Tilting Rotary Furnace World Class Melting Technology

Transcription

1 Tilting Rotary Furnace World Class Melting Technology

2 The Tilt Rotary Furnace Melting Solutions offer the TR range of advanced Tilting Rotary Furnaces available in capacities from tonnes aluminium (1.5-11m3) TR furnaces provide state-of-the-art technology for melting a wide range of scrap and for processing drosses. Complete melting plant solutions are also available from Melting Solutions, including charging machines, holding furnaces, casting equipment and pollution control to meet the very highest environmental standards. All from one experienced supplier built on proven results from our users. The Melting Solutions TR Furnaces offer great flexibility. One furnace able to process drosses, mixed scrap, contaminated scrap (with iron) chips, UBC and foils. For companies looking to upgrade from fixed axis rotary melting or reverberatory melting the TR Furnaces offer significant advantages with attractive pay back. Low energy melting at 350kW per tonne. High production rates, unrivalled melting speed Full automation PLC and SCADA Minimum labour costs Quality engineering ensures long service life with minimum maintenance High metal recovery Integrated turn-key solutions from a world leader in melting technology Tilt Rotary Process Tilt Rotary Furnaces, Double pass burner firing. (blue aluminium / red slag) 1. Furnace is charged very quickly using the large charge opening. 2. Melting by double pass burner arrangement. Saving energy-faster melting. 3. The furnace is tilted to pour out the aluminium. The dry slag remains in the furnace-no wasted time opening tap holes. 4. The furnace is rotated at high speed for 5 minutes in each direction-using burner if required. 5. More aluminium is poured out of the furnace. Repeat steps 4 & 5 until no further aluminium is obtained. 6. The furnace is tilted and rotated simultaneously to tip out the dry salt slag. Amount of slag greatly reduced because a liquid slag is not needed. Faster rotation-better separation of aluminium from slag. 7. After each cycle furnace is quickly cleaned, avoiding the need for a weekly salt wash.

3 WHY CHOOSE MELTING SOLUTIONS? For more than fifteen years Melting Solutions have pioneered tilt rotary design, working closely with our customers, and leading companies in the secondary aluminium industry worldwide. Our furnace designs strive to continuously improve the key objectives of the aluminium industry;- Highest metal recovery. Lowest energy consumption. Maximum productivity. The Melting Solutions tilt rotary with it s innovations set the standard for the industry and deliver high profit margins for our customers. We have proven time and again our tilt rotary furnaces deliver profitable melting plants for our customers using the cumulative benefits of our innovative designs; SUPER EFFICIENT MULTI DIRECTION DOOR Minimises door open time, metal is poured and slag removed with the door substantially closed. Unrivalled operator viewing access to optimise the melting process, without losing melting time or efficiency. Latest development SIMULTANEOUS CHARGING AND MELTING UNDER THE DOOR. Result significant reduction in energy cost and improvements in metal recovery and productivity HEAVY DUTY ENGINEERING Our proven pin drive system more than 15 years success in the field. Customers report little maintenance maximum production time. FE stress analysis backed by our experienced engineering team modelling in 3D. Advanced and proven bearing technology. Our engineering tradition, skills and proven track record mean your investment will pay back quickly and last for years to come. COMBUSTION TECHNOLOGY Melting Solutions offer a wide range of combustion solutions with efficient combustion of all liquid and gaseous fuels. Air gas / oil. Oxy gas / oil. HYBRID COMBUSTION. Air / oxy fuel burners often deliver the ultimate solution, balancing energy cost and maximum melting performance. We look forward to discussing and advising our customers on the most efficient and effective combustion systems. PROVEN REFRACTORY SOLUTIONS We have supplied both monolithic and brick linings successfully for many customers. Pre cast ready to install monolithic lining systems are also available. meltpro Our interactive software developed for the rotary melting plant, which has been highly successful. meltpro can be retrofitted to existing furnaces and is capable of expansion to allow for future growth. Total foundry management, reported data is tailored to individual customer requirements

4 INTEGRATED M OPERATOR CONTROL CHARGING MACHINE WITH WEIGH CELLS TILT ROTARY FURNACE WITH SIDE TILT DOOR MONTHLY PRODUCTION (t) ANNUAL PRODUCTION (t) DAILY PRODUCTION (t) TILT ROTA CAPACITY / M 1,000 12, TR8 1,500 20, TR12 2,500 30, TR15 4,000 50, TR21 INTEGRATED MELTING PLANT

5 ELTING PLANT ROBOTIC INGOT STACKING MACHINE FILTER PLANT INGOT CASTING MACHINE TILTING HOLDING FURNACE POROUS PLUGS RY ODEL HOLDING FURNACE(S) CAPACITY CASTING CAPACITY FILTER PLANT VOLUME m3/hr. 7t 5t/hr 40,000 10t 5t/hr 60,000 15t 8t/hr 80,000 25t 10t/hr 100,000 UNDERDOOR CHARGING

6 CHARGING MACHINES AND MATERIAL HANDLING 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. MOBILE VIBRATORY FEEDER We supply a range of Charging Machines from 1 10 m³ 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 and often with dense and shredded scrap this charging rate is much faster. Our machines are heavy duty for years of trouble free service. We match the correct capacity machine for your furnace and scrap characteristics. The machines are fully integrated into the plant controls. We can include energy chains and machines that have long travel for crane loading. Operations by remote controls are also available to optimise productivity.

7 PERFORMANCE DATA Notes MODEL REFERENCE TR1 TR2 TR4 TR6 TR8 TR12 TR15 TR21 1 Maximum Charge Weight (Including Salt) - Kg 1,150 2,300 4,600 6,900 9,200 13,800 17,250 25,300 Door Opening Inside Diameter - mm Liquid Capacity - Volume in m³ Melt Rate - Kg/Hr 575 1,150 2,300 3,450 4,600 4,600 5,750 7,229 Melting Time for one Charge Above - Hours Non Melting Time, Charging, Casting and Discharging - Hours Total cycle time tap to tap - Hours Number of Cycles per 24 hours Maximum Charge Weight (Including Salt) per 24 hours - Tonnes Input per year (322 x 24 Hour days) - Tonnes 2,962 5,925 11,850 17,774 23,699 26,662 33,327 43,992 ENERGY USING AIR-FUEL BURNER Burner Energy kw PER Tonne of Charge Natural Gas Consumption per lb of Charge (Input). - m³ Oil Consumption per Tonne of Charge (Input). - Litres Burner Power - (Air Fuel) - mw ENERGY USING OXY-FUEL BURNER Burner Energy kw PER Tonne of Charge ~ ~ Natural Gas Consumption per Tonne of Charge (Input). - m³ ~ ~ Oil Consumption per Tonne of Charge (Input). - Litres ~ ~ Oxygen Consumption (Either Gas or Oil) - m³ ~ ~ Burner Power - (Oxy Fuel) - mw ~ ~ MECHANICAL Dive Power - kw Variable Melting Angle, 0-15 angle of Tilt (Subject to Capacity) x x x x x x x x Rotation Speed (variable direction and inverter controlled.) RPM Nominal Filter Plant Volume - (Nm³ /Hour) 10,000 15,000 25,000 35,000 40,000 45,000 65,000 80,000 Notes: 1. Maximum charge weight input including salt flux. 2. Maximum volume in the Furnace body for liquid aluminium. 3. Based on ISRI grades of scrap, no excessive contamination and reasonable density of approx 800 Kg/m³ 4. Assumes efficient automated charging and handling. SPECIFICATIONS MODEL kg Alu A B C D E F Vm³ TR1 1, ,540 1,100 4,450 2,235 2, TR2 2,000 1,100 3,050 1,400 5,400 3,200 2, TR4 4,000 1,600 3,200 1,850 6,800 3,800 4, TR6 6,000 1,800 3,350 2,300 6,800 4,400 5, TR8 8,000 1,800 3,850 2,300 7,800 4,400 5, TR12 12,000 2,000 5,000 2,700 9,100 5,500 5, TR15 15,000 2,000 5,650 2,800 9,500 6,400 6, TR21 21,500 2,000 6,000 3,100 11,500 6,400 6,

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