Scrap Aluminum Melting System (SAMS™)

SAMS FEATURES/BENEFITS

Efficient operation under varying conditions
High production rates
High recovery of light gauge materials
Designed for continuous operation
Easy installation
Low maintenance

TYPICAL APPLICATIONS

Many producers of aluminum products have a need to efficiently melt low-density, light gauge scrap materials at very high rates. Materials such as used beverage containers (UBC), chips, turnings and borings, and shredded scrap are difficult to melt with conventional techniques. The SAMS™ *, operating in conjunction with a Metaullics molten metal circulation pump, provides an integrated melting system for efficiently submerging light gauge aluminum scrap. SAMS™ systems are in use world-wide at dedicated UBC recycling plants, secondary smelters, and foundries which generate large volumes of machining chips. *Patent No. 4598899, 4930986 & 5143357

EFFECTIVE SCRAP MELTING

Materials such as UBC's, scalper chips, and turnings have a large surface-area-to-weight ratio. When these materials are put in a furnace, they tend to float. The combination of high temperature and an oxidizing atmosphere will cause these materials to burn or oxidize and therefore reduce the amount of aluminum that can be recovered. The quicker these materials can be submerged in the molten metal bath, the sooner they will melt and the less they will oxidize. The SAMS™ system from Metaullics does an excellent job of submerging these materials quickly so that high production and recovery rates are possible.

PART OF A COMPLETE SYSTEM

SAMS™ is designed to be part of a complete system. Before light gauge materials can be melted efficiently, they often must be properly prepared. The first step is usually a shredder or crusher. This breaks the material down to a uniform size that can be easily handled with a conveyor system. Depending on the material, non-aluminum components such as iron or glass may need to be removed. The next step is to remove organic materials such as paint or cutting oils. Ideally the percent of organic material should be reduced to less than 2% of the total weight. Once the organics have been removed, the material can be charged into the furnace. If a thermal unit such as a rotary kiln was used to remove the organics, the material should be charged as quickly as possible to take advantage of the heat already in the metal. The SAMS system is usually located in its own section of a furnace side-well that has been divided into three sections. The SAMS™ utilizes a square vortex design to generate a strong downward action in the metal to submerge the charged materials. Round or custom vortexers are available for special requirements. The vortexer and shaft are machined from high quality graphite with enhanced oxidation resistance and protected with ceramic sleeves to provide extended operating life and performance. The vortexer operating speed is selected to achieve rapid submergence of the charged materials while minimizing oxidation, air ingestion and dross to provide high metal recovery rates. In a well adjacent to the vortex well is a Metaullics circulation pump. This pump provides a continuous supply of hot metal from the hearth to the charging well where the melting is taking place. Downstream of the charging well is a dross well. The oxide skins from the charged aluminum scrap float to the surface in this well where the dross can be fluxed and removed. The whole process is designed to provide a continuous operation.

TWO DESIGN MODELS

To provide maximum installation and operation flexibility, the SAMS™ is offered as a permanent overhead mount design or as a portable unit. The overhead system is mounted to a support structure either attached to or adjacent to the furnace and is positioned above the open or side well. It is mounted high so as to keep aisleways and the area in front of the charge well clear. The unit rotates for servicing and uses a remote mounted power supply and control panel. The portable unit is completely self contained and can be moved around the plant with a fork truck. Both units require a 460/480V, 3 Ph., 60 Hz. power supply. A complete hydraulic power system provides control of the vertical and rotary motion. The electrical control panel provides controls for manual or automatic system operation and features displays for vortex speed, vertical position and dwell time. The SAMS™ has been designed to provide continuous performance with minimal operator involvement.

PRODUCTION CAPABILITIES

Production rates will depend on the capacity of the components in the complete system. The SAMS™ system can easily submerge up to 15 tons of aluminum per hour. However, to maintain this rate a feed system must be available to supply this amount of metal and the furnace must be able to continuously melt this volume. The system is optimized when the production rate is maintained at the level of the slowest component. As an example, if the furnace will only maintain a sustained melting rate of 5 tons per hour and all other components will handle this volume or higher, set the system to operate at 5 tons per hour.

BACKED BY METAULLICS

SAMS™, like all Metaullics products, is backed by a capable support staff. In addition to providing systems engineered to meet your needs, Metaullics will supply start-up supervision and operation, and maintenance training. Replacement parts are in stock for quick delivery.

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