Metal Refining and Alloying
Electromagnetic Stirrer
Sistem Teknik R&D Centre has developed electromagnetic stirrers for melting furnaces to speed up the melting process and minimize dross formation. The stirring process of molten aluminum is carried out without human intervention in aluminum melting furnaces by establishing an electromagnetic field with inductors situated beneath the furnace to maintain a more homogenous heat distribution. As a result of the ease of maintenance and the elimination of the need to open the furnace door, a 15% energy savings will be realized. Thus, the melting process is accelerated and slag formation is reduced.
Launder Systems
Launders are used to transfer molten aluminum from one equipment to another. The molten aluminum that comes out of the melting furnace at 750 degrees is expected to arrive at the casting machine at least 720 degrees. In some cases, molten aluminum departing the melting furnace loses more heat than it should when it is transferred to other equipment or a casting machine.
We design and manufacture electric or gas-fired launders for transferring molten aluminum between furnaces and casting machines.
Electric-heated and insulated covers are used to keep the liquid metal temperatures constant during casting in systems that require low liquid metal transfer rates (continuous casting lines, wire rod casting lines, etc.).
The launder system is made of a strong steel construction that will last for a long time. To ensure quality and safety, multiple layers of insulating materials, including porous plugs, are used to ensure minimal thermal losses. Launders can be cleaned easily with the pneumatic actuation system used for covers.
Launder sizes range from 2 to 50 tons/hour and can be adjusted to meet the needs of the customer.
CFF Filtering Units
The last equipment that molten aluminum passes through before entering the casting machine is a ceramic foam filter. This equipment filters molten aluminum avoids dross and impurities including very large and very small particles regulates the molten aluminum flow, and improves the quality of aluminum alloys by decreasing defects gas space.
Sistem Teknik designs and produces ceramic foam filtering systems (CFF) to remove inclusions generated between the degasser and the casting system. CFFs prevent quality issues during downstream operations. The CFF design is made according to the application as both single chamber and double chamber options exist.
Features:
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Filter sizes: Standard 7″ – 26″ (30-50 PPI)
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Capacity: 2-50 tons/hour of molten aluminum.
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Heating: Flat flame burner
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Heating cover: Pneumatically-tilted
Degassing Units
The hydrogen dissolving capacity of solid aluminum is quite low compared to liquid aluminum. Therefore, in an aluminum alloy that has begun to solidify, aluminum becomes unable to dissolve residual hydrogen gas, and the bulk of the hydrogen gas is released. This causes bubbles to form inside the molten aluminum. If these bubbles that are formed are not removed, aluminum will not have a homogeneous grain structure during the solidification process, and these hydrogen gases cause the porosity in solid aluminum will cause the mechanical structure of the material to be much lower than the desired level.
We design and manufacture degassing units for molten aluminum refining from hydrogen, inclusions, and alkalis. Degassers are used in the log, coil, strip, rod, and small ingot casting lines. Excessive mixing and dross formation are avoided with the special bath design and the use of rotating nozzles. Metal remains at low levels inside due to shortened degassing periods, resulting in efficient processes. The degassing system removes hydrogen by purging intert gases (argon) through the rotating nozzles. Our customers can also receive a chlorine-based alternative system.
Sistem Teknik degassers can be easily installed in existing layouts without taking up extra space, and the system is available in both stationary and tiltable configurations. Stationary degassers have a rotating system that allows for easy maintenance.
Specifications :
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5-50 tons/hour capacity
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Immersion type heaters with two SiC heater elements in a Sialon protective tube
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Ar and N2 are the process gases (Optional Cl)
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Gas injection is accomplished via two graphite rotors (or more)
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The amount of aluminum left in the crucible after casting is 400-1350 kg.
Rod Feeders
Sistem Teknik’s innovative rod feeder design has been registered for patent. We customize our designs to meet all specific requirements because we manufacture rod feeders that are ideal for grain refinement and alloying. Depending on the application, we provide grain refiner wire feeding units as single rod feeding or double rod feeding systems. The AC Motor controls the feeding speed. The AC Motor driver in the control system regulates the feeding speed. Feed control is performed manually via the unit’s control panel or via the PLC in the casting machine control system.
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