Single Chamber Melting/Holding Furnaces
Based on customer specifications, Sistem Teknik builds single and multi-chamber aluminum melting/holding furnaces. The capacity of the furnaces ranges from 15 to 150 tons of liquid aluminum, with melting rates of up to 20 tons per hour, and the energy consumption ranges from 500 to 700 kW/ton, depending on the application. Electro-magnetic stirrers, porous plugs, and mechanical or electromagnetic pumps (without a vortex well) are available for these furnaces.
Single chamber aluminum melting/holding furnaces can be stationary or tiltable, depending on the application. These furnaces can withstand thermal and mechanical stresses while operating in harsh foundry conditions. The furnace door is resistant to all damages, thanks to a special sealing clamp system developed as part of a year-long R&D project. The door opens to allow for easy cleaning, charging, and maintenance of the furnace bath.
Sistem Teknik’s aluminum melting furnaces are among the most environmentally friendly furnaces on the market, thanks to the company’s continuous development of furnace technology over the last 40 years. High-quality regenerative burners can be used for clean scrap, while traditional cold air burners can be used for dirty scrap. In addition, to increase the immediate O2 levels after scrap-charging, an O2 injection system can be integrated into the heating system. The furnace atmosphere pressure control system achieves low energy consumption, ensuring an environmentally friendly manufacturing process and low NOx values.
Multi-chamber Furnaces
Multi-chamber furnaces are designed to provide temperature uniformity and higher alloying quality with continuous molten metal transfer between the chambers through an electro-magnetic pump, with a shorter process time. The use of a vortex well allows the furnace to process chips and small scrap.
Scrap is loaded onto the balcony of the scrap chamber in multi-chamber melting furnaces with the bottom-retracted charging machine.
The chamber then pyrolyzes the scrap in a very low O2 environment for 20 to 25 minutes, depending on the scrap type and level of contamination. After the process, the pyrolyzed gas is collected and transferred to the front of the melting chamber’s main burners to be burned for extra energy. This results in an environmentally friendlier process as well as energy recovery. The scrap chambers are also critical for maintaining safety in melting operations by eliminating explosion risks.
While high-efficiency regenerative burners are used in the melting chamber, a cold air burner is used in the scrap chamber to adjust the O2 level in multi-chamber furnaces. The furnace atmospheric pressure remains stable thanks to the fully-automated hood system. This control system avoids the heat or fume from coming out while also removing any excess oxygen inside the furnace that may cause oxidation, by ensuring the furnace atmosphere remains at negative levels.
Turnkey cast houses is an area of expertise for us. This is why provide many additional technologies.
Camera Integration and Software Applications
Camera integration systems in furnaces are becoming increasingly common in the aluminum industry. These systems use cameras and sensors to monitor the interior of the furnace and provide real-time data to operators about the condition of the melt. There are several benefits to using camera integration systems in aluminum melting furnaces, including:
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Improved safety: By allowing operators to monitor the furnace remotely, camera integration systems can reduce the risk of accidents and injuries that could occur from physical inspections.
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Increased efficiency: With real-time monitoring, operators can quickly identify issues with the melt and take corrective action, reducing downtime and improving production efficiency.
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Better quality control: Camera integration systems can help operators identify impurities and other defects in the melt, allowing them to take corrective action and improve the quality of the finished product.
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Reduced energy consumption: By providing operators with more accurate information about the state of the melt, camera integration systems can help reduce energy consumption by optimizing furnace operation.
ST Phoenix: Regenerative Ultra Low NOx Burners
ST Phoenix burners have been uniquely designed for the aluminium recycling process. The special structure of the burner heads allows for lower dross formation and a higher tolerance for contaminated scrap, in addition to a decrease in the emission of greenhouse gasses. ST Phoenix burners use state-of-the-art automation technology. They go through different production phases based on temperature values and initiate the next melting cycle according to the calculation of loading tonnages. In addition to energy efficiency, automation capabilities, and low impact operation, Phoenix presents additional advantages through mechanical innovations that focus on user experience. The alumina ball boxes have been designed with a drop gate mechanism and a quick change lid in order to ensure that the maintenance process is fast and easy.
O2 Injection Systems
Improving the efficiency of the combustion system is pivotal in providing environmentally friendlier solutions for the aluminum industry. Oxygen rate is one of the most crucial variables that influence burner performance in melting furnaces. This is why we have developed an oxygen injection system for our new burner head designs as a part of the Retrofeed project funded by the European Commission within the Horizon 2020 platform.
Electromagnetic Pumps
Electromagnetic pumps and mechanical pumps (EMP/MP) and vortex wells are used for multi-chamber furnaces to ensure the continuous transfer of molten metal between different chambers while also enabling the retrofitting of aluminum chips created during the sawing process. Designed for fully automated operation, EMP/MPs provide high alloying quality and temperature uniformity. Their control system includes a closed-circuit cooling mechanism that is easily tracked on user-friendly interfaces. EMP/MPs are vital in terms of providing the opportunity for aluminium producers to recycle variable sources of scrap. Great performance values are achieved especially with heavy-grade scrap.
Vortex System
The vortex well is located between pre-treatment and melting chambers to feed aluminum chips to the furnace and are crucial in terms of retrofitting aluminum sawdust and reducing metal loss to less than 2%. Liquid aluminum coming out of the melting chamber is fed to the pump inlet line from a certain angle so that it can form a swirl, keeping the aluminum inside the furnace in circulation. This ensures that the temperature in the two chambers is kept close to each other, reducing the energy use in the pre-treatment chamber, and increasing the alloy quality. The hood mechanism used for the vortex well prevents the emission of possible waste gases to the factory environment. Therefore, the amount of aluminum smoke in the factory environment is reduced. The design of the feeding system eliminates the risk of flying chips; since the chips are left in the middle of the vortex formed by the liquid aluminum at a certain speed and angle.
To minizime oxide formation and metal loss, oil/moisture content reduced to 0.5%, and melting furnace charged from a vortex well. The chips are continuously charged with 2 to 5 tons/hour capacity and fed to the melting furnace after moisture and hydrocarbons are removed. The chip is quickly submerged in liquid metal as the melting furnace is fed through the vortex well on the electromagnetic pump, resulting in a metal loss of less than 1%.
Acoustic Chambers
We design and deliver acoustic rooms for aluminum melting furnace fans and eliminate the risk of noise-related hearing loss in the foundry industry. Our solution does not only mitigate the long-term risks posed by high fan noise but also prolongs equipment lifetime by reducing exposure to dust. It also enhances maneuverability during installation and maintenance operations, reducing congestion above the furnaces. Prioritizing safety, durability, and efficiency, our acoustic rooms significantly improve workplace environments in aluminum cast houses.
Porous Plug System
Porous plug systems have been developed for new furnaces as well as existing furnaces to improve the mixing process and to pre-gas the aluminum before casting. In this degassing method, argon or nitrogen gas is passing through liquid aluminum. Because these gases do not react with the liquid and do not dissolve in it, they form bubbles that rise to the surface of the liquid aluminum. The gas should be supplied not only to the surface but also from the very bottom, to increase the efficiency of this process. These bubbles that rise to the surface can clean the liquid by collecting hydrogen gas that is present in it.
The waste gases resulting from the melting process are transferred from the furnaces to the filter baghouse by means of an underground chimney. The toxic gases in the waste gases are cleaned by the filter system and delivered to the air. The melting process is made environmentally friendlier with this system, which can be integrated into melting and holding furnaces.
Air Filters and Baghouse Systems
Filter baghouse units are used to retain dust and coarse particles in the waste gas formed in combustion systems and to reduce the damage caused to the environment. It adjusts the waste gas values given to the environment with low maintenance and energy consumption. In order to increase the filtration performance, the system is reinforced with lime dozing while compressed air is used for bag cleaning.
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