New efficiency class in aluminium melting furnaces
12.12.11 -The new “PurEfficiency” series of aluminium melting furnaces of the Striko Westofen Group now consumes only 525 kWh of energy to melt and keep hot a tonne of aluminium, achieving a previously unattained energy class. Such levels of efficiency have otherwise only been achievable using involved regenerative burner systems. The furnace originated in the framework of a development project supported by the Federal Ministry of Economics and Technology.
In 2011 the first furnace of the new “PurEfficiency” series was shipped to the aluminium die caster Kovolit a.s. in the Czech Republic. The new two-chamber melting and holding furnace MH II (PE)-T 3000/1500 has a holding capacity of 3000 kg, and an hourly melting capacity of 1500 kg. In a benchmark test in real foundry conditions for the first time an energy consumption of 525 kWh/t was achieved. This figure includes melting consumption and after-heating for a constant pool temperature of 720 °C. It was fed with ingots of each 6 kg, as well as return material from die casting, which represented 49% of the overall melted material.
Even in daily foundry operations in which melting is interrupted by holding operation, such as e.g. in the case of reduced capacity or during shift changes, the newly developed furnace still consumes hardly any more energy. For the month of July the foundry registered gas consumption of 560 kWh/t for melting operations as mean value, at 730°C pool temperature. This means that the energy effectiveness of the furnace lies in the efficiency class of furnaces with regenerative burning systems, and far above all previously attained levels in comparable aluminium melting furnaces and cold air burners.