Tilting Rotary Furnace

Transcription

1 Tiltig Rotary Furace A quatum leap i meltig techology

2 The Tilt Rotary Furace Meltig Solutios Limited offer the TR rage of advaced Tiltig Rotary Furaces available i capacities from toes alumiium ( m 3 ). TR furaces provide state-of-the-art techology for meltig a wide rage of scrap ad for processig drosses. Complete meltig plat solutios are also available from Meltig Solutios Limited, icludig chargig machies, holdig furaces, castig equipmet ad pollutio cotrol to meet the very highest evirometal stadards. All from oe experieced supplier built o prove results from our users. The Meltig Solutios Limited TR Furaces offer great flexibility. Oe furace able to process drosses, mixed scrap, cotamiated scrap (with iro) chips, UBC ad foils. For compaies lookig to upgrade from fixed axis rotary meltig or reverberatory meltig the TR Furaces offer sigificat advatages with attractive pay back. Low eergy meltig at 750 kw per toe. High productio rates, urivalled meltig speed Full automatio PLC ad SCADA Miimum labour costs Quality egieerig esures log service life with miimum maiteace High metal recovery Itegrated tur-key solutios from a world leader i meltig techology The advatages are: 25% fuel savig 50% icrease i throughput 30% savig o slag disposal 50% savig i salt flux Reduced labour, fully automated process TR MELTER WITH 5 YEARS 24/7 OPERATION, QUALITY ENGINEERING IN ACTION TILT ROTARY PROCESS Tilt Rotary Furaces have sigificat advatages compared to fixed axis rotary furaces. The diagrams above compare the operatio of fixed axis rotary furaces with tap holes to the OTTO JUNKER (UK) Ltd hydraulic lip axis Tiltig Rotary Furace: Covetioal fixed axis sigle pass (blue alumiium / red slag) 1. Scrap ad salt are charged ito the furace. Chargig is restricted by the small charge hole. 2. The charge is melted by a sigle pass burer arragemet, limitig efficiecy. 3. Alumiium is ru out through a tap hole. Opeig ad closig the tap hole is slow ad labour itesive. 4. Slag is ru out through a secod tap hole. Slow ad labour itesive. A high salt-to-oxide ratio is required to esure the slag is liquid to ru through the small tap hole. 1. Furace is charged very quickly usig the much larger charge opeig. 2. Meltig by double pass burer arragemet. Savig eergy - faster meltig. 3. The furace is tilted to pour out the alumiium. The dry slag remais i the furace - o time wasted opeig tap hole. 4. Fially the furace is rotated ad tilted simultaeously to tip out the dry salt slag for disposal. Amout of slag greatly reduced because a liquid slag is ot eeded - o time wasted opeig slag hole. 5. Faster rotatio - better separatio of alumiium from slag.

3 FURNACE SPECIFICATION The Meltig Solutios TR rage of Tilt Rotary Furaces are available i a stadard rage of capacities from 1,000 kgs to 21,500 kgs. Optios of oil firig or gas firig are available. O furace capacities of 5 toes ad above, oxy-fuel burers firig either oil or gas are available. Please refer to the specificatio chart ad idividual drawigs of the furace rage attached. Normally the stadard Meltig Solutios Limited scope of supply icludes: The mai furace assembly Complete hydraulic system Burer system Supply of refractory liig PLC cotrol Furaces up to 2,000 kgs size are supplied complete from Meltig Solutios Limited with the refractory liig already istalled. Up to 2,000 kgs the furaces ship withi a ope top cotaier, or by road, requirig miimal istallatio ad coectio to adequate services. Refractory liigs o larger sizes are istalled o site. TECHNICAL SUPPORT All Meltig Solutios furaces are backed by full egieerig ad techical support to help pla the furace istallatio, for example, we usually provide desig ad drawigs for furace extractio hoods ad ductwork coectig to filter plats allowig the cliet to maufacture these items locally savig trasport costs. Where required, Meltig Solutios ca provide a complete tur-key solutio icludig chargig machies, holdig furaces, castig ad pollutio cotrol usually usig bag filters. Tur-key projects are backed by o-site istallatio supervisio, commissioig ad operator traiig where required. Assistace is give with evirometal applicatios ad liaiso with local evirometal authorities which is a key part, particularly for ew meltig facilities. TR 2 SUPPLIED COMPLETE, MINIMUM INSTALLATION TIME

4 INTEGRATED MELTING PLANT Meltig Solutios offer Tiltig Rotary Furaces as combiatio tur-key meltig plats for productio of specificatio alloyed igot ad di-oxidat productio from scrap ad drosses. At the heart of the system is a advaced techology Tiltig Rotary Furace that will melt aythig from iro castigs to UBC, bales, ad drosses i the same furace. Operators have see metal recovery improve by 5% o average over the same type of scrap melted i traditioal reverberatory meltig furaces. Average of 5% extra metal recovery Lower eergy cost, 25% savig i fuel Icrease output Fully automated to reduce labour Very flexible to chage alloys Iro cotet i melt closely cotrolled at low levels Meltig Solutios offer a tur-key package with pollutio cotrol Rage of furace sizes ad outputs available TILTING HOLDING / ALLOYING FURNACE FULLY AUTOMATED SYSTEM WITH ADVANCED PLC PROCESS CONTROL WITH SCADA

5 Tilt Rotary Furaces WORLDWIDE REFERENCES ALUSERV Bahrai BALTICAL Kauas, Lithuaia BLAYDON METALS Newcastle-Upo-Tye, UK CAST ALUMINIUM INDUSTRIES Dubai, UAE CHALCO (CHINA ALUMINIUM) Tsigdao, Chia F.E. MOTTRAM Cogleto, UK FORUM Zaporozyhe, Ukraie HONG POH METALS Melaka, Malaysia KRASAINIE Lejumi Riga, Latvia NORTON ALUMINIUM Caock, UK NORTON PVT Mumbai, Idia RMC CUSIANA Italy RUSAL TSVETMETOBRABOTKA Samara, Russia SPONTEX Wjesia, Polad TR 21 gas fired meltig plat with 10 toe tiltig holdig furace, igot castig machie ad filter plat. Processig high volumes of drosses. TR 10 gas fired. Meltig plat complete with 2 x 20 t tiltig meltig/holdig furaces with 2 x igot castig machies. Meltig low grade scrap, castigs with iro ad drosses. TR 3 gas fired. Complete meltig plat with 3.5 m 3 vibratory chargig machie, 5 t tiltig holdig furace ad di-ox cube castig machie. Dedicated plat for meltig tait tabor (old rolled) mixed scrap producig di-ox products for steel works. TR 5 with oxy fuel firig (oxy oil). Dedicated dross meltig plat 15,000 t/year. TR 15 with oxy fuel firig (oxy gas). A flexible meltig plat for all types of scrap, turigs, drosses, UBC etc. Automated 10 m 3 chargig machie, automated slag moulds ad pourig lauder. 100 t per day meltig plat. Project to upgrade furace door o a 9 t MDY/ALTEK furace. TR 1 atural gas fired. Part of a meltig plat 2 x 5 t reverberatory furaces with castig machie. For meltig drosses ad low grade scrap. TR 1 oil fired. Dedicated meltig plat for drosses. Supplied with 10,000 m 3 /hr filter plat. TR 3 atural gas fired. Meltig low grade scrap ad drosses. TR 5 atural gas fired. Meltig mixed low grade scrap. Special 1.8 m extra large diameter door with latest side tilt feature. 2 x TR 6 dual fuel oil/gas fired furaces with elarged door 1.8m. Processig mixed scrap ad drosses. TR6 gas fired with elarged door 1.8m. Processig mixed scrap ad drosses. TR 5 atural gas fired. Meltig plat for drosses ad low grade scrap with a castig lie for 500 kgs sows. Icludig a 30,000 m 3 /Hr filter plat. TR 3 atural gas fired. Specialist plat for di-ox productio for steel works. Meltig UBC ad drosses. TR 1: HONG POH METALS MALAYSIA TR 5: CAST ALUMINIUM INDUSTRIES DUBAI UAE TR 5: TSEVETMETOBRABOTKA RUSSIA TR 10: BALTICAL LITHUANIA

6 Specificatios Tilt Rotatig Furace 1 t t ( m 3 ) 'D' 'F' 'E' 'B' 'A'Ø TR1-3 OIL OR GAS FIRED AIR FUEL A B C D E F V m3 Model kgs Alu TR 1 1, ,540 1,100 4,450 2,235 2, TR 2 2,000 1,100 3,050 1,400 5,400 3,200 2, 'C'Ø TR 3 3,000 1,300 3,200 1,700 6,750 4,500 3, LIQUID VOLUME IN CUBIC METRES 'V' TR5-21 OIL OR GAS FIRED AIR OR OXY FUEL OPTIONS. Model kgs Alu A B C D E F V m3 TR 5 5,000 1,400 3,200 2,100 5,710 5,700 3, TR 8 8,000 1,500 4,000 2,300 6,510 5,700 4, TR 10 10,000 1,800 4,700 2,400 8,040 6,760 5, TR 15 15,000 2,000 6,000 2,800 8,675 7,000 5, TR 21 21,500 2,000 6,000 3,000 8,675 7,250 5, UNIQUE DOOR WITH SIDE TILT FEATURE 1. CLOSED POSITION FURNACE CAN TILT WITH BURNER FIRING DURING THE MELT INCREASING MIXING AND HEAT TRANSFER. 2. SIDE TILT PARTLY OPENS DOOR TO VIEW THE CHARGE WITH BURNER ON. CASTING CAN BE DONE IN PARTLY OPEN POSITION SAVING ENERGY AND OXIDATION. 3. DOOR PIVOTS FULLY OPEN FOR ACCESS WITH CHARGING MACHINE TO THE EXTRA LARGE CHARGE HOLE UP TO 2 M DIA.

7 Performace Data Notes Model TR 1 TR 2 TR 3 TR 5 TR 8 TR 10 TR 15 TR 21 Nomial rated alumiium capacity [kgs]. 1,000 2,000 3,000 5,000 8,000 10,000 15,000 21,500 Door opeig iside diameter [mm] ,100 1,300 1,400 1,500 1,800 2,000 2,000 Liquid capacity [volume i m 3 ]. 0,5 1 1,6 2, ,5 11 Maximum liquid alumiium capacity [kgs]. 1,150 2,300 3,680 5,750 9,200 11,500 17,250 25,300 Maximum charge weight (icludig salt) [kgs]. 1,150 2,300 3,680 5,750 9,200 11,500 17,250 25,300 Melt rate [kgs/hr] ,150 1,840 2,875 3,066 3,834 5,750 7,229 Meltig time hours for oe charge as (4) above ,5 No meltig time chargig, castig ad dischargig slag hours Cycle time tap to tap hours ,5 No. of cycles per day (24 hrs) ,4 Maximum charge weight (icludig salt) per 24 hrs [t] Iput per year (322 x 24 hr days) [t]. 2,962 5,925 9,480 14,812 17,774 22,218 33,327 43,992 ENERGY USING AIR-FUEL BURNER Burer eergy kw per toe of charge (iput) Natural gas cosumptio per toe of charge (iput). [m 3 ] Oil cosumptio per toe of charge (iput). [litres] Burer power (air fuel) [MW] 0,4 0,9 1,4 2,2 2,3 2,9 4,3 5,4 ENERGY USING OXY-FUEL BURNER Burer eergy kw per toe of charge (iput). ~ ~ ~ Natural gas cosumptio per toe of charge (iput). [m 3 ] ~ ~ ~ Oil cosumptio per toe of charge (iput). [litres]. ~ ~ ~ Oxyge cosumptio (either oil or gas). [m 3 ] ~ ~ ~ Burer power (oxy fuel) [MW] ~ ~ ~ 1,2 1,2 1,5 2,3 2,9 MECHANICAL Drive power [kw] 5,5 7, Variable meltig agle 0-15 degrees of tilt (subject to capacity). Rotatio speed (variable directio ad speed iverter cotrolled) [RPM] x x x x x x x x Nomial filter plat volume [Nm 3 /hr] (approximate oly). 10,000 15,000 20,000 30,000 35,000 45,000 65,000 80,000 Notes: 1. Capacity ratig. 2. Max. volume i the furace body for liquid alumiium. 3. Max. capacity liquid alumiium desity of 2,300 kgs/m Max. charge weight iput icludig salt flux. Based o ISRI grades of scrap, o excessive cotamiatio ad reasoable desity of approx. 800 kgs/m 3. Assumes efficiet automated chargig ad hadlig. Performace data give is a idicatio of typical performace. Data does ot costitute a guaratee. Subject to revisio ad chage without otice. Cycle times for lightweight ad material with cotamiatio ad combustibles will be exteded. Please cosult Meltig Solutios Limited for more iformatio. Oxy fuel firig may reduce filter capacity depedig o hood cofiguratio. Please cosult Meltig Solutios Limited for further iformatio. The advatages of the Meltig Solutios Limited Tiltig Rotary Furace are: 25% fuel savig. 50% icrease i throughput. 30% savig o slag disposal. 50% savig i salt flux. Reduce labour, fully automated process.

8 Meltig Solutios Limited is a leadig British maufacturer of electric process heatig ad meltig equipmet. The compay has over 30 years experiece offerig users a uique cosultig ad maufacturig service for all makes ad types of custom built iductio heatig ad meltig equipmet. I additio to this the compay also offers upgradig, modificatio ad spares replacemet of a wide rage of iductio process equipmet ad also offers project maagemet capabilities ad sub-cotract machiig to large maufacturers. Our philosophy is to eter ito a uique partership with the customer right from the iitial stages, through cocept, desig, maufacture to fial istallatio, esurig that each ad every project is delivered o time ad o budget. Meltig Solutios Limited Uit E, Duto Park Kigsbury Road Curdworth Sutto Coldfield B76 9EB Uited Kigdom Phoe: +44 (0) Fax: +44 (0) sales@meltigsolutios.co.uk Web: