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Increasing yield and production in a successful secondary aluminum plant

Detailed computer analysis and process evaluation yields a custom solution.

Issue: A large secondary aluminum processor with multiple rotary furnaces wanted to increase yield and production. Already highly successful, they looked to Air Products for further improvement to help their bottom line.

Solution: Air Products scientists and applications engineers welcomed the challenge. During several site visits and working to understand the customer’s requirements, our team evaluated everything that can influence combustion in the operation, including flue size, burner types, burner placements and orientation, firing rate setpoints, stoichiometric ratios and more. This extensive analysis, combined with computer modeling of the furnace, identified that our High-Yield Oxy-fuel Burner would be a good fit for their operation. This patented burner*, designed specifically for aluminum rotary furnaces, can provide even heating throughout the entire furnace, as well as the ability to keep the free oxygen within the flame envelope, thereby minimizing any oxidation of aluminum that can result in yield loss.

* U.S. Patent No. 8404018

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