Aluminum refining and degassing equipment

 

 

Stationary rotary degassing and fluxing equipment

 

Usage
• A graphite rotor is immersed in the molten aluminum in a crucible (or ladle) to rotate while a high-purity inert gas such as nitrogen (or argon) and refining agent are injected into the molten aluminum for the purpose of degassing, slag removal and molten aluminum refinement.

 

 

Equipment Features
• Able to remove gases (mainly hydrogen) and oxides from molten aluminum more effectively. The equipment has the advantages of both gas refining and flux-refining, with steady effects achieved.
• Low metal loss. After proper flux-refining, there is less dross on the melt surface and the dross is loose; the metal is rarely encased and little metal is taken out during slag removal.
• Low consumption of refining agent, and uniform feeding.
• Equipped with an anti-falling mechanism, a refining agent material level measurer and an air channel leakage detector.
• Multiple technological processes can be executed. When used with different functions of fluxes, it can be used for high-efficiency modification, degassing and slag removal.
• The rotor bearing is a high-temperature bearing, not needing to be air-cooled. The spindle can work without stop at a high temperature of 200°C.
• The dynamically rotary cantilever supports double-position degassing.

 

 

Technical Parameters
• Refining time: 0~99min
• Refining effect: pinhole degree up to level 1, density<1
• Gas flow during refining: 12~40NL/min
• Inert gas for degassing: N2 or Ar with purity of over 99.996%
• Gas working pressure: 0.1-0.4MPa
• Melt temperature: 640－850°C
• Amount of molten aluminum treated: 800－3000kg
• Rotor speed: 0-600r/min (max1000)

 

Stationary rotary degassing and fluxing equipment

 

 

Injection refining equipment

 

Usage
• The injection refining equipment is used for refining, degassing and slag removal of molten aluminum in a static furnace.

Equipment Features
• Good refining effects. The equipment has the advantages of both gas refining and flux-refining.
• Low consumption of refining agent, and uniform feeding.
• Low metal loss. After proper flux-refining, there is less dross on the melt surface and the dross is loose.

• The metal is rarely encased and little metal is taken out during slag removal.

 

Technical Parameters
• Barrel capacity: 15L, 30, 45L
• Refining gas type: high-purity nitrogen or argon
• Refining gas pressure: 0.1－0.4MPa
• Maximum refining gas flow: 300NL/min
• Flux flow: 0-3000g/min
• Flux size: 10－70 meshes

 

 

Injection refining equipment	Injection refining equipment

 

 

Box type in-line rotor degassing unit (BDU)

 

• Dehydrogenation/impurity removal/dealkalization!
• One of the most effective molten aluminum degassing technologies, the first choice for high-end aluminum castings!

 

Equipment Introduction
• The BDU is usually installed between the discharge outlet of the smelting furnace and the filter box. Melts flow into the BDU and rotate the rotor to break inert gases, forming a large quantity of dispersed bubbles, which then enter into the aluminum melts. After collision, capturing, surface adsorption and partial pressure action, the bubbles rise with gases and take hydrogen and oxide slags out of melts, making them into scums. Then, aluminum melts outflow from the degassing unit outlet, thus realizing the purpose of continuous in-line refining.
• The BDU offers more advantages than the commercially available mainstream box-type degassers. For example, multiple key technologies, such as box tightness and anti-turbulent flow on molten aluminum surface, have been improved, ensuring the high-efficiency, continuously stable and low-cost operation of the degassing unit.

 

 

Equipment Features
• Degassing efficiency is above 60%
　- Optimized dispersion of process gases in melts;
　- The maximum area and time of contact between dispersed bubbles and melts;
　- The box is completely sealed, ensuring a stable inert gas environment;
　- There is no turbulent effect on the melt surface.
• Easy to install and maintain. The lining of the preformed degassing box is easy to replace, minimizing production downtime.
• Long component life, low maintenance and operation costs.
　- The heater and heater protection tube have a service life of more than 3 months;
　- The box has a service life of more than 1 year;
　- The rotor and rotating shaft have a service life of more than 3 months;
　- Gases can be cooled without the rotor rotating the main shaft.
• The problem of excess aluminum storage in the box is solved.
　- A wholly tiltable degassing unit is optional. It can be tipped over at a specified time before the end of casting to pour all molten aluminum stored in the box into the launder to finish casting, thus solving the problem of excess aluminum storage in the box.

 

 

Main Performance Parameters

Items	Parameters
Maximum temperature of molten aluminum	750℃
Precision of molten aluminum temperature control (static)	±2℃
Melt heating ability	≥20℃/h
Launder surface temperature rise	≤40℃
Launder lining life	≥12 months
Continuous service life of heater	≥3 months
Heater protection tube	≥4 months
Continuous service life of rotor	≥3 months
Rotor speed (stepless speed regulation)	100-500rpm
Gas refinement	High-purity Ar or high-purity N2: pressure 0.2-0.5 MPa, purity ≥99.996%, Water (ppm) ≤3, Oxygen (ppm) ≤5
Degassing efficiency	-Hydrogen content≤0.12ml/100g after degassing under the following conditions: ≤maximum flow rate, hydrogen content at the inlet≤0.30ml/100gAl, molten aluminum temperature at a range from 700 oC to 740 oC; -Degassing efficiency≥60% when hydrogen content at the inlet>0.30ml/100g-Al.
Dealkalization effect	Each alkali metal content<10ppm before refining, each alkali metal (Na, Li, Ca) content <2ppm after refining
Power supply	Power Supply：380V AC  50Hz，≤60kw

　Notes: Mixed gases, such as chlorine and argon, can be added as the case may be.

　　　The degassing effect refers to 3xxx alloy.

 

Main performance parameter specifications of the BDU

Specifications  Items	Number of Rotors	Maximum Molten Aluminum Flow t/hr	Maximum Gas Consumption L/min	Heating Power kw	Number of Heaters
BDU-15	1	15	90		1
BDU-30	2	30	140		2
BDU-50	2	50	160		2
BDU-70	3	70	180		3

　Notes: Customizable according to customer needs
　1. Three-chamber/four-chamber degasser
　2. Degassing box tipping function or overall degassing box (with launder) tipping function are available to choose from.

 

 

Launder type in-line rotor degassing unit (LDU)

 

• Easy to use, efficient, flexible, low-cost

 

Equipment Introduction
• The LDU has higher degassing efficiency because degassing rotors are mounted between the melting furnace and casting machine in the length direction of the launder and the degassing zone is partitioned into several parts for multilevel in-line degassing. The number of rotors depends on the flow rate of molten aluminum.

 

 

Equipment Features
• The degassing efficiency is high, above 40%. Continuous degassing in multiple sub-zones increases the area and time of contact between bubbles and molten aluminum; seal design is adopted. During the whole casting process, there is an inert headspace maintained on the surface of molten aluminum to avoid the generation of more slags and prevent secondary pollution to improve the degassing efficiency.
• Low use cost and maintenance cost. The molten aluminum heating and heat preservation system is removed, reducing consumption; launders are adopted for degassing, reducing the residual amount of molten aluminum and the loss of metal; it’s easy to replace launders.
• Easy to install. Small size and low weight, space-saving; needless to install the required structure or foundation; installed in the joint positions of launders; a short period of time is required for on-site commissioning, saving production downtime.
• Convenient for alloy conversion. There is no heating device or deep box, so after the end of each casting, most of the degassed metal is made into products with the residual molten aluminum in the degassing launders cleared away, facilitating alloy conversion.
• Easy to use. No special starting procedure; a simple molten aluminum drainage device; convenient slag removal and simple working conditions.
• Especially suitable for semi-continuous casting lines for the production of cast rods and renewable aluminum ingots. This casting technology is featured by frequent replacement of alloys without a very high dehydrogenation level.

 

 

Main Performance Parameters

Items	Parameters
Maximum temperature of molten aluminum	750℃
Launder surface temperature	≤60℃
Launder lining life	≥12 months
Rotor speed	100-600rpm
Inert gases	High-purity N2, high-purity Ar
Degassing efficiency	The content of hydrogen in molten aluminum can be reduced below 0.22ml/100g under the following conditions: ≤maximum flow rate, hydrogen content at the inlet≤0.30ml/100gAl, molten aluminum temperature at a range from 700 oC to 740 oC; degassing efficiency≥35% when hydrogen content at the inlet>0.30ml/100gAl.
Power supply	380V AC  50Hz，≤10KVA

 

Specifications of the LDU

Items       Specification Code	LDU-2	LDU-3	LDU-4	LDU-5	LDU-6	LDU-7	LDU-8
Number of Rotors	2	3	4	5	6	7	8
Maximum Molten Aluminum Flow t/hr	8	15	20	25	30	35	40
Maximum Gas Consumption L/min	90	140	180	270	360	420	480

 

 

CFF Filtration Box (CFB)

 

• The most widely used high-efficiency filtration system

Equipment Introduction
- The CFB is widely used for molten aluminum filtration in the aluminum casting process to prevent the particulate impurities in molten aluminum from entering the casting blank and affecting the quality of aluminum products.
- A satisfactory filtration effect can be achieved if a right type of filtration box and correct specifications of the CFF filtration board are selected in accordance with the quality requirements of casting products, the flow rate of molten aluminum, the total filtration amount of molten aluminum and the purity of molten aluminum.

 

CFF filtration board	CFF filtration board	CFB filtration box lining

 

 

CFB filtration box	CFB filtration box

 

Filtration Box Features
• Significant filtration effects. It meets the production requirements of ordinary products and even the stringent production requirements of aluminum alloy can materials, aero-metals and other relevant materials. The filtration box can effectively filter out bulk inclusions in the molten aluminum, adsorb small inclusions in the molten aluminum, refine the crystalline structure of castings, reduce the content of hydrogen in the molten aluminum and lower the content of harmful elements such as Na and K in the molten aluminum by adsorption.
• The filtering method is easy to use. Standardized and serialized production of the CFF filtration boards has been realized. Different filtration effects can be achieved if filtration boards with different pore sizes (20-60ppi) are combined together in use according to the quality and flow requirements of molten aluminum.
• Economical. The filtration board has high strength and resistance to abrasion by molten aluminum, good thermal shock resistance and a long service life; the heating cover ensures that one filtration board can be reused more than 6 times in the filtrate, thereby reducing the cost of consumables; the lining of the filtration box, similar to that of the degassing box, has high aluminum tolerance, heat preservation and resistance to thermal and cold shocks, and has a longer service life.
• Easy to install and maintain. The preformed lining of the filtration box is easy to replace, minimizing production downtime.

 

Main performance parameters of the CFB filtration box
- Maximum temperature of molten aluminum: 750°C
- Surface temperature: ≤70°C
- Lining life: ≥12 months

Common specifications of CFB filtration box

Filtration Box Type	Code	Filtration Board Size inch	Flow Range t/h	Remarks
Single-stage filtration box	CFB1-12	12	2-5	A single filtration board is placed in the filtration box to filter out more than 85% of the inclusions with a particle size ≥8μm
	CFB1-15	15	4-10
	CFB1-17	17	8-15
	CFB1-20	20	12-20
	CFB1-23	23	16-25
Horizontal two-stage filtration box	CFB2-12/12	12/12	2-5	Two-stage filtration boards with different pore sizes from large to small are placed in the filtration box horizontally or vertically to filter out more than 95% of the inclusions with a particle size ≥8μm
	CFB2-15/15	15/15	4-10
	CFB2-17/17	17/17	8-15
	CFB2-20/20	20/20	12-20
	CFB2-23/23	23/23	16-25
Vertical two-stage filtration box	CFB2-15/12	5/12	2-5
	CFB2-17/15	17/15	4-10
	CFB2-20/17	20/17	8-15
	CFB2-23/20	23/20	12-20
Two-channel filtration box	CFB-12/12	12/12	2-5×2	Two channels in the filtration box for parallel arrangement of filtration boards of the same pore size. Used for continuous filtration of molten aluminum, one for use while the other as backup; used for filtration of large-flow or high-viscosity molten aluminum. Both channels meet the flow requirements together.
	CFB-15/15	15/15	4-10×2
	CFB-17/17	17/17	8-15×2
	CFB-20/20	20/20	12-20×2
	CFB-23/23	23/23	16-25×2

　Notes: Use a heating unit as needed.

 

 

Molten aluminum transfer launder

 

The three performance guarantee parameters of the launder：
• Launder temperature drop (with a cover and heater): ≤0.5°C/m
• Launder lining life: ≥12 months
• Launder outer wall temperature: ≤75°C

 

Notes: The launder cover (launder heater) and launder cover actuator are optional components.

 

 

Introduction
- The launder is of vital importance for the quality and energy-saving effect of molten aluminum metallurgy. Made of high-quality medium-density melted quartz refractory H2000 and pre-sintered at 800°C before assembly, the lining of HYDEB launder has high aluminum tolerance, low thermal conductivity, low shrinkage and high strength. The launder cover can be used to reduce heat loss by over 50% while a launder heating unit can be mounted to minimize the temperature drop of the launder, thus reducing the tapping temperature of molten aluminum and protecting some highly burnable alloying elements.
- There are a number of launder shapes, such as DC slot, elbow, tee joint and cross fitting. They can be combined flexibly together in use according to different site conditions.

 

HL Launder Features
Characteristics	Advantages
High chemical stability	Not reacting with molten aluminum at operating temperature
Low thermal contraction coefficient and expansion 　coefficient	Super-high volume stability and resistance to thermal and cold shocks, reducing the 　maintenance of joints
An addition agent that is non-sticky with molten 　aluminum and able to prevent the permeation of 　molten aluminum	High non-stickiness with molten aluminum, solidified shell is easy to remove
High-strength H2000 material	Anti-erosion, sturdy and durable
High launder strength, low density	Easy to transport and install; once broken, it floats on the molten aluminum, easy to clear away
Poor water absorbability of H2000	Preventing the molten aluminum from absorbing water and increasing hydrogen content, 　without contaminating molten aluminum
Low thermal conductivity of H2000	Less heat dissipation of the launder, low self-heat storage, and low temperature drop caused by 　molten aluminum
Excellent thermal insulation performance and insulating 　layer with a low heat storage rate	The launder has a good Nano-heat insulating layer, with its shell temperature at a low level

 

Main performance parameters of HL launder
Items	Parameters
Launder temperature drop/m	≤0.5℃(with a cover and heater),≤2℃(no cover)
Surface temperature	≤75℃
Launder lining life	≥12 months
Launder flow (molten aluminum)	1000-50 000kg/Hr