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In the aluminum and aluminum alloy casting production line, aluminum liquid filtration, purification, and degassing (usually referred to as rotary jet degassing) are key links that ensure the performance of the final product and improve the yield rate. The core issues that aluminum plants pay great attention to in this process are directly related to their production costs, efficiency, and market competitiveness.
Inclusion removal: Can all kinds of non-metallic inclusions (oxides, flux, furnace lining materials, etc.) be efficiently removed to prevent them from becoming the source of product cracks or reducing performance
Hydrogen removal effect: Can the dissolved hydrogen content be quickly and stably reduced to the target level (usually less than 0.15ml/100g Al or even lower) to prevent the casting from producing pores and looseness
Alkali metal control: Can harmful alkali metal elements such as sodium, lithium, and calcium be effectively removed to prevent hot cracking and processing brittleness
Process stability: Is the equipment performance stable and reliable, and is the treatment effect small between batches to ensure consistent product quality
Equipment and consumables life: Is the ceramic foam filter durable, and how often is it replaced? How long is the life of key components such as degassing rotors and degassing box linings? Frequent replacement leads to huge downtime losses.
Energy consumption: Is the nitrogen/argon consumption and power consumption of degassing equipment (especially large equipment) optimized?
Metal loss: Does the processing process cause excessive aluminum liquid to oxidize or remain in the equipment (such as filter plate tanks, degassing boxes), causing waste?
Maintenance cost: Is the equipment easy to maintain, and is the downtime associated with maintenance too long?
Processing flux: Can the equipment meet the increasing production line speed and large tonnage processing needs?
Online time: Is the alumina ceramic foam filter replacement and degassing equipment maintenance quick and convenient, minimizing production line downtime?
Automation and integration: Is the equipment easy to integrate with the existing production line automation system? Do you know if the operation interface is friendly?
Safety: How to ensure the safety of the equipment in the high-temperature aluminum liquid operation environment?
Secondary pollution risk: Will the filter medium or degassing equipment components themselves shed particles and contaminate the aluminum liquid?
Temperature control: Is the temperature drop of the aluminum liquid controllable during the treatment process? Avoid affecting the subsequent casting process.
Process traceability: Can the equipment provide records and monitoring of key process parameters (such as gas flow, rotor speed, pressure difference, processing time, etc)
As a professional manufacturer of alumina ceramic filter plates and aluminum liquid degassing equipment, we deeply understand these pain points and are committed to providing efficient and reliable solutions that meet the core needs of aluminum plants:
*Advanced ceramic filter plate technology:
Gradient pore structure design: Our alumina ceramic filter plates adopt a unique gradient pore size design (such as 30/50/50ppi) to achieve efficient deep filtration, maximize the capture of inclusions of different sizes, and significantly improve the purity of the melt.
High purity and excellent corrosion resistance: Selected high-purity raw materials (Al2O3 > 90%) and optimized sintering process ensure that the filter plate has excellent chemical stability and corrosion resistance in high-temperature aluminum liquid, avoids self-contamination of the melt, and ensures long-term stability of the filtering effect.
Excellent thermal shock resistance: The special formula and structural design give the filter plate excellent thermal shock resistance, and it is not easy to crack when the temperature rises rapidly, which improves the service life and operational safety.
* Efficient degassing equipment technology:
Optimized rotor design: The use of fluid-dynamically optimized graphite or ceramic rotors (with impeller shape and opening design) produces small, uniform, and dispersed bubbles, thereby significantly increasing the gas-liquid contact area and bubble rising distance, and improving the dehydrogenation efficiency and alkali metal removal rate.
Accurate gas control system: Equipped with high-precision flowmeters, pressure regulating valves, and automatic control systems to ensure correct and stable inert gas (N2/Ar) flow, avoid gas waste, and achieve the best degassing effect.
Optimized degassing box design: The internal flow field is reasonably designed to ensure that the aluminum liquid is fully mixed and has sufficient residence time in the box, thereby improving the purification efficiency; the high-performance refractory material lining is used to resist the erosion of aluminum liquid and extend the service life.
* Extend the life of key components:
High-durability filter plate: By improving material strength and optimizing microstructure (such as introducing reinforcement phase), our alumina ceramic filter plate has a longer service life, significantly reducing the consumable cost and replacement frequency per unit output, and reducing downtime.
Long-life rotor and lining: The rotor is made of high-quality graphite or special ceramic materials, and the optimized degassing box lining material and structural design are used to greatly extend the life of key wearing parts, reduce spare parts consumption, and maintenance costs.
Optimize energy and metal loss: Efficient gas utilization: The precise gas control system and optimized rotor design ensure that the consumption of inert gas is effectively reduced while achieving the same or even better degassing effect.
Low stagnation design: The degassing box and filtration system design focuses on reducing the aluminum liquid retention, reducing metal loss, and minimizing cleaning difficulty.
Insulation performance: Good equipment insulation design reduces the temperature drop of aluminum liquid during the treatment process and reduces the energy consumption of remelting.
* High throughput design:
Provide filter plates and degassing units of various specifications and sizes to meet different processing throughput requirements from laboratory to large-scale industrial production.
* Quick replacement and maintenance:
Modular design: The degassing equipment adopts a modular design, and key components (such as rotor lifting mechanism, heater) are easy to disassemble and replace, shortening maintenance time.
Convenient filter plate replacement system: Design an easy-to-operate filter box structure, with special tools, to achieve fast and safe replacement of filter plates.
* Automation and intelligence:
Integrated control system: The equipment is equipped with an advanced PLC/HMI control system to achieve accurate setting of process parameters, real-time monitoring, data recording and traceability, and facilitate quality management and process optimization.
Remote monitoring and diagnosis (optional): Provide remote support options for fast fault diagnosis and maintenance guidance.
Strengthen safety design: The equipment is equipped with complete safety protection measures (such as emergency stop, liquid level alarm, aluminum leakage detection, protective cover, etc.) to ensure the safety of operators.
"Zero" pollution commitment: High-purity, high-stability alumina ceramic filter plates and carefully designed internal structures of degassing equipment minimize the risk of secondary pollution introduced by the equipment itself.
Process stability guarantee: The high reliability of the equipment and the precise controllability of process parameters are the basis for ensuring high consistency of product quality between batches.
Temperature stability: Effective insulation measures and (optional) heating systems help maintain the stability of aluminum liquid processing temperature.
We are well aware that technological development is endless. To continue to meet and exceed customer expectations, we are committed to:
Material R&D innovation: Continuously explore higher-performance ceramic composite materials and more durable graphite/ceramic rotor materials to pursue longer service life and better purification effects.
Design optimization: Using CFD simulation and other means, continuously optimize the degassing box flow field, rotor structure, and filter plate pore distribution to pursue efficiency limits.
Intelligent upgrade: Deepen the intelligence level of equipment, develop process optimization and predictive maintenance functions based on big data and artificial intelligence, and help customers achieve "smart smelting".
The wide application of aluminum alloy products has put forward strict requirements on their quality. As the key to improving product quality, the aluminum alloy liquid degassing unit is leading the aluminum alloy production industry to achieve a leap from basic manufacturing to high-end quality.
From a technical point of view, the rotary injection method builds the core technical framework of the degassing equipment. With the help of the high-speed rotation of the graphite rotor, the inert gas is broken into tiny bubbles, starting the "purification journey" in the aluminum liquid. The gas partial pressure difference drives the hydrogen to diffuse continuously into the bubbles, and the surface adsorption effect makes impurities nowhere to hide. This ingenious physical process allows the harmful gases and impurities in the aluminum liquid to be gradually removed.
At the practical application level, a degassing unit is present in many fields. In the field of aerospace, it helps to produce high-strength and high-stability aluminum alloy parts; in the wave of lightweight development of automobiles, it provides high-quality guarantees for various aluminum alloy castings and improves vehicle performance and safety; in the recycling process of recycled aluminum, it makes resource recycling more efficient and reduces the pressure of primary aluminum mining.
The diversity of equipment types provides precise adaptation solutions for different production scenarios. Fixed equipment is like a "steel guard", providing stable and efficient degassing services for large production lines; mobile equipment is like a flexible "guerrilla", rushing to different furnaces at any time to complete purification tasks; hoisting equipment plays an important role under special working conditions with its space utilization advantage. The division of labor and cooperation between single-rotor and multi-rotor equipment also makes the degassing treatment more refined to meet the differentiated needs of different companies.
The effect of degassing equipment in actual production is remarkable. The high degassing rate effectively eliminates the hidden dangers of porosity in castings, and the reduction of inclusions greatly improves the purity of the aluminum liquid. Improving product quality not only enhances the market competitiveness of enterprises but also promotes the aluminum alloy industry to develop in a higher quality and more sustainable direction, becoming an important driving force for technological innovation and quality upgrading in the industry.
Fluxes for aluminum can recycling improve the utilization rate of metal, reduce the adhesion of slag on the furnace wall, the furnace is easy to clean and repair, and improve the working environment.
The fluxes for aluminum can recycling uniformly enter the lower layer of aluminum through the powder-carrying refining tank under the action of carrier gas (N or Ar). Through physical and chemical changes, many small bubbles are formed in the molten aluminum to completely contact the molten aluminum, and the molten aluminum is separated.
Some substances contained in the aluminum casting flux will strongly absorb and melt the oxides and suspended solids in the melt and attach them to the bubbles. As the bubbles rise, they are brought to the surface of the molten aluminum to achieve the purpose of degassing and slag removal.
The degassing and slag removal effect of fluxes is good. The refining deposits sprayed to the bottom of the melting pool and the bottom of the furnace undergo physical and chemical reactions, which can melt the alumina and separate the slag from the aluminum.
Bring the gas to the surface of the molten aluminum to keep the bottom of the furnace clean, greatly reducing the number of cleaning furnaces, improving the utilization rate of the furnace, and reducing labor intensity.
Refining Fluxes are used in the aluminum recycling process, the oxides and impurities are removed from the melt in the smelting process. The resulting slag is dry and easily separated from the metal.
EEG collects 5,629 kilograms of aluminum cans and sends them to local industries for recycling, thereby diverting this easily recyclable commodity from the landfill.
Since the start of the can collection campaign in 1997, EEG has collected 351,150 kilograms of aluminum cans for recycling. This is EEG’s first community-based annual recycling program. This directly helped reduce 5,271 tons of carbon dioxide in the atmosphere, saved 8,524 cubic meters of landfill space, and saved 79.917 billion BTU of energy.
Refining fluxes for foundry are usually composed of alkali metal chlorides or alkaline earth metal chlorides, which are mixed to obtain a melting point below the operating temperature of the alloy-the melting point of a pure compound is usually quite high. After adding refining fluxes for foundry to the metal, impurities and salt will float on the surface of the liquid metal and can be easily removed. The particle size is controlled by the use of the solid compound obtained by the molten salt.
Granular refining agents can be used in batch processes or continuous processes.
Various methods can be used to incorporate the salt flux into the alloy:
Before adding aluminum, KCl and MgCl 2 fluxes in solid form were added to the bottom of the preheating vessel.
Currently, the fluxes are added by inert gas in the pipe below the metal surface (spray gun flux).
Recently, a method has been developed in which a hollow shaft uses a gas carrier to bring the salt flux into the alloy, and disperse the salt flux through a stirrer (rotating flux injection). This method reduces the amount of salt flux required for purification and at the same time increases the dispersion of the salt flux in the alloy.
In addition, due to the perceived negative impact on the sodium content of the resulting aluminum or aluminum alloy, the use of salt fluxes with significant sodium chloride content is not recommended. In fact, when sodium chloride is present in the flux used to purify aluminum or aluminum alloys, the use of sodium chloride is currently avoided or limited. More specifically, for certain types of alloys, such as aluminum alloys with a silicon content of more than 10%, and more particularly aluminum alloys with a magnesium content of more than 3%, it is recommended not to use sodium chloride in the salt flux.