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production team clearly understands the marketing and operational objectives involved. These defined objectives measure the effectiveness of the melt quality processes and practices upon the final cast product. Typical challenges include, but are not limited to, how to achieve the same level of product quality consistency time in and time out, combined with how to achieve optimum performance in a practical manner while, at the same time, minimizing costs and maximizing productivity. These challenges and issues vary greatly depending upon whether processing primary or secondary metals. It is important to understand the melt quality and source of impurities at the beginning of the casting process in order to establish successful operational processes that will deliver consistent metal quality to the casting station. Pyroteks mission is to work with casthouse managers to develop a coordinated, holistic approach to a sustainable operations plan for melt treatment. We bring all these operational elements together in a synergistic way that maximizes the performance of each step of the melt treatment process. Pyroteks approach includes a process audit and situation analysis with the customer to jointly understand and document the customers operational objectives, historical operating performance, casting pit capabilities, end user requirements, environmental objectives and safety. Once these are understood and agreed upon, a prioritized list of performance improvement projects (PIPs) are identified. A Pyrotek technical team is then organized to work with the customer to execute, track and evaluate each projects results against preestablished targets and world-class operational norms for similar operations, targeting similar melt quality specifications.
Pyrotek has the expertise, technology, experience and the global resources to maximize the performance of your aluminium melt treatment systems.
PYROTEK SUPPLEMENT
SECONDARY SOURCES OF IMPURITIES
Recycled Scrap
Purchased Scrap
Dissolution of these impurities takes place in the cell/pot at ~ 960C. The chemical bath also contributes alkali metals from the salts used K, Na, Ca and Li. Some cells operate a high Li bath chemistry for added current efficiency. Carbides and oxides are also generated by the turbulent electro-magnetic and chemical activity in the cells and the reactions with the cell lining materials. The bath is frequently tapped along with the metal in the crucible delivered to the cast house. Turbulence during the transfer leads to oxide and dross inclusions in the metal. Refractory wear in transfer ladles also leads to a risk of increased inclusions. Feed stock from secondary melting can introduce an even wider range of impurities depending on the material combination used to charge the furnace. Recycled Secondary Ingot (RSI) cast from metal recovered from dross, saw chips, saw fines and thermal fill scrap, can contribute alkali metals as well as TiB 2 and aluminium oxides. Recycled scrap from internal or external sources is an additional source of
Processing practices are a constant source of contaminates. Inefficient or Poorly Adjusted Poor handling and metal flow Burners arrangements generate metal turbulence, which in turn, generates dross and oxides. Iron pick up can come from uncoated metal tools. Poor housekeeping allows dirt, inclusions and dusts to become entrained in the metal flow as inclusions to the next cast. Waste burner gases and poor burner efficiency allow hydrogen to be absorbed. Open doors and/ or improper burner adjustments can contribute to hydrogen pickup and to melt loss due to direct flame impingement. In-line degassing can be an unintentional source of contaminates from rotor speed too slow (large bubbles), rotor speed too fast (vortexing), rotor particulate, oxide build up and broken baffle plates.
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fully mix the bath and master alloys. In an attempt to overcome this problem of effective mixing, the master alloys are usually made with a special flux that accelerates the mixing of the alloy addition into the melt. The EMP and Metaullics pumping systems for light gauge scrap additions have the advantage of the unique vortex well as a medium for the addition of alloys into the furnace. The furnace door is kept closed during the entire process, with the following three operating benefits: Maintaining the heat transfer efficiency of the furnace, Minimising energy losses, and Minimising environmental emissions to the casthouse and operators. The LOTUSS vortex system eliminates the need to alloy directly through the furnace doors or by using specially made alloy tablets. The pure elemental additions Mn flake, Fe splatter, Cu cuttings/swarf and Mg bars can now be used in an effective way by charging directly through the EMP Vortex.
Purchasing pure alloy elements in a form that can be charged directly into the vortex of an EMP System also can give some financial benefits.
Economic Benefits to Alloying Through The Vortex With the appropriate feeding equipment, alloys from lump silicon to magnesium have been effectively charged into a furnace with significant reductions in alloy losses and an improved dissolution time of the alloy into the melt. The following graph demonstrates the fast dissolution of magnesium ingots through a vortex.
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alloy oil, moisture levels etc.) than when charging through the main furnace door. The use of pure elements offers additional savings in the reduced cost of master alloys and tablets. Additional Benefits of EMP Systems EMP now offers complete solutions to melting furnace problems. EMPs use of a LOTUSS charge well offers casthouse operations the following opportunities: Reduced alloying costs Ability to transfer from furnace to furnace or to casting lines Option to raise metal levels for transfer Add flux additions directly into the melt Reduced emissions when fluxing Improved flux efficiency for Na and Ca removal Capability to incorporate gas injection for hydrogen removal.
Yield Improvement This reduction in alloy losses results from the fact that the alloy addition is immediately submerged sub-surface, minimising any exposure to the air and to the burners in the furnace. Typical yields on pure alloy additions charged in this manner are shown below:
Alloy Addition Lump Silicon Magnesium 10 Kg Ingot Manganese Flake Iron Splatter Yield By Charging Through EMP 97% 98% 98% 98% Yield When Charged Directly To Furnace 94% 90%
94% 90% (Powder/Tablet) Copper 99% Only Tablets Yield Improvement by Charging Pure Alloys Directly Into EMP Vortex
Reduced Mixing Time By charging the alloy additions in this manner, they are immediately mixed in the sub-surface aluminium movement within the vortex. They quickly dissolve and are easily mixed into the full aluminium bath by the rapid sub-surface flow from the electromagnetic pump. Alloy Purchase Costs Purchasing pure alloy elements in a form that can be charged directly into the vortex of an EMP System also can give some financial benefits. Normally it is not possible to use pure additions when charging directly into the furnace due to their ability to go into solution. The yield can also be a concern as they tend to be small in size and oxidise easily. By using the LOTUSS vortex well, it becomes practical to charge these pure elemental additions directly through the vortex. The result is a yield that is much higher (depending upon the quality of the
Pyroteks EMP, Metaullics and SNIF divisions offer a complete line of circulation equipment.
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within the specification limit for the alloy being produced. It has always been necessary for chlorination technology in aluminium recycling to meet rigorous environmental standards. Current MACT (Maximum Achievable Control Technology) standards in the U.S. have taken this requirement to an even higher
The Metaullics gas injection pump is the product of choice where demagging is required.
level. Compared to other chlorination technologies, gas injection pumps provide the safest and most efficient technology for accomplishing this aspect of melting and refining. When demagging is required, the Metaullics gas injection pump is the product of choice due to its proven operating efficiency, low maintenance, rugged construction and reliability.
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Pyroteks early involvement in research programs and technical partnerships with the major aluminium companies aimed at eliminating chlorine usage has improved the efficiency of fused refining agents in in-furnace treatments. We have gained the knowledge, products and practical expertise to resolve most metallurgical problems related to the presence of hydrogen, non-metallic inclusions and alkali metals in aluminium cast products. Pyrotek has proven over recent years that the use of environmentally friendly refining agent injection technology is a truly viable alternative to both chlorine fluxing and fluoride based fluxes. Fluxes and refining agents can improve the quality of aluminium alloys if they are treated while still molten in the furnace. Originally, this type of treatment was restricted to dross reduction and furnace cleaning. However, it usually contributed to magnesium loss in certain alloys (due to chemical and thermal reduction) as well as an increase in alkali Fused Refining Agents metals (from the salts used in the products supplied in previous years). Magnesium is an expensive addition to make to any alloy, thus any treatments by salts or chlorine gas, both of which remove magnesium, are therefore expensive in terms of hidden costs. Alkali metals (Na, Ca, Li) are also undesirable in certain foundry alloys (for example, A356.2) due to the problems they can cause in subsequent processing of the cast products, as well as the undesirable effects that they can have upon their grain structure (such as, modification). A range of fused refining agents has been developed by Pyrotek to counter act these undesirable side effects. They are a blend of fused, anhydrous MgCl2 and KCl which allow them to be injected or immerged, either through a lance, rotor or a vortex, below the surface of the melt, where they melt before coming into intimate contact with the molten aluminium in finely-dispersed liquid droplet form. Refining agents are particularly effective when introduced below the melt surface because the refining agent materials melt below 480C (880F). The refining agent quickly becomes a liquid phase in molten aluminium, facilitating the reaction which
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Robert Bridi Pyroteks Global Product Manager, Fluxes, Refining Agents & Lubricants
PHD-50
STAR FIM5
Refining agents are particularly effective when introduced below the melt surface.
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thermal stratification within the body of the melt. The reaction efficiency of impurity removal is enhanced by improving the metal circulation within the furnace during injection rather than adding the refining agent flux in excess and/or on the melt surface. Pyrotek offers a wide range of flux injection and circulation equipment to maximize the efficiency of the flux refining agents. This minimizes consumable costs, cycle times, and environmental issues associated with proper melt treatment. The product mix of a particular casthouse and its related quality specifications drive the correct choice and combination of melt treatment technology. The good news is that this type of flux injection equipment, combined with the proper refining agent and operating practices, almost always has a rapid pay back (typically 6 18 months) and adds significantly to melt quality consistency, operator safety and environmental objectives with the use of PLC controlled operating procedures.
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Removal (%)
Test #
OK Minimum Detection Limit Reached
Test #
Removal (%)
PYROTEKS MISSION Providing innovative solutions to customer needs utilizing our global resources.
Removal (%)
Test #
AlSCAN 1 AlSCAN 2
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MACT Limit 0.4 lb/ton of feed 8.15 8.21 0.811 0.934 0.273 0.310
Pyrotek CONCLUSION is the aluminium From its early involvement in research programs and technical partnerships with major aluminium companies to eliminate chlorine usage and to improve the efficiency of fused industrys refining agents in in-furnace treatments, Pyrotek has gained the knowledge to resolve most metallurgical problems related to the presence of hydrogen, non-metallic inclusions and comprehensive alkali and alkaline earth metals in aluminium castings. Pyrotek has proven in recent years that the environmentally friendly refining agent injection technology is a viable alternative resource to chlorine fluxing and to fluoride based fluxes. for improving As a partner to the industry, Pyrotek has worked with aluminium companies world-wide to review and improve their melt treatment performance. From melting to casting and everything in-furnace in between, Pyrotek has experienced personnel to help increase productivity while meeting melt treatment customer driven quality goals. performance. Pyrotek is the aluminium industrys most comprehensive resource for improving in-furnace
melt treatment performance. Pyrotek is unique in its ability to provide the integration of innovative technologies, process expertise and a global perspective, all dedicated to assisting customers in the optimization of their casthouse processes and practices.
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EUROPE
CZECH REPUBLIC, Blansko Phone: (420) (0) 516-527-111 e-mail: blansko@pyrotek.info GERMANY, Grevenbroich Phone: (49) (0)2182-8-10-20 e-mail: grevenbroich@pyrotek.info SWEDEN, Ed Phone: (46) (0) 534-62000 e-mail: ed@pyrotek.info SWITZERLAND, Sierre Phone: (41) (0)27-455-82-64 e-mail: sierre@pyrotek.info UNITED KINGDOM, Milton Keynes Phone: (44) (0)1 908-561155 e-mail: miltonkeynes@pyrotek.info
SOUTH AMERICA
BRASIL, So Paulo Phone: (55) (0)11-4786-5233 e-mail: saopaulo@pyrotek.info VENEZUELA, Puerto Ordaz Phone: (58) 286-994 1894 e-mail: puertoordaz@pyrotek.info
U.S.A.
CALIFORNIA, Cerritos Phone: (562) 623-0085 e-mail: cerritos@pyrotek.info INDIANA, Columbia City Phone: (260) 248-4141 e-mail: columbiacity@pyrotek.info INDIANA, Evansville Phone: (812) 867-6343 e-mail: evansville@pyrotek.info NEW YORK, Canastota Phone: (315) 697-8410 e-mail: canastota@pyrotek.info NEW YORK, Elmsford Phone: (914) 345-4740 e-mail: elmsford@pyrotek.info
Pyrotek is unique in its ability to provide the integration of innovative technologies, process expertise and a global perspective.
CORPORATE OFFICE
9503 E. Montgomery Avenue Spokane Valley, WA 99206 Phone: (509) 926-6212 Fax: (509) 927-2408 e-mail: info@pyrotek.info
MEXICO
MEXICO, Santa Catarina Phone: (52) 81-8336-9117 e-mail: mexico@pyrotek.info
MIDDLE EAST
UNITED ARAB EMIRATES, Dubai NORTH CAROLINA, Salisbury Phone: (971) (0)4-883-77-00 Phone: (704) 642-1993 e-mail: dubai@pyrotek.info e-mail: salisbury@pyrotek.info OHIO, Solon Phone: (440) 349-8800 e-mail: solon@pyrotek.info PENNSYLVANIA, Carlisle Phone: (717) 249-2075 e-mail: carlisle@pyrotek.info WASHINGTON, Spokane Valley Phone: (509) 926-6211 e-mail: spokane@pyrotek.info WISCONSIN, Waukesha Phone: (262) 524-9095 e-mail: waukesha@pyrotek.info
AUSTRALIA
AUSTRALIA (ANZ HEADQUARTERS) NEW ZEALAND NEW ZEALAND, Auckland Phone: (61) (0)2 9631-1333 Phone: (64) (0)9 272-2056 e-mail: sydney@pyrotek.info e-mail: auckland@pyrotek.info
CANADA
QUEBEC, Drummondville Phone: (819) 477-0734 e-mail: drummondville@pyrotek.info
RUSSIA/CIS
RUSSIA/CIS, Moscow Phone: (7) 095-230-71-63 e-mail: moscow@pyrotek.info
SOUTH AFRICA
REPUBLIC OF SOUTH AFRICA, Richards Bay Phone: (27) (0)35 7974039 e-mail: richardsbay@pyrotek.info
This supplement can also be viewed at www.pyrotek.info/melt_treatment See the previous supplement at www.pyrotek.info/furnace_operations
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