AN OVER VIEW OF ALUMINUM SCRAP/CHIP RECYCLING PROCESS PLANT LAYOUT
ROTARY DRUM WITH CENTRAL TUBE
Exhaust Gas
400
O
30
CENTRIFUGE UNIT
Material Discharge
850 C
Scrap Recycling Machinery Required
VORTEX PUMP MOLTEN METAL CIRCULATION PROCESS
Sr. No. 1 2 3
VORTEX PUMP
Type Of Machinery Scrap Shredding Machine Shredded Scrap Charging Hopper with Flow Control Lever. Slat Conveyor motorized belt with VFD Drive . Centrifuge unit Machine (Optional) for Chip recycling only. Magnetic Separator Machine. Decoting Dryer Machine. After Burn Chamber Heat Generator Machine for deecoater. Vibrator Feeder Machine Side well Furnace with Three Chambers. Vortex Pump /Scrap Eater Machine. 2ND Tilting Furnace for Making Various Aluminium Alloys Connected through Launder with Side well Furnace. Launder systems To Carry the Molten Metal. Caster Machine for Manufacturing Ingot. With VFD Drive. Water Cooling systems for Ingots. C.I. Mold Weighing Balance Forklift & Over Head Crane suitable capacity Pollution Control Water Scrubber.
4 5 6 7 8
FINISHED ALUMINIUM INGOTS
9 10 11 12 13 14 15 16 17 18
INGOT CASTER MACHINE
WHY RECYCLING OF ALUMINIUM SCRAP IS NECESSARY
TYPICAL DIFFERENT MELTING PROCESS WITH MELT LOSSES.
Flip over to discover... the wonders you can make with Aluminium Scrap ... because its having value more than the SCRAP
Alluminium Scrap/Chip Melting Process
One of the BEST TECHNOLOGY Available in the world for Various type of light gauge scrap Melting in which the material will fed into the SIDE WELL Melting Furnace, DUE TO Molten Metal IS Circulation done by Vortex Pump & specially designed well will have an impact on the METAL RECOVERY yield. By pulling dry material subsurface through the vortex, Aluminium metal oxidation is minimized regardless of scrap type. Hence Recovery rate will be increasesare typically 94% max recovery will get. And 5% to 6% melt loss, depending on the existing method. If the system is operated properly as per designed you will get consistent metal recoveries of 94 %-95% can be expected. And For maximum recovery, salt flux must be required. Aluminum SCRAP/ CHIPS Recycling Benefits. Environment BENEFITS FROM ALUMINIUM SCRAP RECYCLING
Scrap can be reutilized for Various Industrial Application. No Pollution during the process. Very less energy required to get Recycled Aluminium scrap. Very less man power required to operate this plant. Fully automation process controlled with advanced electronic Gadgets with data
Sr.No. 1 2 3
Method of Recycling Direct Charge into Typical Reverbatory Furnace Direct Charge into Rotary Salt Furnace Shred, De coat & Charge into Side well Furnace with Vortex Pump
Overall Recovery (UBC) 70-80% 75-83% 95-96%
Oxidation losses Minimized
ISO 9001:2008 Certified Company
Established in 1990 with Designing capability having work force of 40 Employees (15 Engineers & Technician, 25 Skilled Labour) ISO 9001:2008 Over 500 installations 22000 Sq.Ft. Production facility
Vortex Pump Create Flow in molten metal to REDUCE oxidation melt loss
recording systems.
Clean environment Green Environment.
AEROSPACE AUTOMOTIVE DEFENCE NUCLEAR ALUMINUM STEEL
COMMERCIAL BENEFITS FROM ALUMINIUM SCRAP RECYCLING PLANT Benefits include the following :
High metal recovery rates Maximize metal production Designed for continuous,
Manufacturer of Industrial Furnaces & Aluminium Scrap Recycling Plant
Flow pattern at 600 GPM flow rate
Features to be considered In-house recycling of
We can be a solution for your furnace requirement, wherever you are, wherever you need it.
automated operation Low operating cost Low capital investment Low maintenance Easy installation Can be retrofit to existing furnaces
machining chips No dependency on Alloy supplier Additional melting capacity Rapid return on the investment Impact on foundry environment Improve productivity Compact layout
Mission
To Design the high end Industrial furnaces which are manufacturing as per ASTM standereds 2750-D and to meet Environment Friendly with the high quality performance up to the satisfaction and to become a reliable partner for customers. High furnace energy efficiency
VORTEX PUMP MINIMIZES OXIDATION MELT LOSSES (Close to Center)
Temperature Uniformity up to 5C Decades of furnace life Powered with a vision & Penchant to make Indian technology self reliant.
TYPICAL UBC CAN ALLOY DATA & MELT LOSS
BS 1490 - ALUMINUM Alloys and Approximate Equivalents
UK ISO Germany USA AA / ASTM Japan End Uses Electrical, food, chemical plant ADC12 AC2A Pressure Diecasting Sand gravity diecast manifolds, gear boxes, etc. Sand, gravity; corrosion resistant, for marine use, Food plant, chemical plant Sand, gravity; thin sections, manifolds, etc.
Chemical Containt in Can Mg % Si % Mn % Fe % Cu %
Each Element Wt. 0.132g 0.036g 0.132g 0.060g 0.012g 0.000g 12.00 g
LID Wt. Part1 0.149g 0.007g 0.012g 0.012g 0.005g 0.003g 3.30 g
PULL TAB wt. Part 2 0.014g 0.001g 0.000g 0.001g 0.000g 0.000g 0.30 g
Mixed wt. 0.293g 0.078g 0.144g 0.072g 0.017g 0.003g 15.6
SOME OF OUR PARTNERS
LM0 LM2 LM4 LM5 LM6
AL - 99.5 AL-Si10Cu2Fe Al-Si5Cu3 AL-Mg5Si1 AL-Mg6 Al-Si12 AL-Si12Fe G-AlSi12 (230) G-AlSi6Cu4 (225)
150 384 319 514
A413
AC7A
AC3A
LM9 LM12 LM13
Al-Si10Mg Al-Cu10Si2Mg Al-Si12Cu Al-Si12CuFe Al-Si5Cu1Mg Al-Si12Cu Al-Si12CuFe
G-AlSi10Mg (233)
A360
AC4A
Low pressure, etc; motor housings, cover plates, etc. High strength when treated Gravity, sand cast; machines well, hydraulic equipment
Cr % Total Weight
222 336
AC8A
Sand, Chili; used for pistons
LM16 LM20
355 G-AlSi12 (Cu)(231)
A413
AC4D
Sand, chill; cylinder heads valve bodies, good pressure tightness Pressure diecasting; corrosion resistant, marine castings, water pumps, meter cases
MELT LOASS:-If we assume that the cans contain approximately 3% coating, 1% water and 1% tramp material this equates to a metal loss of 4 6%. Not all of the metal is loss in the furnace, there will be losses due to fines generation within the shredding process.
LM21 LM22 LM24 LM25 LM26 LM27 LM28 LM29 LM30 LM31
Al-Si6Cu4 Al-Si5Cu3 Al-Si8Cu3Fe Al-Si7Mg Al-Si9Cu3Mg Al-Si7Cu3Mn0.5 Al-Si19CuMgNi Al-Si23CuMgNi Al-Si17Cu4Mg Al-Zn5Mg
G-AlSi6Cu4(225) G-AlSi6Cu4 (225) G-AlSi8Cu3(226) G-AlSi7Mg
308 319
A380
AC2A
Sand, gravity; similar to LM4, crankcases, gear boxes, etc. Chill casting; solution treated, good shock resistance, automotive heavy duty parts Pressure diecasting; engineering diecastings Sand chill; general purpose high strength alloy with good castability; wheels, cylinder blocks, heads Chill; used for pistons
TABLE SHOWS MELT LOSSES FOR DECOATED & NON-DECOATED MATERIALS
AC2A AC4B / ADC10 AC4C
Scrap Type % Used Beverage Cans
Metal Loss (No Decoating) Minimum 20-24 %
Metal Loss (With Decoating) Less Than 6-5%
Metal Recovery 94%
A356
332
AC2B
Sand, chill; versatile alloy, good castability; general engineering parts Chill; high performance pistons Chill; high performance pistons
F-23, M.I.D.C., Gokul Shirgoan, Kolhapur - 416 234. Maharashtra (India) T +91-231-2672620 F +91-231-2672461 M 09822056316, 09371634909 E sales@afecoheating.com W www.afecoheating.com
Above table gives the results of melting tests carried out on different materials. The first test was done by direct charging the scrap into a standard reverbatory furnace without decoating. The second test was done on scrap that had been shredded and then after decoated. You can use either UBC Shreded Chips or Turning Chips.
390 712
Pressure diecast; unlined cylinder blocks Sand; large castings, good shock resistance, good strength at elevated temp.
ISO 9001:2008 Certified
