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Te Tilting Rotary Process :: Total Materia Article
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Te Tilting Rotary Process
With te major recycling objective being to recover te metallic aluminum content of scraps and residues with te highest possible yield combined with te lowest effort, te tilting rotary process gives some good advantages over te fixed axis single route.
Key in te application of recovery of aluminum, zinc, lead and platinum te advantages of te tilt rotary process includes greater safety, efficiency, and loading capacities.
Raw materials dedicated to te recycling of aluminum have to contain it in non-oxidized but metallic form. Te transformation of such oxides into metal is technically and economically infeasible. Te major recycling target is to recover te metallic aluminum content of scraps and residues with te highest possible yield combined with te lowest effort. Some countries, particularly those rich in electricity resources have explored te plasma torch route or electric arc type furnace; both working on a similar principal of melting in an ‘oxygen free’ environment under pressure to avoid parasite air ingress and both of these techniques offer efficient recoveries but are not economically viable unless te electrical power source is very cheap.
Also these techniques are limited to small production units (a few tonnes of dross at most). More recently other manufacturers have opted for TRF (Tilt Rotary Furnace) units fitted with oxy/fuel combustion systems - they have their advantages, te main one being te reduction of off-gas volumes but they remain complex and costly.
Tilt Rotary Furnaces have significant advantages compared to fixed axis rotary furnaces. In Figures 1 and 2 is schematically presented both processes.
Conventional fixed axis single route
1. Scrap and salt are charged into te furnace. Charging is restricted by te small charge hole.
2. Te charge is melted by a single pass burner arrangement, limiting efficiency.
3. Aluminum is run out through a tap hole. Opening and closing te tap hole is slow and labor intensive.
4. Slag is run out through a second tap hole.
Figure 1: Fixed axis furnace route
A high salt-to-oxide ratio is required to ensure te slag is liquid to run through te small tap hole.
Tilt rotary process route:
1. Furnace is charged very quickly using te much larger charge opening.
2. Melting by double pass burner arrangement. Saving energy with faster melting.
3. Te furnace is tilted to pour out te aluminum. Te dry slag remains in te furnace – with no time wasted in opening tap hole.
4. Finally te furnace is rotated and tilted simultaneously to tip out te dry salt slag for disposal. Te amount of slag is greatly reduced because a liquid slag is not needed - no time wasted opening slag hole.
5. Faster rotation - better separation of aluminum from slag.
Figure 2: Tilt rotary furnace route
Aluminum light scrap recycling
80% increase in service, compared with rotary furnace (fixed axis), better safety, and longer service life
50% increase in efficiency, compared with reverberatory furnace, production efficiency improvements
5%, recycling ratio improved by 3~5%
300%, loading capacity per batch upgraded by 3 times
30%, reduced final aluminum dross for disposal
50%, reduced flux requirements
50%, reduced labour, one operator can operate two furnaces, totally automatic processing
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