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Low Turbulence Scrap Submergence (LOTUSS*)
LOTUSS FEATURES/BENEFITS
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THE MARKET TREND The increasing use of aluminum for a wide variety of product applications may be attributed to industry’s ability to recycle aluminum effectively. Careful consideration to the melting process is an important requirement to the economic recycling of aluminum. The growth of aluminum products has placed an emphasis on processing the generated scrap created through manufacturing. The current volume and future increase in aluminum castings for the automotive industry is one example of a manufacturing process that produces an increasing scrap segment described as machining chips, turnings, borings, or “swarf”. The bulk density of this material varies between 15-45 lb./cu. ft. (.24-.72 g/cu. cm) depending upon the size and shape of the chip particle. Historically, many aluminum producers have felt that large volumes of this type scrap or expensive melting technology were required to make in-house processing economical. The LOTUSS* system provides aluminum producers with the technology to process their light gauge scrap materials economically in their own facility * Patent Numbers 6,036,745 & 6,217,827 |
PROCESSING LIGHT GAUGE SCRAP Light gauge scrap such as machining chips, turnings, borings or “swarf” exhibits a high surface-area-to-weight ratio. Typically these materials include oxides, lubricants and debris created during the production process. The propensity for aluminum to oxidize increases the metal surface tension, causing light gauge charge materials to remain on the surface of the molten metal. This causes further oxidation, and subsequent melt loss. The use of forced submergence technology, like the LOTUSS system, greatly reduces this effect, permitting high metal yield rates and increased productivity. |
OPERATING PRINCIPLE The LOTUSS system operates in conjunction with a Metaullics molten metal circulation pump. Metal is pumped from the main furnace chamber into a shaped refractory well. The well design generates a downward action for the metal flow. This metal flow pattern forces the scrap charge materials, which are continuously introduced into the top of the LOTUSS, to become quickly submerged below the metal surface. The metal is then directed into the dross well located downstream of the LOTUSS, where proper metal treatment and fluxing can be completed. Because the charge well is separate from the dross well, charging can be continuous even during fluxing and dross removal. |
SYSTEM PERFORMANCE The Metaullics LOTUSS system solves the problem associated with recycling light gauge aluminum scrap while meeting the critical needs of producers and fabricators who desire the efficiencies and cost benefits of remelting. The LOTUSS system is available in melting capacities to 30,000 lbs. (13,610 kg.) per hour. There are many factors to consider when evaluating scrap processing, including scrap type, charge rate, current furnace design and thermal input, scrap quality, furnace operations and metal level. The system is designed to operate at furnace metal depths between 10 in. and 36 in. ( 25-100 cm. ), with 15 in. to 25 in. ( 38-64 cm. ) being the ideal range. Maintaining metal level in this range provides the best possible submergence action, combined with the most reliable circulation pump performance. The size chart shown below provides a general guide to system selection and output. Current and future melting systems requirements should be reviewed when determining your melting system capacity. The LOTUSS system requires the use of a continuous feed system. Metaullics can coordinate with selected vendors to provide a turn-key system, including chip collection, drying, conveying and, of course, the LOTUSS well and appropriate molten metal pump and drive. |
SYSTEM OPERATION The LOTUSS system is designed to operate in open or side-well reverberatory furnaces. It is capable of melting light gauge scrap (chips, turnings and borings) at material charge rates up to 30,000 lb./hr.. To attain the best metal yield rates and assure safe furnace operation, it is recommended that charge materials be dry. This will reduce the amount of oxidation that occurs, dross volume created and minimize air pollution. |
METAULLICS SUPPORT Metaullics has a knowledgeable technical support staff available to assist you in assessing your specific application requirements. Utilizing our application experience and predictive water model studies of the performance of the LOTUSS system, we will work with you to provide an optimum scrap melting system to meet your needs. Metaullics will provide start-up supervision and operation and maintenance training to support your melting system installation. |
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