Refractory Selection Guide for Secondary Aluminium Smelting

Secondary aluminium smelting differs from primary smelting in that it uses recycled aluminium from scrap, rather than refining it from ore. Producing one ton of aluminium from scrap uses about 5% of the energy of that required to produce it from bauxite. As aluminium is readily recycled, producing aluminium from scrap is becoming increasingly popular.

Other than that, both primary and secondary aluminium producers refine the alloys, melt it and pour it into bars called ingots.

Problems Encountered in Secondary Aluminium Melting

Different parts of the melting and holding furnaces face different issues as detailed below:

Upper Side Walls Non-metal contact
High salt and alkali fluxing
Abusive cleaning
Sill and Ramp Abusive cleaning/dross removal
Dross removal
Thermal shock
Ramp and Hearth Metal contact, high salt or alkali fluxing
Heavy charging and corrosion
High chlorine and acid fluxing
Door Jambs/Lintels Mechanical damage
Abusive cleaning
Thermal shock
Repair and Maintenance Rapid fire/ rapid cure products
Hot repair
Roof High temperature stressing
Abusive cleaning

To minimize such problems, appropriate refractory products that suit specific furnace environments and applications need to be used. These products help in extending furnace lifetimes while ensuring minimal maintenance.

ANH Products for Different Applications

Aluminium Contact

Application
Product
Hearth
Versaflow 65/AL C Adtech
Ramp
Armorkast 65AL
Lower Sidewall
Armorkast 80AL Adtech
Charge Well
Versaflow 65/AL Plus
Pump Well
Ultra Green 80 AL

Belly Band

Application
Product
Belly Band
Armorkast Xpur/AL Adtech
Ultra-Express 70 AL

Upper Sidewall & Roof

Application
Product
Upper Sidewall & Roof
Versaflow 55/AR Adtech
Versaflow 60 Plus
Mizzou Castable

Doors & Flue

Application
Product
Doors & Flue
Kast-O-Lite 30 LI
Kast-O-Lite 25

Jambs & Lintels

Application
Product
Jambs & Lintels
Versaflow 55/AR Adtech and C Plus
Versaflow 60 Plus
FRCC
(Fibre Reinforced Ceramic Composite)

Sills

Application
Product
Sills
Versaflow 65/AL C Adtech
FRCC
(Fibre Reinforced Ceramic Composite)

Burner

Application
Product
Burner
Greenpak 85P
Greencast 94

Safety Lining

Application
Product
Sub-Hearth
Lower Sidewall Backup
Versaflow 45/AL Adtech
Greenlite-45-L AL
H-W ES Castable C AL
KS4

Repair / Maintenance

Application
Product
Repair / Maintenance
On-Line 65AL
Excelerate 65/AL Castable
Grefcote 70 AL Plus
Versagun 70/AL Adtech

This information has been sourced, reviewed and adapted from materials provided by ANH Refractories Europe.

For more information on this source please visit ANH Refractories Europe.

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