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i-Pump©
Electromagnetic-Inductive-Stirrer for Aluminium melting
The Electromagnetic-Inductive-Stirrer was developed for
heat and mass transfer intensification in a molten aluminium bath. For
the application of aluminium scrap melting, i-Pump©
stirring will substantially increase productivity, reduce fuel
consumption and dross generation. It will also stabilize operation
conditions for the entire heat cycle and improve reproducibility. Pay
back time on the investment of less than one year can be anticipated,
depending on type of application.
Advantages of electromagnetic inductive stirring
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Homogenization of the melting |
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Equable
temperature distribution |
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Accurate temperature control |
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Increased thermal efficiency and melting rate |
Diagram 1:
Stirring by i-Pump©
has begun after the end of
melting of solid material
Homogenization of the melting
The strong
stirring of the metal bath will rapidly homogenize the chemistry of the
melting, reduces the need for mechanical stirring and shorten the time
needed for alloying. This is of special importance for high alloy
melting’s containing elements like magnesium, manganese and silicon. The
homogeneity of the bath in combination with a uniform temperature
increases the total yield of aluminium, casting included. Furthermore
alloying yields are improved and become more consistent.
Equable
temperature distribution
Inside a
40 t melting furnace with a bath depth of 900 mm, a typical bath surface
temperature is 900 °C, with a corresponding bottom temperature of 660 °C
when operating without stirring. This temperature difference of 240 K
decreases to less than 12 °K using i-Pump©
stirring within 15 to 20 minutes and an average temperature of 730 °C is
achieved. (Diagram 1, results of measurement)The essential advantage of
the i-Pump©
system unlike sub hearth electromagnetic stirrers, is the possibility to
start stirring before finishing of melting the solid metal inside the
furnace bath (Diagram 2).
Diagram 2:
Stirring by i-Pump©
has begun
during the melting of solid material
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Process/Item |
Definition |
Alteration |
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Melting |
Total melting time
"Burner on" time |
Time saving -15 bis -35%
Time saving
-5 bis -15% |
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Dross |
Generation of dross
(down to type of scrap) |
-5 to -40% |
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Energy |
Fuel consumption
Add. Electrical power consumption |
-5 to -15%
4 to 5 kWh/t |
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Refining |
Total refining time |
Time saving
-10 bis -20% |
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Skimming |
Skimming time |
Time saving
-30 bis -50% |
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Fluxing |
Improved degasification of melting |
Time saving |
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Alloying |
Quicker melting of alloys
Efficiency of alloys |
Time saving |
Technichal Data,
i-Pump©
Mass of
stirring molten metal:
Temperature of liquid metal:
Power supply:
Active power: |
300 t/h; 600 t/h; 700 t/h
660 - 750 °C
380 - 440 V, 50 Hz, 3 phases
45 kW; 65 kW; 75 kW |
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Inductor
Sidewall of Furnace
with Inductor
Sidewall of Furnace
(inside) with Flow Channel
Assembly at Furnace |
