Advanced equipment for

the aluminium industry

NEW MELTING
TECHNOLOGIES
 New Generation Melting System for profile scrap,
contaminated with paint and plastic

PREFACE

The scrap market offers increasing volume of profile scrap of 6000 alloys contaminated with
paint and plastic. The amount of nonmetalic contamination is up to 5 %.The goal of remelters
is to convert this scrap into high quality extrusion billets again. Figures 1 and 2 show typical
scrap as delivered to the remelter

Figure 1: Short scrap storage Figure 2: Bundled long scrap. Profiles are painted and
containing plastic thermal breakers

To do this in an environmental and economic best way the following goals must be achieved:

Controlled and close to 100 % gasification of hydrocarbons and burning those gases
completely and in a way that largely avoids the formation of dioxins.

Doing gasification of hydrocarbons and melting of scrap in one single integrated system

Minimising metal losses at the melting process

Minimising manpower requirement and avoiding shredding of scrap

Avoiding oxygen burners and afterburning systems

Minimising energy consumption.

The new Remelt Plant developed by HERTWICH ENGINEERING and installed with one of
the leading Aluminium producers of the world meets all those requirements. Figure 3 depicts
a cross section of the plant.
Figure 3: Cross section of the plant

FULLY MECHANISED CHARGING SYSTEM

Automatic Charging of metal is done by a system of five scrap bins circulating on a two
storey bin conveyor and a bin elevator. This system also serves as a buffer store with a storage
capacity of appprox. 12 tons, equivalent to approx. 2 hours of melting.

The bins have a loading capacity of 11 m. The inside length of the bin of 7,5 m permits to
charge long scrap in bundles. The loading is done in the front position by payloader or fork
truck. An integrated scale takes the net weight of the scrap load. Typical load weight is 2 to 3
tons.

The bins then get on an entry accumulator and then are lifted by the elevator to the top of the
furnace. By automatic opening the two flaps that form the bottom of a bin, the scrap falls into
the gasification compartment of the furnace.

PREHEAT AND GASIFICATION

Figure 4 shows a longitudinal section of the gasification compartment

The gasification compartment is formed as a narrow channel which, after charging is

completed, is almost filled with scrap. Any open space on top of the charge will be filled by
lowering a block integrated in the hood of the compartment.

A very intense recirculation of hot gases is achieved by a powerful ventilator. The design of
the degassing system forces the hot gases through the scrap load and avoids bypassing.
The hot gases pass through the charge in longitudinal direction. On the entry side the
temperature of the gases is just below melting point.
The heating and degassing of scrap starts at the hot gas entry side and then during a period of
15 to 25 minutes gradually moves through the complete charge. This heating regime of the
scrap load has the advantage that the formation of pyrolisis gases is not a sudden process. The
gases will be released gradually at a rate that permits controlled combustion of the gases.

The gasification of the

hydrocarbons include two
different processes:
When heated to elevated
temperature the solid
hydrocarbon molecules will
disintegrate and hydrocarbon
gases will be released. As a
solid residue carbon will
remain with the aluminium
scrap.
To gasify this residue carbon
even elevated temperatures of
above 500 C are required as
well as the presence of
oxygen. Oxygen and Carbon
then will form CO-gas and
residue carbon will be
removed from the scrap.

The oxygen level of the

recirculated gases will be
controlled in a way that most
Figure 4: Longitudinal section of gasification compartment. The
diagram shows the temperature of scrap after certain of the delaquering period the
duration of heating. Since temperature moves gradually O2 level at the entry side will
from entry of hot gases to the exit, gasification also moves be 2 % to 4 % in order to
gradually through the charge (see green and yellow band).
This avoids peaks in the generation of pyrolysis gases. deliver the O2 necessary to
gasify the solid carbon
residues on the scrap.

COMBUSTION

The pyrolisis gases will be combusted in two ways. The combustion system of furnace
chamber 1 is oxygen-level controlled. As soon as pyrolisis gases will be emitted from the
scraps, the supply of fuel gas will be reduced automatically, while maintaining combustion air
on full level to supply oxygen for burning pyrolisis gases.

Since the energy consumption in Chamber 1 + Gasification Compartment is restricted to the

energy needed to heat the scrap additional means of burning hydrocarbons have been
introduced in order to maximise the plants capability to handling contaminated scrap. Thus
the energy content of the organic contamination of the scrap supplies a substantial part of the
energy required.
Part of the gases recirculated in Chamber 1
+ Gasification Compartment will be
ventilated to the burner of chamber 2. This
burner operates also oxygen level
controlled. (See figure 5)

So in periods of heating heavily

contaminated scrap it can happen that both
burners run on full power of in total 4.500
kW. But the fuel gas feed is only 500 kW
in order to maintain stable combustion.
The other 4.000 kW of energy is obtained
by combustion of the hydrocarbon gases
emitted from the scrap. Figure 5: Combustion of pyrolysis gases in chamber 1 and 2

In Chamber 2 of the furnace a constant

high temperature of above 900 C is
maintained all the time as well as an
oxygen level of minimum 2 %. This
enables a thorough combustion of pyrolisis
gases and cracks any dioxins that have
been formed through the pyrolisis process.

All flue gases from the furnace are sucked

from Chamber 2. They pass through
alternating operating static regenerators in
which the flue gases are cooled down to
approx. 200 C. Since the cooling is very
quick the recombination of dioxins from
its components during the cooling process Figure 6: Two static regenerators for preheat of combustion
is minimised. Figure 6 depicts the air to approx. 800 C. The regenerators are filled
with ceramic modules with a honeycomb channel
regenerators. The flue gases then are structure. These modules do not get clogged by dust
ducted through a flue gas treatment / so easily. Cleaning intervals are significant
filtering system before escaping to the extended compared to ceramic balls
atmosphere.

In the regenerators the combustion air is heated to approx. 800 C. This heating together with
the energy from burning the pyrolisis gases results in extremely low fuel gas consumption.
Depending on the quantity of hydrocarbons on the scrap the specific fuel gas consumption
varies from 370 to 450 kWh/ton of Aluminium during continuous operation.

MELTING

The completion of the preheat and degassing of a scrap load is monitored by measurement of
oxygen level and temperature.

By opening the bottom flaps of the gasification compartment the scrap falls onto the melting
platform of Chamber 1.
An electromagnetic pump recirculates the melt between Chamber 1 and Chamber 2. The melt
is moved from Chamber 2 to Chamber 1 and then returns through a hole in the partition wall
to Chamber 2.

When operating the pump at minimum power the melt level in Chamber 1 in only slightly
higher than in Chamber 2. The melting platform in Chamber 1 is above melt level thus
avoiding splashing as the preheated scrap is loaded on the platform.

After loading of scrap the power of pump is increased to its maximum and the melt is
flooding the platform. The scrap is melted through heat transfer from the recirculated hot
melt. This method guarantees the lowest possible metal losses caused by oxidation.
The melt recirculation created by the melt bath also creates a good convection of the achieved
uniform melt temperature in the melt bath in chamber 2.

DROSS AND DROSS HANDLING

Despite the very low oxidation losses from melting a substantial amount of dross is formed.

The reason for that is the following:

Paint and plastic contain 20 to 25 % of inorganic fillers. Those fine particles bind a substantial
quantity of aluminium forming a mushy dross amounting up to 3 % of the scrap charged.
This dross contains 80 to 90 % aluminium that shall be recovered by a separate process.

Efficient skimming is important particularly in Chamber 1 where this dross is formed. If this
dross is not removed in regular intervals melting of scrap will be influenced negatively.

Therefore an efficient skimming tool is important. The plant is equipped with a HERTWICH
Skimming Machine running on rails permitting efficient and quick skimming. The skimming
arm is weight balanced and elastic mounted.

These features minimise damage of refractory lining by the skimming tool.

Figure 7: Skimming machine, cleaning main chamber

 Melting long profiles in a small furnace
The new Remelt Plant at Aluminium Laufen AG

Like many extrusion shops, Aluminium Laufen was in need of a new Casthouse for remelting
of internal scrap and for production of extrusion billet. Since capacity requirements were
limited to 15.000 mt per year everything had to be small in size. The new plant should include
all production steps from charging and melting until homogenizing.

This was a welcome scenario for Hertwich Engineering (HE), who already had installed more
than 15 Compact Type Remelt Plants for extruders, in the capacity range of 3.000 to 20.000
tpy, and who therefore had a wealth of experience in the design of small capacity but efficient
equipment.

Merely the melting furnace represented a certain challenge: Designing a melting furnace with
only 3 tons/hour melting rate, but capable of melting scrap profiles up to 7 m long. The
submersion melting process was imperative to Hertwich in order to minimise melting losses.

The solution was then found in a melting furnace with a small, closed charge well.

A side channel electromagnetic pump creates an intense melt re-circulation between the
furnace chamber and the well. Charging is done by a pusher type charging machine with a 7
m long narrow trough. At the start of the charging cycle the front end of the trough is moved
close to the melt bath at the well. Then the pusher slowly pushes the metal loaded in the
charging trough into the melt.

The re-circulated melt quickly "eats away" the metal, as it gets in contact with the melt. After
only 5 minutes the contents of the charging trough are pushed into the melt and thereby
melted. Typical batch charge weight is 1.000 to 1.500 kgs.

The plant includes a HE Tiltable Casting Furnace, Vertical Casting Machine (supplied by
LKO) and a HE Continuous Homogenizer. An existing old Billet Saw has been integrated at
the exit side of the Continuous Homogenizer.

After months of operation, the melting furnace shows a very satisfactory performance. Total
dross generation for both, melting and holding furnace, over a test period which represents
310 tons of metal, showed a dross generation of 1,68 % of metal charged. Since this dross has
a very high aluminium content of some 65 %, the net melt loss is essentially 0,6 % only.

Average fuel gas consumption is 540 kWh for the melting furnace and 60 kWh for the casting
furnace.
The melting furnace is equipped with regenerative burners. The regenerators are equipped
with honeycomb structured ceramic modules as a heat transfer medium. These ceramic
modules are much less susceptible to clogging compared with regular ceramic ball type
filling. The regenerators are somewhat oversized on purpose, which permit burner cycles of 2
minutes under full power operation.

Figure 1: Compact Remelt Plant Alu Laufen

1. Charging and skimming machine
2. Melting Furnace
3. Charging Well
4. Casting Furnace
5. VDC-machine
6. Accumulator
7. Continuous Homogenizer
8. Cooling Station
9. Billet Saw
Figure 2: Melting Furnace with Charging/Skimming Machine and Casting Furnace

Figure 3: Loading scrap into the charging machine (up to 7 m long profiles can be charged)
Figure 4: Schematic view of charging/melting. A side channel metal pump creates an intense
melt recirculation between furnace chamber and charge well

Figure 5: Scrap is pushed into the melt for submersion melting

Figure 6: Honeycomb ceramic modules inside the regenerator

Figure 7: The skimming unit added to the charging machine permits an effective skimming
operation in both furnaces
 Advanced Remelt Technology at
HYDRO ALUMINIUM PORTALEX

Some years ago HERTWICH ENGINEERING has developed a range of Compact Type
Remelt Plant capable of producing 3,000 to 20,000 tpy of extrusion billets from clean
extrusion scrap and primary metal. Since then more than 15 such plants have been
successfully commissioned world-wide.

During negotiations with the HYDRO ALUMINIUM Extrusion Group over a suitable Remelt
Plant for its PORTALEX extrusion works it very soon become clear to us that the
capabilities of our plant needed to be extended to also accept profile scrap contaminated with
paint and plastics. A new, more sophisticated plant concept is required.

In turn HERTWICH ENGINEERING has taken on the challenge and has developed an
advanced version of the existing Compact Type Remelt Plant concept. It combines the
capability of remelting painted scrap thereby meeting stringent environmental standards, with
low labour requirements, and very good efficiency and safety. Attributes which HERTWICH
ENGINEERING equipment is respected for throughout the industry.

DESCRIPTION OF THE PLANT AT PORTALEX

The plant represents an integrated, continuously operated, fully automated system starting
with the handling of scrap and ending with delivery of cut to length homogenized extrusion
billets (logs).
Continuous production rate is 2,2 tons per hour or 50 tons per day.

Figure 1: overall view of the plant.

From left to right: Part of scrap bin accumulator, Skimming rake storage, Three chamber melting and casting
furnace, Horizontal caster, Continuous Homogenizer, Weighing/Strapping system.

June, 2001
Figure 2: General Layout.

Main components of the plant are:

Charging bin System

There are approx. 20 bins, which circulate within extrusion plant, scrap yard and remelt plant.
Volume per bin is approx. 3 m3, average scrap-load is approx. 800 kgs. In the extrusion plant
clean extrusion scrap is filled directly into the bins. Outside scrap is placed into bins at the
scrap-yard. Full bins are loaded onto the scrap bin accumulator by fork truck.

Automatic Charging and Skimming Machine

The machine automatically picks a full bin from the bin accumulator, charges the scrap into
the first compartment of the melting furnace and return the empty bin to the bin accumulator
from which is removed by fork truck.

The sequence of charging cycles is calculated by the furnace controls. An automatic weighing
system is integrated in the charging machine to record gross- and tare-weight of every bin,
thereby obtaining the exact weight of metal charged.

The charging machine is also designed to be used for smooth and easy skimming of the melt
bath.
Instead of a charging bin the machine docks onto a skimming rake at its parking position next
to the furnace.

Once in front of the furnace, the skimming operation is manually controlled from the operator
cabin, on the machine. The precisely steerable movements of the rake permit smooth and
thorough skimming of dross whilst extracting a minimum of melt with the dross. The rake is
weight balanced and its sideways and forward movements are force restricted by elastic
elements. With these features high forces of the rake to the refractory lining of the furnaces
are ruled out thus maximising the service life of the refractory lining.

June, 2001
Figure 3: Charging/Skimming machine.

Three Chamber Melting and Casting Furnace

This unique design permits steady charging of scrap and continuous tapping of melt of correct
casting temperature.

Figure 4: Three Chamber Melting Furnace.

June, 2001
Charged scrap is loaded onto the preheat ramp of Chamber 1 of the furnace. A hot gas
ventilator sucks hot gases from Chamber 1 and blows them onto the scrap for good heat
transfer by convection. When charging contaminated scrap it is preheated up to 550 C.
During heating the hydrocarbons / contaminants are gasified. The combustion system of
Chamber 1 is oxygen controlled. As soon as hydrocarbons are released from the scrap the
supply of natural gas to the burner is reduced accordingly in order to leave sufficient air
oxygen for burning the organic compounds.

When degassing is completed the scrap is pushed into the melt bath of Chamber 1 where it is
subjected to submersion melting for extremely low melt loss. An electromagnetic liquid metal
pump generates an intense melt recirculation (approx. 400 tons/hour) between Chamber 2 and
Chamber 1. This melt-flow transports the energy required for melting the solid metal by
contact with the melt.

Chamber 2 of the furnace serves two main purposes:

Heat input into the melt bath, so the melt contains sufficient energy for melting solid
metal.
To ensure complete combustion of the hydrocarbons emitted from the scrap. The
Chamber 2 burner system is oxygen controlled too in order to maintain an oxygen level of
1 to 1,5 % at all times. Since Chamber 2 keeps a constant high furnace room temperature
of approx. 1000 C, any dangerous chlorine compounds like dioxin are disintegrated.

All flue gases from the furnace are ducted from Chamber 2 to one of two (alternating)
regenerators. The regenerators cool down the flue gases in a fraction of a second to below 250
C. This quick cooling avoids recombination of toxic chlorine compounds. The energy
reclaimed from the flue gases is used to preheat the combustion air of the burners of
Chambers 1 and 2 to approx. 800 C.

The regenerators are filled with honeycomb ceramic modules instead of ceramic balls. This
structure avoids clogging of the regenerators and the need of exchange of ceramic elements
for cleaning. After 14 months of operation an inspection has revealed that the system does not
require any service.

Figure 5: Longitudinal Section through Melting/Casting Furnace, Degassing Unit, Horizontal Caster and Flying
Saw

June, 2001
A very positive judgement can be made of the electromagnetic hot metal pump as well. Not a
single problem occurred within 14 months. No components had to be replaced. The pump
may not only be used for recirculating melt between two chambers of a furnace but also for
recirculating melt within single chamber furnaces for quick and uniform distribution of
alloying elements, uniform melt temperature etc.
Through a hole in the partition wall the melt flows from Chamber 2 to Chamber 3 of the
furnace. As this hole is arranged below the melt bath surface dross floating on the melt is
retained. The purpose of the small Chamber 3 is to control a constant casting temperature of
the melt. To ensure a uniform melt temperature in Chamber 3, small quantities of purging gas
are introduced through a porous plug integrated in the furnace bottom lining. The rise of gas
bubbles creates a gentle stirring effect to the melt.
The melt is tapped from Chamber 3 through a liquid metal valve from STOPINC and then
passes through an Inline Degassing Unit.

Horizontal Caster
The HERTWICH ENGINEERING Horizontal Caster produces 2 strands of 9 billet or 3
strands of 8. Continuous casting rate is 2 to 2,4 tons/hour. The integrated flying saw
automatically cuts the strands into billets of 7 meter length. In general a casting cycle starts on
Monday morning and stops on Saturday morning.
Cut to length billets are automatically pin-stamped on the cut face and conveyed onto an
intermediate table.

Figure 6: Horizontal Caster with Flying Saw

June, 2001
Continuous Homogenizer

Single billets from the intermediate table are introduced into the Continuous Homogenizer in
regular intervals. While passing through the furnace the billets are subjected to heating and
holding at very narrow temperature and time tolerances, uniform for all billets. Thereafter
billets pass through a cooling station for uniform cooling. After cooling, billets are moved to
the exit station where they are weighed and bundled. Strapping and removing of finished
bundles are the only manual operations of the production cycle after loading of full scrap bins
onto the bin entry accumulator.

OPERATIONAL INFORMATION

Production Rate
Continuous production rate during casting periods is 2 to 2,4 tons per hour. Production per
month is in the range of 1000 tons.

Manning
The complete Remelt Plant is operated by one man per shift. A second man is engaged with
handling of purchased scrap and scrap bin transport.

Metal recovery at the Melting Furnace

When charging clean scrap exclusively the quantity of dross removed from the furnace is
lower than 0,5 % of the metal charged.

When charging contaminated scrap dross generation is substantially higher. This is not due to
increased oxidation losses during the melting process. The reason is rather that the inorganic
fillers from paint and plastic together with melt form a greasy residue. The quantity of dross
removed from the furnace is approx. 4 % of the metal charged and the aluminium content of
that dross is more than 90 %. This dross, of course, is subjected to metal recovery.

Energy Consumption

Natural gas consumption of the melting and casting furnace in continuous operation is 600
kWh/ton.

Gas consumption of the homogenizer in continuous operation is 240 kWh/ton.

June, 2001
LIEFERPROGRAMM
Durchlaufhomogenisierungsanlage
Kapazitt: 1.000 kg/h 23.000 kg/h
Kammerhomogenisierungsofen
Ultraschall Prfeinrichtung
a) Kernrisse und Einschlsse
b) fr 100 % Prfung: Multi Kopf System
Sge- und Verpackungsanlagen,
Stapel- und Transportmaschinen
Brikettierpresse
Horizontale und Vertikale Stranggie-
Anlage fr Rundbarren, Stromschienen,
T-Bars, Massel und Walzbarren
Kompakt Umschmelzanlage
Kapazitt: 4.000 30.000 T/Jahr
Chargiermaschinen
Schmelzeentgasungseinheiten
Spezialmaschinen
NEU:
Schmelz- und Giefen der neuesten
Technologie, fr beschichtete Schrotte etc.
Schmelzleistung:1.000 10.000 kg/h
Dreh-Kippofen, URTF 3 14
Universell einsetzbar + Alurec
Horizontalstranggieanlagen fr
Schmiede- und SSM Barren und
Magnesium Massel
Durchmesser 25 bis 150 mm
Masselgieband
!Khlung ausschlielich mit Luft!
Elektromagnetische Pumpen und Rhrer
Vorrichtung zum Einschmelzen von
Spnen
PRODUCT RANGE
Continuous Homogenizing Plant
Capacity: 1.000 kg/h 23.000 kg/h
Batch Homogenizing Furnace
Ultrasonic Testing Equipment
a) Centre cracks and random inclusions
b) For 100 % testing: multi head system
Sawing and Packing Plants,
Stackers and Handling Equipment
Briquetting Press
Horizontal and Vertical Casting Plant for
Billet, Busbar, T-Bar, Foundry Ingot and
Rolling Ingot
Compact Type Remelt Plant
Capacity: 4.000 30.000 tpy
Charging Machines
Inline Degassing Units
Customized Machinery
NEW:
Melting and Casting Furnaces of
Advanced Technology for
contaminated scrap etc.
Melting Capacity: 1.000 10.000 kg/hour
Rotary Tilting Furnace, URTF 3 14
The Universal Furnace + Alurec
Horizontal DC Casting Plants for
Forging, SSM Feedstock and
Magnesium-Ingot
Diameter range 1 6
Ingot Casting Belt
!Cooling exclusively with air!
Electromagnetic Pumps and Stirrers
Facilities for Remelting of Swarf
HERTWICH ENGINEERING
Weinbergerstrasse 6
A 5280 BRAUNAU AUSTRIA
Phone : +43 (0) 7722 / 806-0
Fax : +43 (0) 7722 / 806-122
E-mail : info@hertwich.com
Internet : www.hertwich.com