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HE Melting
HE Melting
MELTING
2 HERTWICH - Melting HERTWICH - Melting 3
Introduction
Recycling of aluminium scrap has requirements several furnace types To identify the best suited furnace
gained paramount significance. In and processes have been devel- concept, several typical scrap
Germany secondary aluminium ac- oped. types and other major aspects are
counts for more than 60% of total shown in relation to the main fur-
consumption, which is still on the Today Hertwich covers all aspects nace types. (see table below).
rise. of melting furnace construction with
its product range: For certain applications with vari-
Content HERTWICH has built melting fur- • Single-chamber melting & cast- ous scrap types a combination of
naces for more than 15 years, and ing furnaces for clean scrap two different furnace types is the
has from the beginning paid particu- • Multi-chamber furnaces for con- preferred solution, in order to en-
lar attention to efficiency, economy taminated scrap (painted, oiled, sure good flexibility and compete-
of operation and the environment. foil coated, chips, cans, auto- tiveness.
Introduction 3 motive, etc.)
Due to the multitude of different • Rotary tilting furnaces for low-
scrap types and customer specific grade scrap and dross
Scrap definition 3
Type IV
Dross, scrap with iron, etc.
imise heat losses. furnace wall. An electromagnetic into combustible gases. Combustion and post
Single chamber melting furnaces stirrer supports even temperature combustion takes place in all furnace cham- HOT
GASES
HOOD
Since no scrap is charged into the The capacity of the charging ma-
furnace main chamber, a constant PREHEAT AND chine is approximately 13m³ with a
GASIFICATION
high furnace temperature of more CHARGING BIN
COMPARTMENT EMPTY BINS maximum load of 5t.
BOTTOM FLAPS OPEN
than 950 °C can be maintained. CONVEYOR Before opening the furnace door for
Possible toxic chlorine compounds, charging the attached hood docks
BIN ELEVATOR
which may occur upon gasification HOOD to the furnace to extract escaping
CHARGING BINS
of organic impurities, are no longer FOR SCRAP
fumes.
CHAMBER 1
stable at such high temperatures UP TO 7,2 M LONG Preheated scrap on the ramp is
and are disintegrated. All flue gas- LOADING
pushed into the melt bath with the
es from the furnace are ducted from POSITION charging machine front shield and
the main chamber through the flue the new scrap load is deposited
gas duct to two alternating regen- onto the ramp in turn.
erators, which cool down the flue Charging Machine docking on Preheating Chamber
gases to below 200 °C within split
SCRAP JUST CHARGED
seconds. The fast cooling prevents SCALE
CHAMBER 2
recombination of dioxins in the criti-
FULL BINS
cal temperature range 600 °C to ELECTROMAGNETIC PUMP
FOR MELT CIRCULATION
SUBMERSION MELTING
OF DELAQUERED SCRAP CONVEYOR
250 °C.
In the regenerators combus- During melting of moderately Despite consistent design criteria,
tion air is preheated to approx. contaminated scrap the typi- furnace design may be somewhat
800 – 1000 °C. Such intense air cal gas consumption is merely adapted, depending on individual
preheating in combination with the 450 – 500 kWh/ton. specifications and capacities.
thermal utilization of pyrolysis gas- After passing through the regenera-
es, leads to extremely low energy tors flue gases are ducted to a filter
consumption values. plant.
Melt Circulation
Pump
SHAFT GATE
BURNER WITH
REGENERATOR
MAIN CHAMBER
PREHEAT AND
PREHEAT GASIFICATION SUBMERSION MELTING
CIRCULATION FAN SHAFT OF PREHEATED SCRAP
Ecomelt PS-100
The Ecomelt PS unlike Ecomelt PR Most stringent environmental and a melting capacity of 12 tons/hour
furnace is not limited to a single emission regulations are met due to (250 tons/day) is achieved.
batch, rather is the melting process the combination of closed charging Scrap is loaded with a payloader combustion whereby the inherent Launder Pump
continuous. The Ecomelt PS multi unit and high efficiently combustion Specific Energy consumption is as into containers. The charging crane energy of volatile hydrocarbons is As an option to the conventional
chamber furnace accepts several equipment. low as 350 - 550 kWh/ton subject takes one full container at the time thermally reclaimed, to contribute cone and plug tapping arrangement
batch loads in the preheat compart- With the development of the pre- to organic impurities. and charges the scrap load via a to the energy needed for melting. an electromagnetic inductor (linear
ment. heat shaft furnace material lock at the top of the pre- Through an opening in the partition- motor) is used for safely raising the
heat shaft. ing wall hot air flows from the main melt into a transfer launder without
Hot air from the melt chamber is chamber to the melting chamber to interrupting melting operation.
circulated through the scrap in up- supply energy for scrap preheating.
ward direction and back to the melt
chamber. All organics are properly gasified
The long retention time of scrap prior to scrap being submerged.
inside the preheat shaft ensures Melting of scrap is started by raising
adequate preheating and thorough of the melt bath level at the preheat-
gasification of organic compounds ing/melting chamber with the liquid
even for problematic (baled) scrap. metal pump, thereby flooding the
As the hot air temperature inside chamber. The melt rate is controlled
the preheat shaft is at all times over the melt flow speed and melt
controlled to below 650°C, local or level in the chamber.
partial melting is ruled out during
gasification of hydrocarbons and An outstanding feature is the “foot”
preheating. of the scrap pile, which is at all times
immersed during melting. The con-
Pyrolysis gas is generated quite stant metal flow, generated by the
gradually, whereby gas generation electromagnetic pump, ensures the
can be regulated with the intensity steady melt rate.
of the re-circulating hot air flow Due to the submersion melt pro-
(controlled by the fan speed). cess metal loss from oxidation is
reduced to a minimum.
Pyrolysis gases are ducted to the
Ecomelt PS-160 with container charging system main chamber of the furnace for Launder Pump
10 HERTWICH - Melting HERTWICH - Melting 11
Furnace Data
The CTRP is particularly suited for extruders and forging plants who remelt their own turn-around scrap as well
as scrap from the market into extrusion billet (logs) or forging stock. It represents an integrated, continuously
operated, fully automated concept starting with the handling of scrap and ending with cut to length homogenized
extrusion billets (logs). Typical continuous production rate is 2,2 tons per hour or 50 tons per day.
Accumulator
Skimming Tool
Flying Saw
METAL LEVEL
The melting furnace main chamber Schematic overall view of plant Hot gas and material flow
is equipped with regenerative burn-
ers. Hertwich regenerators are filled
with honeycomb structured ceramic This melting furnace has been the melting process in hot con-
modules. Such ceramic modules specifically designed for melting of dition, thereby avoiding further
are much less prone to clogging loose swarf and light gauge scrap. oxidation or moisture pick-up.
compared to regular ceramic ball It is the result of extensive inhouse • Electromagnetic liquid metal
type filling. R&D to achieve outstanding values pump for quick, energetic sub-
in terms of economic throughput mersion of the charged material
Combustion air is preheated to and the environment. and for melt bath movement
800 - 1.000 °C while flue gases are
cooled down below 250 °C. Specific The main characteristics are: The following outstanding targets
energy consumption with regenera- are achieved:
tive burners is within 600 kWh/ton. • Chips are charged continuously Schematic concept of chip-submerging
and heated to some 400°C in • Melting capacity 2 to 5 tons/h or
A skimming unit is mounted on seconds, whereby hydrocar- 40 to 100 tons/day
the base traversing carriage of the bons and moisture are evapo- • Very low specific energy con- • Low manpower for operation
charging machine. It permits easy rated. sumption (< 550 kWh/ton inclu- and maintenance
and careful skimming of both, melt- • Thermal reclamation of organic sive drying) due to LOW-NOx • Good metal quality of the melt
Scrap is pushed into the melt bath for submersion melting ing- and casting furnaces. components as dryer and melt- regenerative burner systems, (low oxide and hydrogen con-
ing furnace are combined into yet very low NOx emissions tent)
one process. • Extremely low melt loss (< 1 %), • Meeting most stringent environ-
• Swarf is introduced directly to thus high metal recovery mental standards
View on VDC-casting plant, casting and melting furnace Honeycomb ceramic inside regenerator Melting furnace with chip conditioning station
18 HERTWICH - Melting
MELTING
• Single Chamber Furnace for clean scrap (tiltable for casting)
Melt rate: 2 - 15 tons/hour
• Twin Chamber Furnace for contaminated scrap
Melt rate: 1 - 12 tons/hour
• Rotary Tilting Furnace
Melt rate: 1 - 6 tons/hour
• Compact Type Remelt Plant for recycling scrap into billets
Capacity: 4.000 - 30.000 tons/year
• Furnace Charging Machines
CASTING
• HDC - Horizontal Casting Plant for ingots, busbars and billets
Production rate: 2 - 15 tons/hour
• VDC - Vertical Casting Plant for extrusion and forging billets
• Open Mould Ingot Caster (Air or water cooled)
Production rate: 5 - 16 tons/hour
• Inline Degassing Unit
• Compact Type Remelt Plant for billets
Capacity: 4.000 - 30.000 tons/year
ULTRASONIC TESTING
• Linear Ultrasonic Testing Equipment for crack detection in billets
and slabs
• Helical Ultrasonic Testing Equipment for full metal volume
inspection of billets
HOMOGENIZING
• Continuous Homogenizing Plant for billets
Production rate: 4.000 - 180.000 tons/year
• Batch Homogenizing Plant for billets and slabs
Capacity: 40 - 180 tons/batch
• Full automatic Stacking & Unstacking Equipment for Batch
Furnaces
BRIQUETTING
• Swarf Briquetting Press, Capacity: 400 kg/hour
Stand alone units or integrated with billet saw
Hertwich Engineering GmbH
Weinbergerstrasse 6
A-5280 BRAUNAU
AUSTRIA
Tel +43-7722-806-0
Fax +43-7722-806-122
info@hertwich.com
www.hertwich.com