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Secondary aluminum processor sees company-wide improvement

Issue: We visited an aluminum processor with rotary and reverb furnaces which was supplied by a competitor. After discussing our latest technology we were invited to take a plant tour to see if we could improve their operation.

Solution: Based on the short tour Air Products applications engineers arranged to come back to the site for a thorough overview of the operation. The team spent several days onsite and identified many operational issues, equipment problems and opportunities to improve the combustion technology, which had not been upgraded in over a decade. The team found numerous calibration and control logic errors during a full inspection of the existing oxygen and gas flow trains—leading to both inaccurate control and unresponsive control of valves. Once issues with the equipment and controls were fixed, the Air Products team installed a new burner better suited for the process. With this combination of Air Products recommendations and improvements, the company has realized higher production, better recoveries and lower flux usage. The implementation was so successful that the company is now working with Air Products to evaluate new burner developments so they can continue to make enhancements.

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