The primary furnaces used for melting aluminum include vertical aluminum melting furnaces, induction furnaces, and reverberatory furnaces. Each type has its unique features and efficiency levels, making them suitable for different applications and industries.
Vertical Aluminum Melting Furnace: This type of furnace is particularly popular in small to medium-sized enterprises and the die-casting industry. It features a vertical flue with a large cross-section at the rear, and a high-speed burner is installed at the bottom of the flue. Aluminum ingots and charge are added from the top of the flue and are quickly melted at the bottom by the impact of the flame. The flue gas exchanges heat with the cold charge during discharge, resulting in high thermal efficiency, often exceeding 50%. This setup ensures a relatively low energy consumption index.
Induction Furnaces: Induction furnaces, especially medium frequency furnaces, are highly efficient for melting aluminum. They can increase efficiency by 60% to 75% and reduce oxidation losses. These furnaces emit low levels of pollution and produce aluminum with higher purity and uniformity. The heat source in induction furnaces does not directly contact the aluminum, which is beneficial for alloy production as it allows for the mixing of smelts without contamination.
Reverberatory Furnaces: Reverberatory furnaces use fuels like natural gas, coal gas, or heavy oil. The thermal efficiency of these furnaces is significantly affected by the air content in the fuel combustion. Too much air can lead to low thermal efficiency as excess air takes away heat in the exhaust smoke, while too little air results in incomplete combustion and reduced efficiency, along with increased emissions of polluting gases. These furnaces heat aluminum to melting temperatures using direct-fired wall-mounted burners, with heat transfer primarily through radiation from refractory brick walls and convective heat transfer from the burners. They are available in capacities up to 150 tons of molten aluminum, with typical melting efficiencies ranging from 15% to 39%.
Conclusion: The choice of furnace for melting aluminum depends on the specific requirements such as production rate, quality and composition of the scrap aluminum, and whether batch or continuous operation is desired. Vertical aluminum melting furnaces are efficient for small to medium-scale operations, induction furnaces offer high efficiency and purity, and reverberatory furnaces provide a balance between efficiency and capacity.
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