improving performance in melt treatment insert web

8/13/2019 Improving Performance in Melt Treatment Insert Web

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PYROTEK

SUPPLEMENT n-Furnace Melt Treatment Process
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In-Furnace Melt Treatment Process PYROTEK SUPPLEMENT

IMPROVING PERFORMANCE INFURNACE MELT TREATMENT PROCESS

ANALYZING THE MELTTREATMENT PROCESSQuality is generally defined asconformance to mutually agreed uponcustomer specifications. This definitionmatches well with any discussion aroundaluminium melt quality and the relatedmolten metal treatment process. The melttreatment processes addressed in thisarticle include alloying and furnace meltrefining. In-line degassing and filtration,which are important components inachieving final melt quality, will beaddressed separately in the next article inthis series titled, Improving Performance Degassing and Filtration Processes.

The five main melt quality culprits for thecasthouse are the following: Trace elements, causing off specification

or inconsistent casts.Alkali metals, causing cracking and

missed specifications.Hydrogen, causing porosity and density

complaints.Inclusions, causing downstream

processing complications. Product inconsistency due to either

chemical or thermal variations duringcasting.

The process of melt treatment starts with therequirements of the finished products end-user. These requirements vary widely andneed to be understood, agreed upon anddocumented so that melt quality processescan be managed to deliver this specificationwith zero defects at the lowest possiblecost. While it starts with consistentlymeeting customer specifications, it does notend there. Other critical factors in managingmelt quality processes include operationalcosts/cycle times, operational health andsafety, and environmental impact/ compliance.

To maximize casthouse performance in allthese critical areas, it is important that the

Jonathan Prebble,Pyroteks Manager of Aluminium ProcessTechnology

production team clearly understands themarketing and operational objectivesinvolved. These defined objectives measurethe effectiveness of the melt qualityprocesses and practices upon the final castproduct. Typical challenges include, but arenot limited to, how to achieve the samelevel of product quality consistency time inand time out, combined with how to achieveoptimum performance in a practical

manner while, at the same time, minimizingcosts and maximizing productivity.

These challenges and issues vary greatlydepending upon whether processingprimary or secondary metals. It is importantto understand the melt quality and sourceof impurities at the beginning of the castingprocess in order to establish successfuloperational processes that will deliverconsistent metal quality to the casting

station.

Pyroteks mission is to work with casthousemanagers to develop a coordinated, holisticapproach to a sustainable operations planfor melt treatment. We bring all theseoperational elements together in asynergistic way that maximizes theperformance of each step of the melttreatment process. Pyroteks approachincludes a process audit and situation

analysis with the customer to jointlyunderstand and document the customersoperational objectives, historical operatingperformance, casting pit capabilities, enduser requirements, environmentalobjectives and safety. Once these areunderstood and agreed upon, a prioritizedlist of performance improvement projects(PIPs) are identified. A Pyrotek technicalteam is then organized to work with thecustomer to execute, track and evaluate

each projects results against pre-established targets and world-classoperational norms for similar operations,targeting similar melt quality specifications.

Pyrotek hasthe expertise,technology,experience

and theglobal

resources tomaximize theperformance

of youraluminium

melttreatment

systems.

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PRIMARY VS. SECONDARYWhat are the different impurities?Primary smelting can introduce thefollowing impurities: From the refined alumina we obtain

elements such as Si, Fe, and traces of Ti,Ca, V, B, etc.

From the coke blend used to make theanodes we pick up further traces of Ti, V,Ca, Si, Fe, etc.

From the carbon plant operations, weattract traces of Si, P, Fe, Mn mainly fromthe anode but also from the cast ironthimbles and the steel stubs on the anoderod assemblies.

Dissolution of these impurities takes placein the cell/pot at ~ 960C. The chemical bathalso contributes alkali metals from the saltsused K, Na, Ca and Li. Some cells operatea high Li bath chemistry for added currentefficiency. Carbides and oxides are alsogenerated by the turbulent electro-magneticand chemical activity in the cells and thereactions with the cell lining materials. Thebath is frequently tapped along with the

metal in the crucible delivered to the casthouse. Turbulence during the transfer leadsto oxide and dross inclusions in the metal.Refractory wear in transfer ladles also leadsto a risk of increased inclusions.

Feed stock from secondary melting canintroduce an even wider range of impuritiesdepending on the material combinationused to charge the furnace. RecycledSecondary Ingot (RSI) cast from metalrecovered from dross, saw chips, saw fines

and thermal fill scrap, can contribute alkalimetals as well as TiB 2 and aluminiumoxides. Recycled scrap from internal orexternal sources is an additional source of

hydrocarbons, paints, lacquers,surface treatments, oils andlubricants. Fumes, dioxins andfurans can be produced in largeamounts depending on the quality

and quantity of recycled materialthat is melted. Customer returnsand in-house scrap can add Li andZn in 7000 series, Cu in 2000series, Mn in 3000 series, Si in4000 series, Mg in 5000 series andFe in 8000 series.

Alloying elements such as siliconcan introduce dusts, as well ashigh levels of iron and calcium.These can be slowly absorbed into

the solution. Magnesium additionscan contribute magnesium oxide,Fe and Ca. Boron waffle, whenadded to the furnace for ECgrades, fades in as little as 90minutes developing into TiB 2,which settles and turns thefurnace bottom into a stickysludge. Tibor rod, when added tothe trough outside the furnace inroute to the casting table, can

have a tendency not to mix wellin the trough, developing intocoarse TiB 2 particles, which canaffect degassing efficiency and/orclog the downstream filtrationsystems in use.

Processing practices are aconstant source of contaminates.Poor handling and metal flowarrangements generate metalturbulence, which in turn,

generates dross and oxides. Iron pick up cancome from uncoated metal tools. Poorhousekeeping allows dirt, inclusions anddusts to become entrained in the metal flowas inclusions to the next cast. Waste burnergases and poor burner efficiency allowhydrogen to be absorbed. Open doors and/ or improper burner adjustments cancontribute to hydrogen pickup and to meltloss due to direct flame impingement. In-linedegassing can be an unintentional source

of contaminates from rotor speed too slow(large bubbles), rotor speed too fast(vortexing), rotor particulate, oxide build upand broken baffle plates.

Recycled Secondary Ingot (RSI)

SECONDARY SOURCESOF IMPURITIES

Recycled Scrap

Purchased Scrap

Uncoated Metal Tools

Inefficient or Poorly AdjustedBurners


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ALLOYING - A Critical First StepIn Improving Melt TreatmentPerformance

Alloying is the modification of melt

chemistry to meet casting specifications. Itis typically done in the melting furnace andadjusted in the holding furnaces or duringtransfer. Alloying elements include, but arenot limited to: silicon, iron, magnesium,manganese, copper and chromium. Stirringand melt homogenization are keycomponents of the alloying process.Alloying cycle times must allow foradequate dissolution time as well as for thetime required to complete proper furnaceskimming, refining and settling. For certainapplications, there is a need to select high-grade alloys (for example, low Fe and Casilicon metal for wheel/rim alloys).

To maximize efficiency, operating practicesmust measure alloying recoveries, adjustfurnace temperatures and processingtechniques to optimise alloy additions. If operating in conjunction with a primarysmelter, it is often possible to utilise the hotmetal superheat a potential source of freefurnace energy. Use powders, flakes andtablets rather than ingot or waffle to reduceenergy costs and to accelerate dissolutionrates when they can be efficiently stirredinto the metal.

The use of effective techniques to facilitateforced circulation of the melt during themelting and alloying phases of the processdemonstrates improvements in cycle timesand more efficient use of expensive alloying

materials.The EMP and Metaullics division both offerthe LOTUSS vortex system which is ahighly effective method of submergence forboth scrap and alloying materials.

Traditional methods for alloying in the casthouse utilized pre-prepared master alloys.These are charged directly into the meltingor holding furnace and stirred in with theassistance of the dross rake. The problemassociated with this technique is that it tendsto take longer for the alloy addition tobecome fully mixed into the melt as themixing is reliant upon the drossing tool to

fully mix the bath and master alloys. In anattempt to overcome this problem of effective mixing, the master alloys areusually made with a special flux thataccelerates the mixing of the alloy additioninto the melt.

The EMP and Metaullics pumping systemsfor light gauge scrap additions have theadvantage of the unique vortex well as amedium for the addition of alloys into thefurnace. The furnace door is kept closedduring the entire process, with the followingthree operating benefits: Maintaining the heat transfer efficiency

of the furnace, Minimising energy losses, and Minimising environmental emissions to

the casthouse and operators.

The LOTUSS vortex system eliminates theneed to alloy directly through the furnacedoors or by using specially made alloytablets. The pure elemental additions Mnflake, Fe splatter, Cu cuttings/swarf and Mgbars can now be used in an effective wayby charging directly through the EMPVortex.

Economic Benefits to Alloying ThroughThe VortexWith the appropriate feeding equipment,alloys from lump silicon to magnesium havebeen effectively charged into a furnace withsignificant reductions in alloy losses and animproved dissolution time of the alloy into

the melt.The following graph demonstrates the fastdissolution of magnesium ingots through avortex.

Alan Peel,Managing DirectorEMP Division

Fig. 1 Magnesium Ingots Charged Directly Intothe EMP Vortex

Purchasingpure

alloy elementsin a form

that can bechargeddirectlyinto the

vortex of anEMP Systemalso can give

somefinancialbenefits.


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PyroteksEMP,

Metaullicsand

SNIF

divisionsoffer a

completeline of

circulationequipment.

Yield ImprovementThis reduction in alloy losses results from thefact that the alloy addition is immediatelysubmerged sub-surface, minimising anyexposure to the air and to the burners in thefurnace. Typical yields on pure alloy additionscharged in this manner are shown below:

Reduced Mixing TimeBy charging the alloy additions in thismanner, they are immediately mixed in thesub-surface aluminium movement within thevortex. They quickly dissolve and are easilymixed into the full aluminium bath by therapid sub-surface flow from theelectromagnetic pump.

Alloy Purchase CostsPurchasing pure alloy elements in a form thatcan be charged directly into the vortex of anEMP System also can give some financialbenefits. Normally it is not possible to usepure additions when charging directly intothe furnace due to their ability to go intosolution. The yield can also be a concern asthey tend to be small in size and oxidiseeasily.

By using the LOTUSS vortex well, itbecomes practical to charge these pureelemental additions directly through thevortex. The result is a yield that is muchhigher (depending upon the quality of the

Fig. 2 Chemical Homogeneity

Alloy Yield By Yield When Addi tion Charging Charged Dir ectly

Through EMP To Fu rnace Lump Silicon 97% 94% Magnesium 98% 90% 10 Kg Ingot Manganese Flake 98% 94% Iron Splatter 98% 90%

(Powder/Tablet) Copper 99% Only Tablets

Yield Improvement by Charging Pure Alloys Directly Into EMP Vortex

alloy oil, moisture levels etc.) than whencharging through the main furnace door.The use of pure elements offers additionalsavings in the reduced cost of masteralloys and tablets.

Additional Benefits of EMP SystemsEMP now offers complete solutions tomelting furnace problems. EMPs use of aLOTUSS charge well offers casthouseoperations the following opportunities: Reduced alloying costs Ability to transfer from furnace to

furnace or to casting lines Option to raise metal levels for transfer Add flux additions directly into the melt Reduced emissions when fluxing Improved flux efficiency for Na and Ca

removal Capability to incorporate gas injectionfor hydrogen removal.

Metaullics Tensor Circulation Pump in CombinationWith a LOTUSS Charging System

LOTUSS (Low TurbulenceScrap Submergence System)The LOTUSS (Low Turbulence ScrapSubmergence System) in conjunction witha Metaullics mechanical pump or EMPelectromagnetic pump, has proven

especially effective for submerging andblending silicon alloy additions and lightgauge scrap such as machining chips,turnings, borings or swarf exhibiting ahigh surface-area-to-weight ratio.Typically, these types of materials includeoxides, lubricants and debris createdduring the production process. Thepropensity for aluminium to oxidiseincreases the metal surface tension,causing light gauge charge materials toremain on the surface of the molten metal.This causes further oxidation andsubsequent melt loss. The use of a forcedsubmergence technology, likethe LOTUSS system,greatly reduces this effect,permitting high metalyield rates and increasedproductivity.

Dave Plant,Project EngineerEMP Division


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DEMAGGING WITH CHLORINE

In order to produce foundry alloys,secondary smelters often use chlorine gasto demag, degas, or both. Foundry alloysfor sand, permanent mold, and die castingrequire low magnesium levels. Wroughtalloys such as building materials,extrusions, beverage containers,and a wide variety of othercommonly recycled consumerproducts contain substantially highlevels of magnesium. To the extentpossible, scrap is often blendedbased on pricing, availability, andcomposition to meet or approachthe magnesium specification forthe material being produced. In

many cases, however, thespecification cannot be met byblending alone and smelters havefound that gas injection pumps arean effective tool to achieve therequired result.Demagging efficiencies aredependent on thermodynamic and kineticconsiderations. Under favorableconditions, magnesium can be removedfrom molten aluminium alloys by addinghalogen compounds such as chlorine. Thereaction between magnesium and chlorineoccurs because there is a preferredchemical affinity at normal moltenaluminium operating temperatures.In accordance with the following reactions,when gaseous chlorine is introduced intomolten aluminium, aluminium chloride isproduced as a gaseous product (seeequation below). When magnesium ispresent, the aluminium chloride reactivelydecomposes to form magnesium chloridewhich rises to the surface where it can beremoved by skimming. Favorablethermodynamics alone do not guaranteeefficient magnesium removal. Kineticfactors such as rate of mixing, contact area,and concentrations will all have dramaticeffects.2Al + 3Cl2 2AlCl3 (1)2AlCl3 + 3Mg 3MgCl2 + 2Al (2)The following graph represents typicaldemagging results in the production of foundry ingot in a 75 ton furnace with a 38ton heel from the previous heat. Scrapcontaining high percentages of magnesiumwas charged into the furnace while thepump was operating. The gas injectionpump was able to remove the magnesiumat essentially the same rate that it wasadded to the furnace, maintaining the alloy

METAULLICS GAS INJECTIONPUMPSAdvanced technology, with therevolutionary 6-barrel impeller design,achieves longer life, higher efficiencies,and reduced maintenance requirements.

TheMetaullics

gas injectionpump is theproduct of

choicewhere

demagging is

required.

Paul CampbellMarketing ManagerMetaullics SystemsDivision

within the specification limit for the alloybeing produced.It has always been necessary for chlorinationtechnology in aluminium recycling to meetrigorous environmental standards. CurrentMACT (Maximum Achievable ControlTechnology) standards in the U.S. havetaken this requirement to an even higher

level. Compared to other chlorinationtechnologies, gas injection pumps providethe safest and most efficient technology foraccomplishing this aspect of melting andrefining.When demagging is required, the Metaullicsgas injection pump is the product of choicedue to its proven operating efficiency, lowmaintenance, rugged construction andreliability.

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IN-FURNACE REFINING - The CorrectMethods Can Benefit Your Melt QualityPyroteks early involvement in research programsand technical partnerships with the major aluminium

companies aimed at eliminating chlorine usage hasimproved the efficiency of fused refining agents inin-furnace treatments. We have gained theknowledge, products and practical expertise toresolve most metallurgical problems related to thepresence of hydrogen, non-metallic inclusions andalkali metals in aluminium cast products. Pyrotekhas proven over recent years that the use of environmentally friendly refining agent injectiontechnology is a truly viable alternative to bothchlorine fluxing and fluoride based fluxes.

Fluxes and refining agents canimprove the quality of aluminiumalloys if they are treated while stillmolten in the furnace. Originally,this type of treatment wasrestricted to dross reduction andfurnace cleaning. However, itusually contributed to magnesiumloss in certain alloys (due tochemical and thermal reduction)

as well as an increase in alkalimetals (from the salts used in theproducts supplied in previousyears). Magnesium is an expensive addition to maketo any alloy, thus any treatments by salts or chlorinegas, both of which remove magnesium, are thereforeexpensive in terms of hidden costs. Alkali metals(Na, Ca, Li) are also undesirable in certain foundryalloys (for example, A356.2) due to the problems theycan cause in subsequent processing of the castproducts, as well as the undesirable effects that they

can have upon their grain structure (such as,modification).

A range of fused refining agents has been developedby Pyrotek to counter act these undesirable sideeffects. They are a blend of fused, anhydrous MgCl 2and KCl which allow them to be injected orimmerged, either through a lance, rotor or a vortex,below the surface of the melt, where they melt beforecoming into intimate contact with the moltenaluminium in finely-dispersed liquid droplet form.

Refining agents are particularly effective whenintroduced below the melt surface because therefining agent materials melt below 480C (880F).The refining agent quickly becomes a liquid phasein molten aluminium, facilitating the reaction which

Fused Refining Agents

Robert BridiPyroteks GlobalProduct Manager,Fluxes, Refining Agents& Lubricants

(Continued on page 8)

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PHD-50

Furnace Mounted HD2000 in theTreatment Position Utilizing aSpinning Rotor

EMP Charge Well With Gas Injection

STAR FIM5

Refiningagents areparticularly

effectivewhen

introducedbelow the

meltsurface.

NorthAmerica
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Proper furnacerefining with

Pyroteks refiningsystems candelivermeasurable,repeatableimprovements inmetal quality by:

Reducing AlkaliMetals

ReducingHydrogen Levels enabling thedownstreamdegasser toachieve a betterexit result

ReducingInclusion Levels better filtrationefficiencies and

product qualitydownstream

Using the correctinjection methodto refine the melt Optimises flux

consumption

Speeds up scrapand hardenermelting

Minimisesvariations inchemistry andtemperaturethrough the melt

Reduces oreliminates theuse of chlorinegas or degassertablets.

thermal stratification within the body of themelt.

The reaction efficiency of impurity removalis enhanced by improving the metalcirculation within the furnace duringinjection rather than adding the refiningagent flux in excess and/or on the meltsurface.

Pyrotek offers a wide range of flux injectionand circulation equipment to maximize theefficiency of the flux refining agents. Thisminimizes consumable costs, cycle times,and environmental issues associated withproper melt treatment. The product mix of aparticular casthouse and its related quality

specifications drive the correct choice andcombination of melt treatment technology.The good news is that this type of fluxinjection equipment, combined with theproper refining agent and operatingpractices, almost always has a rapid payback (typically 6 18 months) and addssignificantly to melt quality consistency,operator safety and environmentalobjectives with the use of PLC controlledoperating procedures.

NA REDUCTION IN A PRIMARY SMELTER CASTING HIGH MGALLOYSThe table below depicts a primary smelter that replaced 100-150 Kg MgCl 2 /KCl powderblended flux with 30-50 Kg Pyrotek Promag RI fused refining agent addition in the furnace.The objective was to bring the Na below 1ppm in casting, to reduce the treatment cost, toreduce fume emissions associated with the excess of powder flux and to eliminate edge-cracks due to Na during hot rolling of high Mg alloys. Promag RI is the refining agent used

in all casthouses of this aluminium company. In a large number of primary plants the PromagRI is being injected via a spinning nozzle system in the furnace. In 2006, tests of Promagaddition in the vortex of the EMP system will be performed at a primary smelter.

Product Quantity Na Before Furnace Na After Furnace Final Na In TheTreatment, ppm Treatment, ppm Casting Table, ppm

Powder Blend 150kg 6.6 2.3 0.4Powder Blend 100kg 15.8 2.2 0.6

Promag RI 50kg 9.6 1.6 0.3Promag RI 50kg 16.4 3.2 0.6Promag RI 50kg 14.5 5.0 0.6

Promag RI 50kg 14.0 2.4 0.3Promag RI 50kg 22.9 3.1 0.3Promag RI 30kg 16.7 3.0 1.0Promag RI 30kg 5.5 1.5 0.2Promag RI 30kg 24.6 1.5 0.5Promag RI 30kg 38.1 3.0 0.4

removes the alkali metals. Reactions andimpurities removal take place in the liquid-liquid contact areas (Collision Theory). Thedensity of the liquid phase of the refiningagent is 2.17 and that of the liquid

aluminium is 2.35. Being relatively similarin density, the droplets of refining agent canremain within the liquid metal for some timebefore floating out. During their period of suspension, the droplets of the refiningagent react with Na, Li and Ca, while alsoabsorbing some of the inclusions andhydrogen present in the melt.

This process also has valuable secondarybenefits. During and after the alkali metalreaction stage, a fall in both hydrogen andinclusion levels has been measured. Thisindicates that during refining, degassing andcleansing of the melt is also taking place.These refining agents also assist in keepingthe furnace walls clean (thereby retainingfurnace capacity often without the needfor additional cleaning fluxes), improvingthe recovery of alloying additions. Thephysical mixing process also promoteschemical homogeneity and reduced


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PYROTEKSMISSION

Providinginnovativesolutions

to customerneeds

utilizingour global

resources.

REDUCTION OFHYDROGEN,CALCIUM ANDINCLUSIONS IN

SECONDARYPROCESSING

In 2004, Pyrotek presenteda technical paper at TMSon the effective removal of calcium and hydrogen in asecondary remelt castingbillet for internalconsumption. The casestudy was based onsustained sampling andtesting. It clearlydemonstrated that thecombination of PyroteksHD-2000 with PyroteksFIF-50 can be used forinjecting solid fluxes andrefining agents along withthe standard process gas.This process producedsignificant reductions in

hydrogen, calcium, andinclusion levels within thefurnace. It alsodemonstrated that theselevels could be maintainedinto the cast metal if properfurnace controls weremaintained.

The Pyrotek system wassimple and reliableperforming with a minimumof dross formation andfurnace disruption whileoperating within currentenvironmental standards.The system had the effect of consistently improvingmetal quality in the billetwith the unquantifiedbenefits of increasedextrusion speeds, extendeddie life, reduced breaks anddefects.

Dr. Robert FrankPyroteks Manager of Technology forSNIF Systems

Pete FlisakowskiPyroteks Aluminium

Metallurgical Engineer

Calcium Removal Results

Total Inclusion Removal

Hydrogen Removal Results

Calcium & Inclusion Data Versus Time for Holder andCasting Line During and After HD 2000 Treatment

0

1

2

3

4

5

6

7

8

9

-20 0 20 40 60 80 100 120 140

Relative Time (minutes)

C a

l c i u m

C o n

t e n t

( p p m

)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

T o

t a l I n c

l u s i o n s

( m m

2 / k g

)

Calcium Inclusions

Flux MixMix Idle Cast

0

10

20

30

40

50

60

70

80

90

100

1a 3a 5a 7a 9a 11a 13a 15a 17a 19 23 27 31 35 39 43

Test #

R e m o v a

l ( % )

OK Minimum Detection Limit Reached

-60

-40

-20

0

20

40

60

80

100

1a 3a 5a 7a 9a 11a 13a 15a 17a 19 23 27 31 35 39 43

Test #

R e m o v a l

( % )

-137

0

5

10

15

20

25

30

35

40

45

1a 3a 5a 7a 9a 11a 13a 15a 17a 19 23 27 31 35 39 43

Test #

R e m o v a l

( % )

AlSCAN 1 AlSCAN 2

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Run # Run #1 Run #2 Run #3 Three run avg.Run time (sample time) 507 minutes 473 minutes 442 minutes 474 minutesMolten metal, tons/hr 2.73 2.97 3.01 2.90

Particulate PM MACT Limit 0.4 lb/ton of feedConcentration, gr/DSCF 0.00607 0.00754 0.00622 0.00661Emission rate, lb/hr 0.819 1.13 1.07 1.01Emission rate,lb/ton of molten metal

0.300 0.380 0.355 0.345

Hydrogen Chloride MACT Limit 0.4 lb/ton of feedConcentration, ppm 8.14 8.15 8.21 8.17Emission rate, lb/hr 0.727 0.811 0.934 0.824Emission rate,lb/ton of molten metal

0.266 0.273 0.310 0.283

TEQ Three run average MACT Limit 15.0 g/ton of f eedTotal CDD/CDF lb/ton 1.56E-08Total CDD/CDF g/ton 7.07

Pyrotekis the

aluminiumindustrys

mostcomprehensive

resourcefor improving

in-furnace

melt treatmentperformance.

Dr. Neil KeeganPyroteks MetallurgicalServices GroupManager

Dr. Dave Neff Metaullics MoltenMetal TreatmentManager

ELIMINATION OF CHLORINE IN THE FURNACE MELT TREATMENT

In 2002, a major producer in South America, recognized Pyrotek as Supplier of the Yearlargely for its contribution to the elimination of chlorine in their melt treatment processes.Pyroteks service after the sale, timely deliveries and fast, innovative solutions to their

technical needs, were also factors in Pyrotek receiving this distinguished award.In North America, numerous primary and secondary processors have also been able toimprove their melt quality while significantly reducing or eliminating chlorine treatments,including the ability to meet the MACT (Maximum Achievable Control Technology) standards.

The use of Pyroteks various refining agent injection techniques has allowed many facilitiesin the U.S. to continue using dirty and painted scrap and to comply with the new MACTstandards for new and existing group 1 furnaces (dirty scrap or reactive agent in the furnace).The following table shows the stack emissions achieved by a billet caster in the U.S. thatsuccessfully switched from chlorine lance fluxing to the use of a refining agent with aPyrotek FIF-50 flux injection system (lance). Actual test results below demonstrate that

when the furnace treatment is performed with Pyroteks refining agent injection system, thelevels of HCl particulates and dioxin/furans fall well below the new MACT standards despitethe dirty and painted scrap added to the charge.

CONCLUSION

From its early involvement in research programs and technical partnerships with majoraluminium companies to eliminate chlorine usage and to improve the efficiency of fusedrefining agents in in-furnace treatments, Pyrotek has gained the knowledge to resolvemetallurgical problems related to the presence of hydrogen, non-metallic inclusions andalkali and alkaline earth metals in aluminium castings. Pyrotek has proven in recent yearsthat the environmentally friendly refining agent injection technology is a viable alternativeto chlorine fluxing and to fluoride based fluxes.

As a partner to the industry, Pyrotek has worked with aluminium companies world-wide toreview and improve their melt treatment performance. From melting to casting and everythingin between, Pyrotek has experienced personnel to help increase productivity while meetingcustomer driven quality goals.Pyrotek is the aluminium industrys most comprehensive resource for improving in-furnacemelt treatment performance. Pyrotek is unique in its ability to provide the integration of innovative technologies, process expertise and a global perspective, all dedicated to assistingcustomers in the optimization of their casthouse processes and practices.


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CORPORATE OFFICE9503 E. Montgomery AvenueSpokane Valley, WA 99206Phone: (509) 926-6212Fax: (509) 927-2408e-mail: [email protected]

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