Skip to main content

Our ECO-furnace system is not just a melting furnace.

It is a promise made up of top quality engineering, years of in-depth industry experience and outstanding service at the most affordable prices.

What does our stack melters offer?

Low energy use, reduced material losses, increased productivity and reduced emissions.

 
With our stack or shaft melter, aluminum ingots and/or scrap are loaded into the top stack of the melter.
Fuel-fired burners, firing up through the charge, serve to both melt the material lower in the stack and heat the higher material.
As the melted aluminum flows from the melt chamber to the hold chamber, the preheated metal drops lower and is itself melted.
New material is added to the top of the stack.
Automatic metal transfer wells are available for ladle filling.
The furnace waste gases are used to preheat the scrap as it is introduced into the furnace to lower the fuel consumption.
Also the waste gases are preheating the air for the burners which reduces even more the energy consumption.
Energy recuperation was the first target when we developped the melting furnace. 

Value proposition

High thermal performance.
High production in small spaces.
Fully automated loading and self-operational (optional).
Minimum worker involvement.
Minimal oxidation losses.
Premium-quality clean metal obtained.

Our Aluminium Smelters

Optimum heat use, low material losses and self-operation

A smelter (stack or shaft melter) is a furnace for melting aluminium or aluminium alloy ingots or medium size scrap.

It is used both in foundries and in plants for recovering secondary aluminium.

It can be added to an existing plant to increase melting capacity or be placed immediatly beside the casting machine.

Flue loading aluminium melting furnaces make optimal use of heat from fumes, and loads descend evenly to the high-temperature zone.

By using systems with a stock of baskets or stacks, and sometimes return of empty baskets, it requires minimum worker involvement for loading.

The most important criteria for assessing our quality beside machine auto-loaded shaft melting furnace:

  • Improve safety due to limited exposure to molten metal and pre-heating of the charge material. Simple and safe operation during charging and tapping
  • Floor space reduced due to 2.5x holding capacity versus 10x
  • High thermal efficiency and low energy consumption per ton of molten metal
  • Lowered holding costs caused by 2.5x holding capacity versus 10x in a reverb
  • CO2 emissions lowered (less gas burned = less CO2)
  • Lower melt loss (<1% vs. 3-8%) due to lower oxidation (dross forming)
  • Improved process control and resulting metal quality caused by only a +/- 6 °C holding temperature variation versus large swings each time a cold charge is placed into the hot bath
  • Improved process control and resulting metal quality due to reduced gas levels created by more stable temperatures and reduced burner fluctuation and reduced surface area within the bath
  • Faster melting due to 3 times higher thermal heat absorption of solid aluminium compared to liquid aluminium.
  • Reduced manpower requirements with automated charging systems vs. manual charging exposing operators to metal splash. 
  • High metal quality, i.e. low gas pick-up and low non-metallic contamination of the melt
  • Low maintenance requirements and long service life of the refractory lining
  • High temperature uniformity of the melt ready for tapping
  • Easy accessibility of the furnace interior. This contributes to minimized metal loss during dross removal and facilitates cleaning of the furnace (removal of build-ups on the refractory lining)
  • High degree of automation, e.g. installation of an automatic charging system, automatic burner control system as well as bath temperature control and temperature and weighting monitoring systems
  • Compliance with environmental and safety regulations, specifically concerning noise emissions, exhaust gas emissions and pollutant concentrations at the work place

Construction

Our furnace casings are designed to hold up for many years of continuous industrial operation. They are constructed of top quality steel plate and structural tubing reinforced with high integrity welding.

Refractories

Since furnace service life is so dependent on proper refractory selection and installation, we have spent many creative hours with some of the foremost ceramic engineering companies in the world to offer furnace refractory applications that last.

Combustion

We design our burner systems to be dependable, efficient and easy for maintenance crews to troubleshoot if problems arise. Conventional or regenerative burner systems are available.

Machine Side Melting holding furnace

Capacity is between 50 -1000 kg/hour - Manual or automatic loading

Centralized Melting holding furnace

Capacity is between 100 -8.000 kg/hour - Single or double melting chamber

Standard models of our beside machine shaft furnace

Model 100/500 150/500 200/600 250/900 350/1050 500/1500
Melting capacity (KG / H) 100 150 200 250 350 500
Retention capacity (KG) 500 500 600 900 1050 1500
Combustion management              
Melting burner (Kcal / h) 120 000 120 000 150 000 200 000 200 000 300 000
Holding burner (Kcal / h) 120 000 120 000 150 000 200 000 200 000 300 000
Control mode              
measurement points PID-OFF interlock control   3 3 3 3 3 3
Gas flow rate (m 3 / H) 30 30 30 40 50 60
Supply parameters              
Gas pressure (Kpa) 5<>7 5<>7 5<>7 5<>7 5<>7 5<>7
Compressed air pressure (Mpa) 0.5 0.5 0.5 0.5 0.5 0.5
Molten Aluminum Temperature Accuracy   ± 5 ℃ ± 5 ℃ ± 5 ℃ ± 5 ℃ ± 5 ℃ ± 5 ℃
Aluminum material burning rate   <1.5% <1.5% <1.5% <1.5% <1.5% <1.5%
               

Which furnace fits for which die casting machine

Furnace Model Ladling mouth size (LWH) Ladling Height Suitable for diecast machines of
100/500 320 * 320 * 300mm Custom made 150 - 500T
150/500 380 * 380 * 360mm Custom made 300 - 650T
200/600 420 * 420 * 400mm Custom made 400 - 900T
250/900 480 * 480 * 430mm Custom made 650 - 1000T
350/1050 550 * 550 * 450mm Custom made 800 - 1000+T
500/1500 600 * 600 * 520mm Custom made 1600 - 4000+T