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Die Casting: Tower/Shaft Furnace

By Furnace Engineering

Furnace Engineering designs and offers the Aluminium Tower/Shaft Melting and Holding Furnace for the high efficiency melting of ingots and casting returns.

Key features

  • Low energy consumption (Approx 2340 MJ to melt one-tonne aluminium).
  • High quality non-wetting cast refractory for long lining life.
  • Superior insulation: Low furnace skin temperatures.
  • Pouring / discharge of metal from below the bath surface.
  • Separate holding chamber.
  • Load cell weighing system to control charging and melting sequence.
  • Robust casing including charging and cleaning doors.
  • Tilt frame and hydraulic control system for lip axis pouring.

The furnace is divided into two chambers with the holding section located directly under the melting bridge.

The vertical alignment of the chambers enables the holding bath to have a large surface area and small bath depth which provides very good homogeneity of the bath temperature. The melt burner exhaust gases are utilised to heat the holding bath. Consequently, the melt chamber will run at higher temperatures, typically 1000°C, which is sufficient to incinerate the fumes from oily returns.

These gases then pass over the holding bath to maintain the required metal temperature before exhausting from the rear or side of the furnace. This enables considerable energy savings and low exhaust temperatures. Also the liquid aluminium can be taken from the furnace during melting.The furnace can be equipped with an integral charging machine for charging of ingots and returns.

Control Panel:

The fully programmable PLC system controls and monitors the following functions:

  • Melting chamber temperature.
  • Bath temperature.
  • Aluminium level.
  • Gas consumption.

The option is available to integrate this data acquisition with a computer supervisory system.

Combustion System:

The burner system is designed as medium speed burners with integrated ignition devices and ionisation control. The burners are positioned in the melt chamber to reduce the formation of dross. Combustion products are fully eliminated in the holding chamber before exhausting.

Doors:

The furnace doors, charging and cleaning, are lined with selected insulating materials and door seals which are replaceable. The cleaning door permits easy access for cleaning of both melting bridge and holding chamber. Dross deflector chutes are located beneath cleaning doors.

Delivery:

The furnace is pre-assembled and fully tested at factory before delivery. The kit is assembly consists of:

  • Furnace body mounted in tilting frame & hydraulic power unit.
  • Maintenance platform with ladder and railings, and combustion blower with gas/air control pipework.
  • Control panel including PLC.
  • Lifting/tilting charging machine with protective guards.