TILTING ROTARY FURNACES

The high performance tilting rotary furnace range from Melting Solutions produce the most effective melting furnace technology available in the market for processing mixed scrap and drosses. It is able to process many types of scrap including:

• Drosses
• Mixed scrap often with contamination (tense, taint, tabor etc)
• Turnings/Swarf/Chips
• UBC
• Scrap contaminated with iron and steel inclusions

The tilting rotary furnace range combines advanced melting technology, process control and high-quality engineering.  It is aimed primarily at recycling applications.  The advantages and flexibility of the tilting rotary furnace continues to deliver savings and efficiencies throughout the aluminium processing industry.

It delivers outstanding energy savings and increases productivity as a bulk melter for die-casting applications. For melting mixed, contaminated scrap including oxidised materials such as dross, the combination of low energy, high metal recovery and flexibility of feedstock, have shown the tilting rotary furnace to be a class leader.

Comparing the tilting rotary furnace range to other traditional rotary and fuel-fired reverberatory furnaces show significant savings:

• Low energy – typically 15% saving
• High metal recovery 3–5% increase in recovery
• Improved productivity – cycle times improve by up to 50%
• Labour savings – the automated process requires only one operator to manage multiple furnaces.

Advantages of our Tilting Rotary Furnaces:

The latest tilting rotary furnaces also deliver savings and efficiencies by using a proven innovative design backed by in-depth process knowledge. They are offered with the following:

• Choice of fuels to suit local conditions, oil, gas, if available, with or without oxygen (oxy-fuel)
• Double pass burner firing with ‘proportionator’ combustion system to meter and mix the precise ratio of fuel (carbon) to oxidant (air or oxygen)
• Proportionator – accurate real-time ratio control gives maximum fuel efficiency and process control. For example to ‘oxidize’ smoke during the start of a charge or to fire with ‘reducing’ atmosphere and save metal oxidation
• A unique door arrangement, enabling the furnace to tilt and fire simultaneously. This gives better mixing of the charge, faster melting and higher metal recovery
• Fast charging of all types of scrap, even oversize bulky materials, door openings available up to 79" internal diameter. Fully integrated charging machines. Fast charging means faster melting, less energy and more production
• Variable melting angles. The tilt rotary door design enables the furnace body to be reclined to maximize load capacity.

All of the furnace controls and functions are controlled using the latest PLC and SCADA software.  These are then communicated to the operator by a full size color HMI (Human Machine Interface) monitor. SCADA control is offered as an option. The data communicated to the central PLC from the various furnace sensors is displayed and stored.  Data includes energy consumption, process temperatures and melt results etc. These are then available to print and transmit via ethernet or wireless applications to remote locations. The tilt rotary range is available in a number of standard capacities from 1 – 23 ton.

SIDEWELL FURNACES

Melting Solutions can supply a range of sidewell melting furnaces in capacities from 10t to 100t.

The principle of the sidewell furnace is well proven. It utilises a metal circulation pump which draws hot metal from the main heating chamber into an open or closed well on the side of the furnace. Scrap can be loaded into the sidewell or through a submergence system, giving high recovery. Using this technology means turnings and foils, which would be uneconomic to process in a conventional furnace, can now be used.

HOLDING FURNACES 

Holding furnaces have a very important function in the Casthouse for:

• Alloying of elements such as Copper and Silicon
• Metal treatment, removal of Hydrogen, Magnesium and Calcium
• Maximizing productivity so melting furnace time is not taken up alloying or casting

In some cases, for example with a Tilting Rotary Furnace, the cycle time is no more than 3 hours, so very often two holding furnaces are used.

CHARGING MACHINES

The efficient charging of the furnace is one of the most important considerations in creating a modern and efficient melting plant.

Melting Solutions lead the industry in effective charging and handling equipment. We supply a range of charging machines from 1 – 10m3 hopper capacity rated from 1T – 6T per charge and above.

Using powerful vibratory motors, a wide range of scrap can be rapidly charged into the furnace at a nominal 1T/minute. With dense and shredded scrap this charging rate is often much faster.

Our machines are heavy duty for years of trouble-free service. We match the correct capacity machine for your furnace scrap characteristics. The machines are fully integrated into the plant control. We can include energy chains and machines that have long travel for crane loading.

Operations by remote controls are also available to optimise productivity.