Freebee FY-5 Salt Flux

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1 Freebee FY-5 Salt Flux Salt flux is used when recycling aluminium. This is an introduction to salt flux composition, usage and ratios. Rotary furnace fluxes and techniques will be explained, and you will get to know more about environmental impact, recovery efficiency and the many benefits of using Freebee FY-5 Salt Flux

2 Advantages that works for you Freebee FY-5 Salt Flux is of very high purity and offers several advantages in aluminium recovery Freebee FY-5 Salt Flux is of very high purity and it offers several advantages over the standard salt fluxes presently used in the majority of reclamation plants. Freebee FY-5 Salt Flux benefits 1. Lower flux consumption. 2. Higher metal recoveries. 3. Lower energy costs. 4. A reduction of black dross generated; therefore less disposal costs. 5. The high purity of Freebee FY-5 reduces the possibility of contaminating the metal with unwanted elements. 6. Safety - mixing under strict control ensures the absence of oxidising agents. USAGE Salt flux is used for recovering aluminium from high surface area or dirty aluminium scrap and dross. The furnaces used may be reverberatory with side well or fixed and tilting rotary salt bath furnaces, each of these furnaces is trying to accomplish the same thing; that is to melt scrap with minimal losses arising from the oxidation of the aluminium. Using a salt flux in these furnaces provides several beneficial actions: 1. It protects the aluminium from further oxidation during melting. 2. It strips the dirt and oxides away from the surface of the molten aluminium. 3. It suspends the dirt and oxide materials thereby preventing them from contaminating the aluminium metal. Freebee FY-5 Salt Flux SALT FLUX RATIOS Usually a mixture of Sodium Chloride (NaCl) and Potassium Chloride (KCl) is used to make a salt flux. It may be seen from the phase diagram that at a weight ratio of 42% NaCl and 58% KCl the binary mixture gives a minimum eutectic melting point of 658 C. Pure NaCl melts at C and pure KCl at 790 C. (Pure aluminium melts at 660 C and its alloys will melt at lower temperatures). The benefits of using a mixture close to the eutectic melting point is that less heat energy would be required to melt it and so less oxidation of the aluminium would occur. However, salt flux mixtures with larger proportions of NaCl are frequently used because NaCl is cheaper to buy than KCl. These mixtures will melt at higher temperatures but the decrease in metal recovery and increased energy cost due to the higher melting point of the flux is balanced against the less expensive salt flux. Eutectic melting point Ratio NaCl /KCL Melt Temp Aluminum 0/ ºF/777ºC 70/ ºF/697ºC 50/ ºF/660ºC 40/ ºF/665ºC 100/0 1480ºF/804ºC

3 COMPOSITION Freebee s FY-5 Salt Flux offers distinct advantages over other commercially available salt fluxes. These advantages are due to its composition and very high purity. Freebee FY-5 Salt Flux composition 47.5% NaCl 47.5% KCl 5% Synthetic cryolite THE CRYOLITE EFFECT A binary mixture of molten NaCl and KCl will protect aluminium from oxidation and will suspend oxide films and other particulate but it is not effective in disrupting the oxide film surrounding the aluminium droplet. The addition of small amounts of cryolite (3-5%) has the effect of stripping off the oxide skin surrounding the aluminium droplets and allows them to coalesce to form larger droplets that can escape from the liquid salt flux into the main pool of metal. This increases metal recovery as it reduces the amount of aluminium droplets becoming trapped in the spent salt cake. It is also claimed that when pieces of aluminium scrap such as shredded cans are melted in a salt flux containing cryolite, they melt and change shape to a nearly spherical drop due to the least interfacial area. Without cryolite the shape remains far from spherical, thus there is more surface area for oxidation to occur. Also additions of small quantities of cryolite will depress the melting point of the salt flux mixture, which will inhibit still further the possibility of oxidation of the aluminium and also reduce energy costs. ROTARY FURNACE FLUXES The fluxes now used in rotary furnace operation worldwide have been developed in laboratory and field use over several years. It is understood that the most effective salt mixtures are those that melt rapidly at the lowest melting temperature. Various combinations of metallic salts have been tested and reported in technical papers and although some disagreement is normal in laboratory findings and conclusions, it is agreed that a flux that melts at the lowest possible temperature below the melting point of aluminum is important. The flux mixture must have the ability to dissolve and absorb aluminum oxide, dirt and other impurities while reducing the surface tension of liquid aluminum globules. Coalescence of the globules is promoted by the reduction of the surface tension; therefore rapid fluidity of the aluminum is achieved. Fluxes must not contaminate the metal nor be volatile or harmful to employees. Several mixtures of chemical salts achieve the desired results, however cost is a major factor due to the quantities used in a production furnace. Therefore various blends of sodium chloride (NaCl), potassium chloride (KCl), aluminum fluoride (ALF3), cryolite (Na3ALF6), and flour-spar (CaF2) are routinely used in rotary furnaces. The grain size of the salts should be the same to promote homogenous blending but should not be so fine that it is dusty. Proper sizing is 2-3 mm to minimize dusting and properly mix with the charge material. FLUX USAGE TECHNIQUES The tilting rotary furnace utilizes a dry flux method. Fixed axis furnaces use a wet method that uses a flux ratio 0.9 to The dry method uses a flux ratio of 0.35 to 0.5. Ratios are calculated on the non-metallic portion of the charge material. With a 50% dross charge weighing 10 ton the wet method would require 5 ton of flux while the dry method would require approximately 2.5 ton. Therefore, with the dry flux method, furnace capacity is increased, energy saving is realized, and salt slag disposal is substantially reduced.

4 The introduction of melting fluxes into the furnace differs with the type material, amount of contamination, and metallic percentage in the material. The furnace condition is also important to the process and the furnace walls must be kept clean or flux will stick and build out reducing the capacity of the drum and adversely affect furnace and energy performance. Best results with clean high recovery material is achieved when the flux is charged and melted before scrap charging whereas flux can be charged with dross at the same time the dross is charged. With certain types of contaminated scraps it is often desirable to charge the flux in stages to curtail burning of hydrocarbons and other contamination. Flux must be stored in a dry, clean area. Accurate weighing of flux is essential to furnace control, optimum recovery and cost saving. In-sufficient amount of flux will result in thermitting of the furnace resulting in lost recovery. Too much flux also results in lost recovery due to metal becoming trapped in the salt slag. Flux can often be used more than once with clean materials. Properly designed salt slag pans are essential to optimum recovery by capturing any metal removed with the slag. Environmental Impact The use of a salt flux, however, generates spent flux (black dross), which has high disposal costs. The amount of black dross produced depends upon type of furnace and the percentage of aluminium present in the scrap being melted. E.g. a tilting rotary salt furnace can use half the amount of flux needed in a fixed rotary salt furnace, also the more non metallics present in the scrap the more flux is required. Impurities The impurities that are found in commercially available industrial salts have a pronounced effect on the efficiency of the scrap re-melting process. Insoluble materials These are any materials that do not dissolve into the molten salt flux, and usually the same materials do not dissolve in water. Examples are aluminium oxide, iron oxide, silica and dirt. These materials are detrimental because they inhibit metal droplet coalescence and they use up some of the salt flux capacity to hold oxides. Calcium Sulphate Calcium Sulphate (CaSO4) occurs naturally as Gypsum and is frequently found in the NaCl salt deposits. The CaSO4 reacts with the molten aluminium and any magnesium present so that the metals are no longer available for metal recovery. The reaction may best be explained by the following reactions. 8Al + 3CaSO4 = 4Al2O3 + 3CaS 10/ 2/3 Al + 4CaSO4 = CaS + 4 1/3Al2O3 + Al2S3 + Ca0 8Mg + 2CaSO4 = 6MgO + MgS + CaOMgO Rotary Tilting Furnace For the first two equations it can be calculated that 1 kg of CaSO4 in the salt flux would consume 0.53 kg of aluminium. A skin of oxides and sulphides is formed around the droplets of molten aluminium, which ends up suspended in the molten salt and contributes to extra dross formation.

5 Moisture Water in the salt flux is detrimental for two reasons. Firstly you do not want to pay for water and secondly the presence of water during melting can lead to enhanced oxide formation and so reduce metal recovery. Hazards In addition to the impurities mentioned above there may also be the risk of the salt flux being contaminated with powerful oxidising agents that are of similar appearance to the salt flux in both colour and texture and yet are extremely hazardous. When these oxidising agents and molten aluminium come into contact there is a rapid and high release of energy in the form of heat, from the reaction: 2AL + 3/2O2 = Al2O3 sodium sulphate; this also is a powerful oxidising agent. Sodium sulphate is widely used in the manufacture of a variety of products including glass and detergents. An explosion, which occurred in a rotary furnace, has been attributed to contamination of the salt flux with sodium sulphate. Preliminary investigations at a U.K. University using small laboratory experiments support this. Turning the downsides up! Despite the environmental side effects of recycling aluminium, we must bear in mind, that aluminium has a very high recovery rate. Therefore the reclamation plants are doing a very important job when it comes to preserving nature. By using the Freebee FY-5 Salt Flux in a rotary tilting furnace, the salt cake for landfill will decrease remarkably. This together with the huge energy savings turn out to be essential to our environment. Used Beverage Cans Fertilisers such as ammonium nitrate are common substances and are powerful oxidising agents. There have been occasions when small quantities of these substances have been accidentally charged into aluminium melting furnaces with disastrous consequences. One kilogram of ammonium nitrate reacting completely with molten aluminium releases the equivalent energy of 4 kilograms of TNT. The many benefits of using the Freebee FY-5 Salt Flux when recovering aluminium from different type of alumimium scrap are worth considering. Optimize your business savings and more importantly contribute to improve sustainability and nature. Another common substance that we believe is used in China to promote a thermite reaction in furnace skim is

6 RECOVERY EFFICIENCY The recovery efficiencies listed below are based on actual experience. These efficiencies are to be viewed as guidelines as to what might be expected from the furnace. It should be noted that actual recoveries are dependent on many factors and may vary from those given below. Average Recoveries and Flux Usage for Typical Materials in rotary furnaces Material type Recovery Target Flux Efficiency % Addition % Low Copper Sheet-Unpainted New 95 3 Low Copper Sheet Painted - New 90 6 Low Copper Sheet-Unpainted Old 90 3 Low Copper Sheet Painted - Old 85 6 New Cast 95 3 Old Cast Shredded Cast 90 6 Swarf-Dry 96 5 Swarf-5%0il 89 8 Swarf-10% Oil Closure Bale Scrap 85 8 Class 1 Can Body-Clean 96 8 Class 2 Can Scrap Lid Laquered 89 5 Class 3 Can Scrap-Body-decorated 89 7 Class 4 Can Scrap Lid Laquered plus compound 87 6 UBC Delacquered 89 8 UBC Un-Delacquered Foil Bare-Mixed Gauge-New Production 93 5 Foil Decorated-Mixed Gauge New Production Painted Extrusions 91 5 Litho Print Sheet-New coated without paper 95 4 Litho Print sheet-new coated with paper 83 8 Old Sheet Fragmented Automobile Scrap 85 8 Greasy Flashings Dross 40% Metallic Dross 50% Metallic Dross 60% Metallic Dross 70% Metallic Dross 80% Metallic Contact us today Our team of experts is looking forward to provide you with further specifications and pricing. January The information in this folder is subject to change.

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