Aluminium Slat Slag Treatment
Aluminium Slat Slag Treatment
CHARACTERISTICS OF ENGITEC STE PROCESS
The STE process for the treatment of aluminium salt slag is a proprietary process of Engitec Technologies S.p.A.
The process is suitable also for small installations, so it can be installed directly
at the aluminium recyclers' site.
STE allows the recovery of the aluminium and of the salt, which is re-used in the melting process, and of clean fine oxides, which can be suitable for other
industrial applications as the cement manufacturing.
All polluting gases generated during the aluminium salt slag leaching are
combusted and the heat generated is used for water evaporation and salt
crystallization.
No liquid effluents are released from the plant and the gaseous emissions are
kept within regulatory limits.
• Salt recovery is highly efficient (99%).
• The recovered oxides have a low chloride content (below 0,2 %) and are
environmentally safe and well accepted by the cement industry.
• The process involves low labour requirement.
PROCESS OVERVIEW
SLAG TREATMENT
The slag as produced in the aluminium foundry is pre-crushed in a mill (impactor or jaw crusher). The big lumps of aluminium are separated by screening, then the pre-crushed slag is directly leached in the water by a milling operation in special drums. From the resulting slurry the remaining Al grains are washed, separated by means of a rotating screen and finally dried to obtain an highly valuable metal (>80% recovery efficiency). The oxides slurry
is filtrated on a continuous vacuum belt filter, where the oxides cake is deeply washed from the chlorides. The resulting cake has a very low chloride content (<0.2%) suitable for industrial application, as the cement production. Upon request an inertization unit is available for the reduction to <0.1% of the gas volumetric aluminium content.
GAS BURNING
The Gas Burning ensures the thermo destruction of all the pollutants collected from every sources inside the plant. The gas evolved during leaching, together with the gas released from the other controlled points, are conveyed and burnt in a special designed combustor, where the pollutants (mainly hydrogen, ammonia, phosphine and methane) are transformed into water and clean gases. The heat produced to destroy the pollutants is recovered to produce live steam, which is finally used to run the crystalliser for the salt production.
SALTS RECOVERY
A single or a multistage crystalliser unit is designed to recover the salt in form of crystals. The energy source is the steam generated by the thermo-destruction of the gases produced during the leaching. The crystalliser may be
designed either for the production of only NaCl or NaCl and KCl separated.
PRODUCTS
The plant operating in steady conditions gives the following products and by-products:
ALUMINIUM LUMPS
Metal content: > 80% b.w. on dry
basis
ALUMINIUM GRAINS
Metal content: > 80% b.w. on dry
basis
INERT OXIDE
Chloride content: < 0.2% b.w.
ALKALINE SALTS
NaCl and KCl suitable for immediate
re-use
EFFLUENTS
• LIQUID EFFLUENTS
No liquid effluents are released from the
process.
• SOLID EFFLUENTS
No solid effluents are released by the plant.
• GASEOUS EFFLUENTS
The plant releases only the burnt process
gases from the stack, having composition
which meets all the regulations worldwide.
ENERGY CONSUMPTION
Values referred to 1 ton of slag:
- fuel : 2.5 x 106 kJ
- electric power: 170 kWh
Ref. CGS121344
LAKE ERIE 3000 TON ALUMINUM EXTRUSION PRESS
3000 TON LAKE ERIE ALUMINUM EXTRUSION PRESS
SPECIFICATIONS:
Extrusion Press -
Manufacturer - LAKE ERIE U.S.A
Year of Manufacture - 1970
Type - Direct. Oil hydraulic.
Horizontal - four columns
Capacities: -
Press at 3000 psi - 3000 tons. (metric)
General:
Range of billet diameter - 200/154 mm (8" / 10")
Maximum billet length - 900 mm (35 1/2")
Container liner length - 950 mm (27 1/2")
Container heating - Castool SMART container
Hydraulic Power unit:
Revamped at 2008 by OILGEAR USA
Main pump manifold 2008
Pump diverter manifold 2008
Main pump - Two (2) Oil-gear DVV - 15030, servo
Two (2) Oil-gear c - 15030
Total output of main pumps - 2,300 LPM (608 GPM)
Auxiliary pump - Vickers
Output of Aux. pump - 63 lpm at 3000 psi
Sealing pump - Oilgear PVWH
Motors for main pumps - 2 of 400 hp motor,
Oil filtration with double heat exchanger cooling system - 10 micron.
Press control - OILGEAR CONTROL SYSTEM including HMI Allen Bradley plc slc4
Die-shuttle double cassette
Replaceable castool dummy block
Billet log heater:
Producer: Granco Clark USA
Type: 4 zone direct gas fired
Allen Bradley plc control system
HOT SAW
Producer: ASSIMAKIS
Profile cutting length control system with movable hot saw
PLC controlled
Lead out Table
Type - Fixed Graphite Covered
Including:
Vertical height regulated - hydraulic, hand operated jack.
Profile shear - fix location. Hydraulic drive. Auto/manual control.
Run out Table
Type - Kevlar free rollers
Distance between rollers - 406 mm (16")
Total length - Approx. 25 m (82 Ft.)
Effective working width - 520 mm (20 1/2")
Drive - hydraulic force controlled Drive unit for speed/torque Control.
Kevlar belt system with heavy duty belts BWF Germany
Polyester belts bwf Germany
Profile Air Cooling System
No. of Top fans (overhead mounted)
No. of bottom fans
Puller
Year of manufacture - 2008
Pulling force - 0-1000 kg (0-2200 Lbs.)
Pulling speed (max.) - 60 m/min. (190 FPM)
Return speed (max.) - 400 m/min. (132 FPM)
Drive - hydraulic motor
Drive features - torque control
PLC control system
Stretcher
Manufacturer - Granco Clark
Drive - hydraulic
Pulling force - 20 ton
Profile Saw
800 mm width of cutting
Include new roller exit table with accurate stopper
Chip collector - Cyclone type
Miscellaneous
Double chamber Die Heating Oven-gas indirect
Monorail to convey dies from oven to press die oven station
Water Cooling System Water cooling Tower and Circulating Pumps
Ref. CGS11432
Castal 1350mm Twin-Roll Aluminum Continuous Strip Caster
1350mm Twin-Roll Aluminum Continuous Strip Caster
Manufacture Castal
Cast Strip Width 1350mm max 53.15"
Cast Strip Thickness Maximum: 12.0mm .472"
Minimum: 4.2mm .165"
(4.2mm thickness was achieved by owner)
Casting Speed 1050 alloy = 1.5mton/hr achieved
3003 alloy = 900 kg/hr achieved
Caster Configuration Horizontal, 15 degree tilt
Equipment
- Two Melting/Holding Furnaces 12 mton tilting type, Scrap charge car
- Molten Metal Level Pour System
- Titanium-Boron Grain Refiner Rod Feeder
- Tips 2 sets of tip tables included
Electric tip bake-out oven
Material for 30 hard and 20 soft tips included
- Caster
- Cylinders Hydraulic tilting type
- Drive Siemens DC motor, Single drive type
Flender gearboxes
- Rolls 2 pairs included
660mm diam x 1450mm face
Akers internal H2O cooled type
Bottom shell each set = cracked
Cores = perfect condition
Chocks & bearings included
- Electrics and Controls Siemens PLC and SCADA system
Central control for all system, Drawings included
- Edge Trimmer Not installed but there is space to install a system
- Pinch Roll Stand Hydraulic, Siemens DC motor, Flender gearbox
- Shear Hydraulic traveling type
Fully automatic, Limit switch control
- Strip Feeder Feeds strip into coiler
- Recoiler Hydraulic action, Coil push-off, Coil car
- Other Equipment Included:
- Uninterruptible Power Supply GE system
- Spectrometer Arun type design, 24 channels
- Heat Exchanger Alfa Laval water cooling system
Maintains roll skin temp at 80-85 degrees
Herlan P12 Impact Extrusion Press 1956
ALUMINIUM Impact extrusion equipment
A)
Herlan P12 Impact Extrusion Press
Manufacture Herlan / 1956
Condition Constantly maintained and in full production condition.
Capacity 1000 mtons
Stroke Length 385mm max / 15.2"
Strokes per Minute 50
Aluminum Impact Size 120mm max diam
0.6mm min wall thickness
320mm max extruded length
Zinc Impact Size 90mm max diam
0.8mm min wall thickness
170mm max extruded length
Motor 55 kW
Clutch and Brake Combination Ortlinghaus pneumatic / together on flywheel side
Press Size (from Herlan spec sheet) 16'3" L x 10'2" W x 8'7" H / 72,000lbs
Overall Installed Footprint 24ft L x 15ft W x 8ft H
B)
Herlan P5 Impact Extrusion Press
Manufacture Herlan P5 / New 1965
Condition Constantly maintained
Currently in full-production condition
Capacity 240 mtons
Stroke 300mm
Strokes per Minute 85 max with standard tooling
Aluminum Impact Size 38mm diam
0.1mm wall thickness
250mm extruded length
Zinc Impact Size 32mm diam
0.35mm wall thickness
80mm extruded length
Motor 15 kW, 480V / 3ph / 60Hz
Electric drive panel
Controls Complete control panel
Slug Elevator Included
Overall Installed Footprint 12ft L x 6ft W x 5.5ft H
C)
Herlan P12 Impact Extrusion Press
Manufacture Herlan / 1964
Condition Off foundation but fully operational when removed.
No electrics included.
Capacity 1000 mtons
Stroke Length 385mm max / 15.2"
Strokes per Minute 50. Actually ran 45 spm regularly.
Aluminum Impact Size 120mm max diam
0.6mm min wall thickness
320mm max extruded length
Zinc Impact Size 90mm max diam
0.8mm min wall thickness
170mm max extruded length
Motor 55 kW
Clutch Ortlinghaus pneumatic on flywheel side
Brake Ortlinghaus spring assembly type on opposite side
Press Size (from Herlan spec sheet) 16'3" L x 10'2" W x 8'7" H
72,000lbs
Ref. CGS41622
