
Shaft furnace
Process Description
Aluminum shaft furnaces are suitable for the high melting performance required of Class 3 scrap containing up to 10% organic impurities. The specific energy requirement is 370 - 450 kWh/t. The melt is preheated in the shaft and the energy introduced using burner systems.
Aluminum shaft furnace
Gas Application
Combustion with oxygen (oxyfuel) instead of with air as an oxidising agent reduces fuel consumption and increases process efficiency.
Advantages of Oxyfuel burner systems at a glance:
- Higher combustion efficiency
- Higher melting rate
- Faster heating-up times
- Lower fuel consumption
- Higher processing temperatures possible
- Faster reaction speeds
- Lower exhaust gas levels
- Less dust
- Lower emissions
- Lower production costs
Application of Oxipyr-Burner technology in 15t shaft furnaces:
The table shows application possibilities for shaft furnaces and the increase in performance and potential energy savings typically associated with the use of Oxipyr burner technology in shaft furnaces.
air burner | air/oxygen burner | oxygen burner + hot air blower | |
Smelting output [t/h] | 1,4 | 2,1 | 3,5 |
Smelting output [%] | 100 | 150 | 250 |
Natural gas consumption [Nm³/t] | 100 | 45 | 43 |
Oxygen consumption [Nm³/t] | 0 | 75 | 86 |
Energy costs [€/t Al] | 15,40 | 18,40 | 19,80 |
Production capacity [t/a] | 10080 | 15000 | 25200 |
Dross volume [%] | 100 | 71 | 45 |
aluminum yield [t/a] | 150 | 554 | |
Savings [€/t] | 0 | 12,35 | 29,35 |
Messer Solution
In addition to the gases required for your process, Messer offers a variety of equipment for its optimisation under the brand names Oxipyr and Oxijet.
In order to select the optimum system, experts from Messer first carry out a comprehensive process analysis. Following calculations and basic engineering, suggestions are made for optimisation and further procedures.
Oxipyr flame inside aluminum shaft furnace
The characteristics of the burner types are multi-faceted and range from low to high momentum burners, oxyfuel to oxygen/air mixing burners and burners for different fuels or fuel combinations. The systems are controlled manually, semi- or fully automatically following compositions or temperature.
Oxipyr |
Fuel |
Burner protection |
Flame |
||||||
Burner Technology |
gas |
liquid |
solid |
low NOx |
refractory material |
traversing devices |
cooling |
monitoring |
ignition |
Oxipyr – P |
X |
|
|
|
X |
X |
X |
X |
X |
Oxipyr – F |
X |
X |
X |
X |
X |
X |
X |
X |
X |
Oxipyr – Flex |
X |
X |
X |
X |
X |
X |
X |
X |
X |
Oxipyr – Air |
X |
X |
X |
X |
X |
X |
X |
X |
X |
Oxipyr – SVNR |
X |
X |
X |
X |
X |
X |
|
X |
X |
Oxipyr- IPC (internal post-combustion)
The combustion ratio of fuel and oxidising agent is selectively altered, with the oxygen flow regulated as a function of exhaust gas parameters. As a result, through the post-combustion of pollutants in the exhaust gas, high-quality fuels can be relieved especially of the burden of volatile organic components (VOC). Messer developed the Oxipyr-IPC process for this purpose. When using the Oxipyr-IPC process, oxygen and fuel requirements are controlled automatically. Oxygen is always supplied via Oxipyr burners; with Oxijet oxygen lances used for certain types of furnace.
Advantages:
- Lower fuel consumption
- Reduces post-combustion burden
- Reduction in production costs