INSERTEC

The ALUSWIRLER® system is designed for continuous melting of aluminium chips, by submersion in a hot molten metal vortex.
 
The ALUSWIRLER® is the hearth of the system. The aluminium chips are melted because their submersion into the liquid metal and the quick heat transfer from the hot molten metal. The vortex is generated by a mechanical pump electrically driven.
 
The ALUSWIRLER® chamber is a side well attached to the main furnace chamber, linked by communication channels, which direct the flow of molten metal generated by the mechanical pump.
 
The impeller, its housing and the vortex chamber are ceramic pre-cast shapes,
easily replaceable. They are located into the refractory living of the side well,
becoming so the ALUSWIRLER® chamber.

The impeller rotation produces a high flow of molten metal, that downwards becomes a vortex of hot liquid metal, point where the pretreated and dried aluminium chips are charged for its melting, being submerged nearly instantaneously. The melting process is so quick that all the chips are melted before they can reach the main chamber of the furnace.
 

The COMBINATION MELTOWER® Furnace has the capability to melt prealloyed ingots and foundry returns and additional continuous melting and blending with machining chips.
 
Both forced convection and submergence systems are employed to optimize melting efficiency and to facilitate the efficient and high metal recovery on recycling of the machining chips.
 
Combination MELTOWER® process will provide clean quality molten metal on demand from the casting cells and with the correct temperature uniformity and alloy composition at all times.

Improved Metal Recovery

ECO-KILN® system is an option to more conventional pretreatment lines where the dryer incorporates two (2) main components a rotary kiln and afterburner. One burner is employed and serves both as chips dryer and fume incinerator and hence improves thermal efficiency. This dual function combined with the heat source of the combustible coolant results in extremely low specific energy consumption.
 
An additional safety benefit of the ECO-KILN® is the avoidance of the hermit reaction on drying from short run of ductwork. The short routing of the ductwork work from the kiln to the stack also reduces improves radiation losses.
 
Fume is reduced and it is not necessary collect fumes in the sink vortex melting area.
 
All waste gases are discharged directly via a vertical stack chimney.
 
The success of any melting system depends on the physical characteristics and nature of the feedstock, therefore, the integration of durable, efficient pre-treatment equipment is crucial in achieving full processing efficiency and hence, a high metal recovery and payback in small sizes up to 300 kg/hr.
 
This is particularly important when recycling the machining chips, which have a high surface area per unit volume. Even small residues of water-soluble fluid will have a significant impact on metal recovery. Our many proven case references demonstrate that materials suitably dried, graded and without finds or ageing produce an extremely high metal recovery.
 
Assumed that the Aluminium chips are collected from the machining operation and centrifuged to reduce the content of the soluble water and organic residues to <5%. 

Advance technology for continuous decoating and drying, from 500 kg/hr to 20 ton/hr, complying with the strictest environmental regulations.
The IDEX® system is designed for removing the volatile organic (paint, lacquers, oils) and inorganic (water) contaminants from a wide range of aluminium scraps by a continuous thermal process.
Typical applications
• Decoating aluminium shredded scrap such as
UBC, profile, litho, caps, foil, ...
• Drying machining chips, turnings, swarf, ...
IDEX® system main components are:
• The Rotary Kiln for processing the dirty scraps
• The Post-combustion chamber, for the incineration of the gases generated in the rotary kiln
• The recirculation fan between both equipments, in order to reuse part of the hot gases generated in the Post-combustion chamber
• The intermediate cyclone, for removing the small particles from the process, such as fines, dust, ...
Economical & Environmental benefits
• Very low overall energy consumption
• Reduce the metal losses and energy consumption in the melting process
• Improved the Foundry safety (no water)
• Controlled volatilization of the VOC
• Full incineration of the generated gases
• Reduces emissions to the environment

MELTOWER furnace is distinguished from other designs available in the market in:
• its holding chamber of circular section,
• excellent mechanical rigidity with independent frame support,
• durability of refractory lining, easy access for cleaning and minimum space.
 
That joined to the long experience achieved by INSERTEC in the use of non-wetting castables allow to design and build with guarantee this kind of holding chambers.