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Secondary aluminium smelting differs from primary smelting in that it uses recycled aluminium from scrap, rather than refining it from ore. Producing one ton of aluminium from scrap uses about 5% of the energy of that required to produce it from bauxite. As aluminium is readily recycled, producing aluminium from scrap is becoming increasingly popular.
Other than that, both primary and secondary aluminium producers refine the alloys, melt it and pour it into bars called ingots.
Problems Encountered in Secondary Aluminium Melting
Different parts of the melting and holding furnaces face different issues as detailed below:
| Upper Side Walls |
Non-metal contact
High salt and alkali fluxing
Abusive cleaning |
| Sill and Ramp |
Abusive cleaning/dross removal
Dross removal
Thermal shock |
| Ramp and Hearth |
Metal contact, high salt or alkali fluxing
Heavy charging and corrosion
High chlorine and acid fluxing |
| Door Jambs/Lintels |
Mechanical damage
Abusive cleaning
Thermal shock |
| Repair and Maintenance |
Rapid fire/ rapid cure products
Hot repair |
| Roof |
High temperature stressing
Abusive cleaning |
| |
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To minimize such problems, appropriate refractory products that suit specific furnace environments and applications need to be used. These products help in extending furnace lifetimes while ensuring minimal maintenance.
ANH Products for Different Applications
Aluminium Contact
| Application |
Product
|
| Hearth |
Versaflow 65/AL C Adtech
|
| Ramp |
Armorkast 65AL
|
| Lower Sidewall |
Armorkast 80AL Adtech
|
| Charge Well |
Versaflow 65/AL Plus
|
| Pump Well |
Ultra Green 80 AL
|
Belly Band
| Application |
Product
|
| Belly Band |
Armorkast Xpur/AL Adtech
|
|
Ultra-Express 70 AL
|
Upper Sidewall & Roof
| Application |
Product
|
| Upper Sidewall & Roof |
Versaflow 55/AR Adtech
|
|
Versaflow 60 Plus
|
|
Mizzou Castable
|
Doors & Flue
| Application |
Product
|
| Doors & Flue |
Kast-O-Lite 30 LI
|
|
Kast-O-Lite 25
|
Jambs & Lintels
| Application |
Product
|
| Jambs & Lintels |
Versaflow 55/AR Adtech and C Plus
|
|
Versaflow 60 Plus
|
FRCC
(Fibre Reinforced Ceramic Composite)
|
Sills
| Application |
Product
|
| Sills |
Versaflow 65/AL C Adtech
|
FRCC
(Fibre Reinforced Ceramic Composite)
|
Burner
| Application |
Product
|
| Burner |
Greenpak 85P
|
|
Greencast 94
|
Safety Lining
| Application |
Product
|
Sub-Hearth
Lower Sidewall Backup |
Versaflow 45/AL Adtech
|
|
Greenlite-45-L AL
|
|
H-W ES Castable C AL
|
|
KS4
|
Repair / Maintenance
| Application |
Product
|
| Repair / Maintenance |
On-Line 65AL
|
|
Excelerate 65/AL Castable
|
|
Grefcote 70 AL Plus
|
|
Versagun 70/AL Adtech
|
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This information has been sourced, reviewed and adapted from materials provided by ANH Refractories Europe.
For more information on this source please visit ANH Refractories Europe.