity prevents melting. The furnace transfer system has a roller conveyor and is designed to work in congruity with the hot billet cutting machines. The first 200 mm can be heated above the set values with the front heaters and the last zone burners located at the furnace outlet (tapper heating).