What is the power consumption for melting solid aluminum scrap? Optimize Your Foundry's Energy Efficiency

Melting solid aluminum scrap requires a power consumption range of 500 to 575 kWh per ton. This figure represents the energy input needed for processing heavy, solid forms of aluminum, serving as a benchmark for high-efficiency operations.

Core Insight: Material density dictates energy efficiency. While solid aluminum is relatively efficient to melt, processing lighter scrap forms significantly increases power consumption, approaching levels required for steel.

Analyzing Energy Requirements by Material Type

Solid Aluminum Scrap Efficiency

For solid aluminum scrap, the energy requirement is the lowest among the categories analyzed, falling between 500 and 575 kWh per ton.

This range suggests that denser, heavier scrap allows for better thermal transfer and melting efficiency compared to lighter alternatives.

The Cost of Light Aluminum Scrap

If you are processing light aluminum scrap, the power consumption rises to 600 to 625 kWh per ton.

This increase indicates that physical form plays a massive role in operational costs; light scrap requires roughly 20% more energy at the upper end compared to the most efficient solid scrap melting.

Comparative Analysis: Aluminum vs. Steel

Steel Melting Benchmarks

To understand the relative efficiency of aluminum, it is helpful to compare it to ferrous metals. Melting Mild Steel (MS) or Stainless Steel (SS) requires 600 to 650 kWh per ton.

General steel melting is often cited specifically at 625 kWh per ton.

The Efficiency Overlap

While solid aluminum is distinctly more energy-efficient than steel, light aluminum scrap blurs this line.

At 600–625 kWh per ton, melting light aluminum consumes nearly the same amount of power as melting steel, negating the inherent energy advantages usually associated with aluminum's lower melting point.

Understanding Operational Trade-offs

Scrap Density vs. Energy Cost

Choosing between scrap types involves a trade-off between material cost and energy cost.

While light aluminum scrap may be cheaper to acquire, the higher power consumption (up to 625 kWh/ton) will inflate your operational expenditures (OpEx).

Material Type vs. Throughput

Solid aluminum scrap allows for lower energy usage per ton, likely correlating with faster processing times and higher furnace throughput.

Relying on light scrap or steel requires more robust power infrastructure to handle the sustained load of 600+ kWh per ton.

Making the Right Choice for Your Goal

To optimize your melting strategy, align your material choice with your operational priorities:

• If your primary focus is energy efficiency: Prioritize solid aluminum scrap, which keeps consumption in the optimal 500–575 kWh per ton range.
• If your primary focus is processing mixed or light scrap: Budget for higher energy costs, anticipating consumption between 600 and 625 kWh per ton, similar to steel processing levels.
• If your primary focus is ferrous metals (MS/SS): Ensure your power supply can support a consistent load of 600 to 650 kWh per ton.

Select your raw material feedstock carefully, as the physical density of the scrap drives your energy bill as much as the metal type itself.

Summary Table:

Material Type	Scrap Density	Power Consumption (kWh/ton)	Efficiency Rating
Solid Aluminum Scrap	High (Heavy)	500 - 575	Superior
Light Aluminum Scrap	Low (Thin/Light)	600 - 625	Moderate
Mild/Stainless Steel	Varies	600 - 650	Standard
General Steel Melting	Standard	625	Standard

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