EP1402078B1 - Method for melting down aluminium - Google Patents

Method for melting down aluminium Download PDF

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Publication number
EP1402078B1
EP1402078B1 EP02780764A EP02780764A EP1402078B1 EP 1402078 B1 EP1402078 B1 EP 1402078B1 EP 02780764 A EP02780764 A EP 02780764A EP 02780764 A EP02780764 A EP 02780764A EP 1402078 B1 EP1402078 B1 EP 1402078B1
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EP
European Patent Office
Prior art keywords
furnace
burner
gas
oxygen
starting material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
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EP02780764A
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German (de)
French (fr)
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EP1402078A2 (en
Inventor
Davor Spoljaric
Dietmar Wieck
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Air Liquide Deutschland GmbH
Messer Group GmbH
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Air Liquide Deutschland GmbH
Messer Group GmbH
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Publication of EP1402078A2 publication Critical patent/EP1402078A2/en
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B1/00—Shaft or like vertical or substantially vertical furnaces
    • F27B1/10—Details, accessories, or equipment peculiar to furnaces of these types
    • F27B1/26—Arrangements of controlling devices
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B21/00—Obtaining aluminium
    • C22B21/0084—Obtaining aluminium melting and handling molten aluminium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B1/00—Shaft or like vertical or substantially vertical furnaces
    • F27B1/10—Details, accessories, or equipment peculiar to furnaces of these types
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D17/00—Arrangements for using waste heat; Arrangements for using, or disposing of, waste gases
    • F27D17/001—Extraction of waste gases, collection of fumes and hoods used therefor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D7/00—Forming, maintaining, or circulating atmospheres in heating chambers
    • F27D7/04—Circulating atmospheres by mechanical means
    • F27D2007/045—Fans

Definitions

  • the present invention relates to a method of smelting aluminum comprising the steps of: supplying an aluminous feedstock to an oven, preheating the feedstock by furnace exhaust gas in an upper portion of the furnace, and heating the feedstock by means of at least one burner to form an aluminum melt in a lower one Area of the furnace, wherein the burner is supplied to an oxygen-rich gas and fuel and thus a force acting on the feedstock in the melting region and contributing to the furnace exhaust gas burner flame is generated.
  • Such methods are for example in the JP 10 311688 A or the JP 04 160123 A described. Also from the US 4,664,702 a corresponding method is known in principle.
  • shaft melting furnaces are frequently used in which feedstocks are melted in the form of aluminum ingots, cycles or scrap.
  • the exhaust gas from the burners from the holding zone and the melting zone is used to preheat the feedstocks. These are charged into the furnace shaft, preheated in the fall and melted in the lower area by means of burners.
  • the molten aluminum flows via a melt bridge into a hearth area, which is required as a collector and for adjusting the temperature.
  • the shaft melting furnaces are usually designed for a specific burner capacity. An increase in the burner power for the purpose of increasing the melting performance therefore usually also requires an adaptation of the exhaust system and the filter system.
  • Suitable oxygen burners are also mixed burners (for example so-called “combination burners") in which the fuel is burned with air or with oxygen-enriched air or with oxygen.
  • a temperature-controlled burner with low emission still describes the US 5,542,839 However, this burner is not suitable for the melting of aluminum.
  • the invention has for its object to modify the method for melting aluminum-containing feedstock using an oxygen-rich gas so that the associated disadvantages are avoided with respect to the preheating of the aluminum insert.
  • oxygen-rich gas oxygen or oxygen-enriched air.
  • the kiln exhaust gas consists mainly of the combustion products CO 2 and H 2 O. According to the invention, it is sucked out of the upper region of the kiln with a blower and returned to it in the lower region as recirculated gas.
  • a blower By reintroducing the kiln exhaust gas or a part thereof as a “heated, recirculated gas", the reduction in burner exhaust gas associated with the use of the oxygen-rich gas can be fully or partially compensated.
  • the additional amount of gas inside the furnace improves the convective heat transfer to preheat the feedstock in the furnace shaft.
  • a particular advantage of this procedure compared to an additional air feed is that the furnace exhaust gas - when using an oxygen burner - is substantially nitrogen-free and thus the NO x formation is reduced.
  • Another advantage is that the recirculated gas is already heated and thus contributes to better energy utilization. The amount of heat of the recirculated gas additionally increases the melting capacity of the furnace.
  • the recirculated gas is supplied to the at least one burner.
  • An additional opening in the furnace wall for introducing the recirculated gas and a corresponding conversion measure of an existing furnace can be avoided.
  • the furnace exhaust gas is removed by means of a blower and serves at the same time to supply the burner, the furnace exhaust gas - or a part thereof - as recirculated gas again.
  • the blower thus ensures the circulation of the kiln exhaust gas.
  • the amount of extracted furnace exhaust gas can be adjusted to the requirements.
  • a controllable hot gas blower is suitable. In view of this, it has proved to be favorable to detect according to the invention a characteristic characteristic of the furnace atmosphere and to regulate the performance of the blower as a function of the parameter.
  • the oxygen content or the temperature are detected.
  • the oxygen content of the furnace atmosphere is measured and the measured value is used as a manipulated variable for regulating an oxygen supply to the burner. This makes it possible to keep the stoichiometry of the burner flame constant with respect to oxygen.
  • the oven is additionally combustible components, such as oil on aluminum shavings.
  • the measurement of the oxygen content in the furnace atmosphere ensures a stable and reproducible melting process by controlling the flame stoichiometry.
  • the post-combustion eliminates flammable components of the furnace atmosphere, such as oil on aluminum shavings, from the furnace exhaust gas, thus ensuring stable combustion.
  • a controlled supply of oxygen is advantageous, which is ensured by a measurement of the oxygen content in the furnace atmosphere.
  • the recirculated gas is introduced into the furnace above and / or below the burner flame.
  • the recirculated gas is colder than the burner flame and therefore contributes to a reduction in their temperature. This reduces the formation of NO x .
  • the vault is additionally protected from the radiation of the burner flame and thereby reduces the wear of refractory material.
  • the recirculated gas is introduced into the furnace so as to envelop the burner flame.
  • the method according to the invention will be explained in more detail below with reference to an exemplary embodiment.
  • the embodiment relates to the conversion of a previously operated with air burners shaft melting furnace for aluminum ingot and -niklaufmaterial with oxygen burners.
  • the aluminum is transported via an automatic charging in the shaft, there preheated in the sinking and melted with burners.
  • the molten metal flows into a hearth area, which is required as a collector and for adjusting the temperature.
  • the exhaust gas is used to preheat the solid aluminum.
  • the use of oxygen is also advantageous in shaft melting furnaces.
  • the furnace oxygen burner which are installed in a ceramic block, used.
  • the ceramic block is simply mounted in the wall of the furnace. Cooling of the burner is not required.
  • the furnace was therefore additionally equipped with a hot gas recirculation.
  • a hot gas blower was installed at the top of the furnace shaft, by means of which the combustion exhaust gas is withdrawn and returned to the furnace via the burner.
  • a large volume of gas is obtained for the convective heat transfer, which - depending on the size of the furnace - up to 10,000 m 3 / h.
  • the exhaust gas exits the burner via an annular outer nozzle, so that the oxygen flame is enveloped by hot furnace gas. This shielding of the burner flame protects the refractory lining from overheating.
  • the flame temperature and nitrogen content of the furnace atmosphere are lowered, thereby reducing NOx formation.
  • a speed control is installed.
  • the oxygen content of the furnace atmosphere is measured. The measured value is used to regulate the oxygen supply to the burners, in such a way that the burners are operated with constant flame stoichiometry.
  • the temperature of the kiln exhaust gas in the blower is approx. 1200 ° C.
  • the supply of oxygen in the blower enables afterburning of pyrolysis gas containing combustible components.
  • the shaft melting furnace is operated with two burners, wherein the volume fraction of the supplied furnace exhaust gas depending on the operating mode between 2 to 10 times the other burner gases (fuel gases and oxygen) is.
  • the thermal efficiency is increased during combustion, so that the melting rate of 1.4 t / h (using air burners, charging 50% cycle / 50% piglets) increased to 3.5 t / h and the Energy consumption could be more than halved.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Vertical, Hearth, Or Arc Furnaces (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)
  • Furnace Details (AREA)

Abstract

In order to melt down aluminium in an oven, a method is known whereby a starting material containing aluminium is supplied to an oven, is pre-heated in an upper region of the oven by means of oven flue gas, and is then heated by means of a burner, in order to form an aluminium melt, in a lower region of the oven. An oxygen-rich gas and fuel are supplied to the burner, producing a burner flame acting on the starting material in the melting region and contributing to the formation of the oven flue gas. On the basis of the above, the aim of the invention is to provide a method using an oxygen burner or a mixed burner, whereby the disadvantages in terms of the re-heating of the aluminium starting material are avoided. According to the invention, the oven flue gas is extracted from the upper region of the oven and is reintroduced into the lower region, at least partially, as recirculated, heated gas.

Description

Die vorliegende Erfindung betrifft ein Verfahren zum Einschmelzen von Aluminium, umfassend die Verfahrensschritte: Zufuhr eines aluminiumhaltigen Einsatzmaterials zu einem Ofen, Vorwärmen des Einsatzmaterials durch Ofenabgas in einem oberen Bereich des Ofens, und Erhitzen des Einsatzmaterials mittels mindestens eines Brenners unter Bildung einer Aluminiumschmelze in einem unteren Bereich des Ofens, wobei dem Brenner ein sauerstoffreiches Gas und Brennstoff zugeführt und damit eine auf das Einsatzmaterial im Schmelzbereich einwirkende und zum Ofenabgas beitragende Brennerflamme erzeugt wird. Solche Verfahren sind beispielsweise in der JP 10 311688 A oder der JP 04 160123 A beschrieben. Auch aus der US 4,664,702 ist ein entsprechendes Verfahren prinzipiell bekannt.The present invention relates to a method of smelting aluminum comprising the steps of: supplying an aluminous feedstock to an oven, preheating the feedstock by furnace exhaust gas in an upper portion of the furnace, and heating the feedstock by means of at least one burner to form an aluminum melt in a lower one Area of the furnace, wherein the burner is supplied to an oxygen-rich gas and fuel and thus a force acting on the feedstock in the melting region and contributing to the furnace exhaust gas burner flame is generated. Such methods are for example in the JP 10 311688 A or the JP 04 160123 A described. Also from the US 4,664,702 a corresponding method is known in principle.

In Aluminiumgießereien werden häufig Schachtschmelzöfen eingesetzt, in denen Einsatzstoffe in Form von Aluminiumbarren, -kreislauf oder -schrott erschmolzen werden. Bei diesem Ofentyp wird das Abgas der Brenner aus dem Warmhaltebereich und dem Schmelzbereich zur Vorwärmung der Einsatzstoffe genutzt. Diese werden in den Ofenschacht chargiert, darin beim Absinken vorgewärmt und im unteren Bereich mittels Brennern erschmolzen. Das geschmolzene Aluminium fließt über eine Schmelzbrücke in einen Herdbereich, der als Sammler und zum Einstellen der Temperatur erforderlich ist.In aluminum foundries, shaft melting furnaces are frequently used in which feedstocks are melted in the form of aluminum ingots, cycles or scrap. In this type of furnace, the exhaust gas from the burners from the holding zone and the melting zone is used to preheat the feedstocks. These are charged into the furnace shaft, preheated in the fall and melted in the lower area by means of burners. The molten aluminum flows via a melt bridge into a hearth area, which is required as a collector and for adjusting the temperature.

Die Schachtschmelzöfen sind üblicherweise für eine bestimmte Brennerleistung ausgelegt. Eine Erhöhung der Brennerleistung zum Zweck einer Steigerung der Schmelzleistung erfordert daher in der Regel auch ein Anpassung der Abgasführung und der Filteranlage.The shaft melting furnaces are usually designed for a specific burner capacity. An increase in the burner power for the purpose of increasing the melting performance therefore usually also requires an adaptation of the exhaust system and the filter system.

Durch einen Einsatz von Brennstoff-Sauerstoffbrennern oder Luft-Sauerstoff-Mischbrennern lässt sich zwar - im Vergleich zu Schmelzverfahren, bei denen Luft als Oxidationsmittel eingesetzt wird - die Schmelzleistung des Ofens ohne größeren konstruktiven Aufwand steigern und der Energiebedarf reduzieren. Die Einsparung an Brennstoff beruht jedoch im wesentlichen darauf, dass der Stickstoffanteil der Luft nicht aufgeheizt werden muss. Der im Abgas fehlende Stickstoffanteil und die damit einhergehende geringere Menge an Brennerabgasen wirkt sich jedoch nachteilig auf die Vorwärmung des Aluminiumeinsatzes im Ofenschacht aus.By using fuel-oxygen burners or air-oxygen mixing burners, it is possible to increase the melting performance of the furnace without major design effort and reduce the energy requirement, in comparison with melting processes in which air is used as the oxidizing agent. The saving However, fuel is essentially based on the fact that the nitrogen content of the air does not have to be heated. However, the lack of nitrogen in the exhaust gas and the associated lower amount of burner exhaust gases has a disadvantageous effect on the preheating of the aluminum insert in the furnace shaft.

Als Sauerstoffbrenner kommen auch Mischbrenner (zum Beispiel sogenannte "Kombibrenner") in Betracht, bei denen der Brennstoff mit Luft oder mit sauerstoffangereicherter Luft oder mit Sauerstoff verbrannt wird.Suitable oxygen burners are also mixed burners (for example so-called "combination burners") in which the fuel is burned with air or with oxygen-enriched air or with oxygen.

Aus der DE 23 15 748 A ist es auch schon für einen Schachtkalkbrennofen bekannt, Ofengas im oberen Bereich des Ofens abzuziehen und im unteren Bereich wieder zuzuführen. Dies erfolgt mittels eines Gebläses, jedoch wird das zurückgeführte Ofengas nicht geregelt und separat von einem Brenner wieder zugeführt.From the DE 23 15 748 A It is also already known for a shaft lime kiln to deduct furnace gas in the upper part of the furnace and feed back in the lower area. This is done by means of a blower, but the recirculated furnace gas is not regulated and fed separately from a burner.

In der DE 43 24 111 A1 ist auch schon beschrieben, dass in einem speziellen Brennofen für mineralogische und petrographische Verbindungen Ofengas temperaturabhängig zum Brenner zurückgeführt werden werden kann, jedoch sind die Verhältnisse in einem solchen Ofen nicht mit denen beim Einschmelzen von Aluminium vergleichbar.In the DE 43 24 111 A1 It has also been described that in a special furnace for mineralogical and petrographic compounds furnace gas can be recycled depending on the temperature of the burner, but the conditions in such a furnace are not comparable to those in the melting of aluminum.

Aus der EP 0 428 117 B1 ist auch ein Heizkessel mit Abgasrückführung zum Brenner bekannt, bei dem sich aber auch nicht die Probleme stellen, die beim Vorheizen von einzuschmelzendem Aluminium auftreten.From the EP 0 428 117 B1 Also, a boiler with exhaust gas recirculation to the burner is known, but in which also do not face the problems that occur during preheating of einschmzendem aluminum.

Einen temperaturkontrollierten Brenner mit geringer Emission beschreibt noch die US 5,542,839 , wobei dieser Brenner aber nicht für das Einschmelzen von Aluminium geeignet ist.A temperature-controlled burner with low emission still describes the US 5,542,839 However, this burner is not suitable for the melting of aluminum.

Der Erfindung liegt die Aufgabe zugrunde, das Verfahren zum Einschmelzen von aluminiumhaltigem Einsatzmaterial unter Einsatz eines sauerstoffreichen Gases so zu modifizieren, dass die damit einhergehenden Nachteile hinsichtlich der Vorwärmung des Aluminiumeinsatzes vermieden werden.The invention has for its object to modify the method for melting aluminum-containing feedstock using an oxygen-rich gas so that the associated disadvantages are avoided with respect to the preheating of the aluminum insert.

Diese Aufgabe wird mit den Merkmalen des Anspruchs 1 gelöst. Vorteilhafte Ausgestaltungen sind in den abhängigen Ansprüchen angegeben.This object is achieved with the features of claim 1. Advantageous embodiments are specified in the dependent claims.

Unter einem "sauerstoffreichen Gas" wird Sauerstoff oder mit Sauerstoff angereicherte Luft verstanden. Das Ofenabgas besteht hauptsächlich aus den Verbrennungsprodukten CO2 und H2O. Es wird erfindungsgemäß aus dem oberen Bereich des Ofens mit einem Gebläse abgesaugt und diesem im unteren Bereich als rezirkuliertes Gas wieder zugeführt. Durch das Wiedereinleiten des Ofenabgases oder eines Teils davon als "erwärmtes, rezirkuliertes Gas" kann die mit dem Einsatz des sauerstoffreichen Gases einhergehende Verminderung an Brennerabgas ganz oder teilweise kompensiert werden. Die zusätzliche Gasmenge innerhalb des Ofens verbessert die konvektive Wärmeübertragung zur Vorwärmung des Einsatzmaterials im Ofenschacht.By "oxygen-rich gas" is meant oxygen or oxygen-enriched air. The kiln exhaust gas consists mainly of the combustion products CO 2 and H 2 O. According to the invention, it is sucked out of the upper region of the kiln with a blower and returned to it in the lower region as recirculated gas. By reintroducing the kiln exhaust gas or a part thereof as a "heated, recirculated gas", the reduction in burner exhaust gas associated with the use of the oxygen-rich gas can be fully or partially compensated. The additional amount of gas inside the furnace improves the convective heat transfer to preheat the feedstock in the furnace shaft.

Ein besonderer Vorteil dieser Verfahrensweise gegenüber einer Einspeisung zusätzlicher Luft besteht darin, dass das Ofenabgas - bei Einsatz eines Sauerstoffbrenners - im wesentlichen stickstofffrei ist und somit die NOx-Bildung reduziert ist. Ein weiterer Vorteil besteht darin, dass das rezirkulierte Gas bereits erwärmt ist und somit zu einer besseren Energieausnutzung beiträgt. Die Wärmemenge des rezirkulierten Gases erhöht die Schmelzleistung des Ofens zusätzlich.A particular advantage of this procedure compared to an additional air feed is that the furnace exhaust gas - when using an oxygen burner - is substantially nitrogen-free and thus the NO x formation is reduced. Another advantage is that the recirculated gas is already heated and thus contributes to better energy utilization. The amount of heat of the recirculated gas additionally increases the melting capacity of the furnace.

Es ist ein Brenner vorgesehen oder mehrere Brenner. Erfindungsgemäß wird das rezirkulierte Gas dem mindestens einen Brenner zugeführt. Eine zusätzliche Öffnung in der Ofenwandung zum Einleiten des rezirkulierten Gases und eine entsprechende Umbaumaßnahme eines bestehenden Ofens können so vermieden werden.There is one burner or several burners. According to the invention, the recirculated gas is supplied to the at least one burner. An additional opening in the furnace wall for introducing the recirculated gas and a corresponding conversion measure of an existing furnace can be avoided.

Dabei wird das Ofenabgas mittels eines Gebläses abgezogen und dient gleichzeitig dazu, dem Brenner das Ofenabgas - oder einen Teil davon - als rezirkuliertes Gas wieder zuzuführen. Das Gebläse sorgt somit für die Zirkulation des Ofenabgases.In this case, the furnace exhaust gas is removed by means of a blower and serves at the same time to supply the burner, the furnace exhaust gas - or a part thereof - as recirculated gas again. The blower thus ensures the circulation of the kiln exhaust gas.

Durch Veränderung der Gebläsedrehzahl kann die Menge des abgezogenen Ofenabgases den Erfordernissen angepasst werden. Zu dem Zweck eignet sich insbesondere ein regelbares Heißgasgebläse. Im Hinblick hierauf hat es sich als günstig erwiesen, erfindungsgemäß eine für die Ofenatmosphäre charakteristische Kenngröße zu erfassen und die Leistung des Gebläses in Abhängigkeit von der Kenngröße zu regeln.By changing the fan speed, the amount of extracted furnace exhaust gas can be adjusted to the requirements. For the purpose, in particular, a controllable hot gas blower is suitable. In view of this, it has proved to be favorable to detect according to the invention a characteristic characteristic of the furnace atmosphere and to regulate the performance of the blower as a function of the parameter.

Als charakteristische Kenngröße werden vorzugsweise der Sauerstoffgehalt oder die Temperatur erfasst.As a characteristic parameter, preferably the oxygen content or the temperature are detected.

In einer bevorzugten Ausgestaltung des erfindungsgemäßen Verfahrens wird der Sauerstoffgehalt der Ofenatmosphäre gemessen und der Messwert als Stellgröße für eine Regelung einer Sauerstoffzufuhr zum Brenner eingesetzt. Damit ist es möglich die Stöchiometrie der Brennerflamme in Bezug auf Sauerstoff konstant zu halten.In a preferred embodiment of the method according to the invention, the oxygen content of the furnace atmosphere is measured and the measured value is used as a manipulated variable for regulating an oxygen supply to the burner. This makes it possible to keep the stoichiometry of the burner flame constant with respect to oxygen.

Dies macht sich insbesondere dann vorteilhaft bemerkbar, wenn in den Ofen zusätzlich brennbare Bestandteile gelangen, wie zum Beispiel Öl auf Aluminiumspänen. In dem Fall gewährleistet die Messung des Sauerstoffgehalts in der Ofenatmosphäre einen stabilen und reproduzierbaren Schmelzvorgang durch eine Regelung der Flammenstöchiometrie.This is particularly advantageous if the oven is additionally combustible components, such as oil on aluminum shavings. In that case, the measurement of the oxygen content in the furnace atmosphere ensures a stable and reproducible melting process by controlling the flame stoichiometry.

Dies spielt auch bei einer weiteren vorteilhaften Weiterbildung der Erfindung eine Rolle, bei der im Gebläse eine Nachverbrennung brennbarer Bestandteile der Ofenatmosphäre erfolgt. Durch die Nachverbrennung werden brennbare Bestandteile der Ofenatmosphäre, wie Öl auf Aluminiumspänen - aus dem Ofenabgas beseitigt und damit eine stabile Verbrennung gewährleistet. Hierfür ist eine geregelte Zufuhr von Sauerstoff vorteilhaft, die durch eine Messung des Sauerstoffgehalts in der Ofenatmosphäre gewährleistet wird.This also plays a role in a further advantageous embodiment of the invention, in which a post-combustion of combustible constituents of the furnace atmosphere takes place in the fan. The post-combustion eliminates flammable components of the furnace atmosphere, such as oil on aluminum shavings, from the furnace exhaust gas, thus ensuring stable combustion. For this purpose, a controlled supply of oxygen is advantageous, which is ensured by a measurement of the oxygen content in the furnace atmosphere.

In einer besonders bevorzugten Verfahrensvariante wird das rezirkulierte Gas oberhalb und/oder unterhalb der Brennerflamme in den Ofen eingeleitet. Das rezirkulierte Gas ist kälter als die Brennerflamme und trägt daher zu einer Verringerung von deren Temperatur bei. Dadurch wird die Bildung von NOx gesenkt. Bei dieser Verfahrensweise wird insbesondere das Gewölbe vor der Strahlung der Brennerflamme zusätzlich geschützt und dadurch der Verschleiß an Feuerfestmaterial reduziert. Im Hinblick hierauf wird im Idealfall das rezirkulierte Gas derart in den Ofen eingeleitet, dass es die Brennerflamme umhüllt.In a particularly preferred variant of the method, the recirculated gas is introduced into the furnace above and / or below the burner flame. The recirculated gas is colder than the burner flame and therefore contributes to a reduction in their temperature. This reduces the formation of NO x . In this procedure, in particular the vault is additionally protected from the radiation of the burner flame and thereby reduces the wear of refractory material. In view of this, ideally, the recirculated gas is introduced into the furnace so as to envelop the burner flame.

Nachfolgend wird das erfindungsgemäße Verfahren anhand eines Ausführungsbeispiels näher erläutert. Das Ausführungsbeispiel betrifft die Umrüstung eines bisher mit Luftbrennern betriebenen Schachtabschmelzofens für Aluminiumbarren und -kreislaufmaterial mit Sauerstoffbrennern.The method according to the invention will be explained in more detail below with reference to an exemplary embodiment. The embodiment relates to the conversion of a previously operated with air burners shaft melting furnace for aluminum ingot and -kreislaufmaterial with oxygen burners.

Typische Daten dieses Schachtabschmelzofens vor der Umrüstung waren:

  • Schmelzleistung: 1,4 t/h (bei Einsatz von Luftbrennern)
  • Vorwärmtemperatur: 200 bis 450 °C
  • Energieverbrauch: 1000 kWh/t Aluminium
  • Krätzeanfall: 3 bis 4 %
Typical data of this shaft melting furnace before the conversion were:
  • Melting capacity: 1.4 t / h (when using air burners)
  • Preheating temperature: 200 to 450 ° C
  • Energy consumption: 1000 kWh / t aluminum
  • Scratching attack: 3 to 4%

Das Aluminium wird dabei über eine automatische Chargierung in den Schacht befördert, dort beim Absinken vorgewärmt und mit Brennern geschmolzen. Das geschmolzene Metall fließt in einen Herdbereich, der als Sammler und zum Einstellen der Temperatur erforderlich ist. Bei diesem Ofentyp wird das Abgas zur Vorwärmung des festen Aluminiums genutzt.The aluminum is transported via an automatic charging in the shaft, there preheated in the sinking and melted with burners. The molten metal flows into a hearth area, which is required as a collector and for adjusting the temperature. In this type of furnace, the exhaust gas is used to preheat the solid aluminum.

Aus den oben genannten Gründen ist der Einsatz von Sauerstoff auch bei Schachtabschmelzöfen von Vorteil. Für die entsprechende Umrüstung des Ofens wurden Sauerstoff-Brenner, die in einem keramischen Block eingebaut sind, eingesetzt. Der keramische Block wird einfach in die Mauerung des Ofens montiert. Eine Kühlung des Brenners ist nicht erforderlich.For the reasons mentioned above, the use of oxygen is also advantageous in shaft melting furnaces. For the corresponding conversion of the furnace oxygen burner, which are installed in a ceramic block, used. The ceramic block is simply mounted in the wall of the furnace. Cooling of the burner is not required.

Aufgrund der niedrigeren Abgasmengen beim Einsatz von Sauerstoff geht weniger Energie mit dem Abgas verloren. Die geringeren Abgasmengen verringern aber auch den konvektiven Wärmeübergang bei der Schrottvorwärmung im Schacht. Um eine hohe Schmelzleistung bei niedrigen NOx-Werten zu erhalten, wurde der Ofen deshalb zusätzlich mit einer Heißgasrezirkulierung ausgestattet.Due to the lower amounts of exhaust gas when using oxygen, less energy is lost with the exhaust gas. The lower exhaust gas quantities also reduce the convective heat transfer during the preheating of the scrap in the shaft. In order to obtain a high melting performance with low NOx values, the furnace was therefore additionally equipped with a hot gas recirculation.

Hierzu wurde am oberen Ende des Ofenschachts ein Heißgasgebläse installiert, mittels dem das Verbrennungs-Abgas abgezogen und über den Brenner dem Ofen wieder zugeführt wird. Dadurch wird ein großes Gasvolumen für den konvektiven Wärmeübergang erhalten, das - abhängig von der Ofengröße - bis zu 10.000 m3/h beträgt. Das Abgas tritt aus dem Brenner über eine ringförmige Außendüse aus, so dass die Sauerstoffflamme von heißem Ofengas umhüllt wird. Diese Abschirmung der Brennerflamme schützt die feuerfeste Auskleidung vor Überhitzung. Zusätzlich wird die Flammentemperatur und der Stickstoffgehalt der Ofenatmosphäre gesenkt und dadurch die NOx-Bildung reduziert.For this purpose, a hot gas blower was installed at the top of the furnace shaft, by means of which the combustion exhaust gas is withdrawn and returned to the furnace via the burner. As a result, a large volume of gas is obtained for the convective heat transfer, which - depending on the size of the furnace - up to 10,000 m 3 / h. The exhaust gas exits the burner via an annular outer nozzle, so that the oxygen flame is enveloped by hot furnace gas. This shielding of the burner flame protects the refractory lining from overheating. In addition, the flame temperature and nitrogen content of the furnace atmosphere are lowered, thereby reducing NOx formation.

Zur Leistungsregelung des Heißgasbläses ist eine Drehzahlregelung installiert. Außerdem wird der Sauerstoffgehalt der Ofenatmosphäre gemessen. Der Messwert wird für die Regelung der Sauerstoffzufuhr zu den Brennern verwendet, in der Art, dass die Brenner mit konstante Flammenstöichiometrie betrieben werden.To regulate the power of the hot gas blower, a speed control is installed. In addition, the oxygen content of the furnace atmosphere is measured. The measured value is used to regulate the oxygen supply to the burners, in such a way that the burners are operated with constant flame stoichiometry.

Die Temperatur des Ofenabgases im Gebläse liegt bei ca. 1200 °C. Durch die Zufuhr von Sauerstoff wird im Gebläse eine Nachverbrennung von Pyrolysegas, das brennbare Bestandteile enthält, ermöglicht.The temperature of the kiln exhaust gas in the blower is approx. 1200 ° C. The supply of oxygen in the blower enables afterburning of pyrolysis gas containing combustible components.

Im konkreten Ausführungsbeispiel wird der Schachtabschmelzofen mit zwei Brennern betrieben, wobei der Volumenanteil des zugeführten Ofenabgases je nach Betriebsweise zwischen dem 2- bis 10-fachen der übrigen Brenneregase (Brenngase und Sauerstoff) beträgt.In the specific embodiment of the shaft melting furnace is operated with two burners, wherein the volume fraction of the supplied furnace exhaust gas depending on the operating mode between 2 to 10 times the other burner gases (fuel gases and oxygen) is.

Durch den Einsatz von Sauerstoff wird der thermische Wirkungsgrad bei der Verbrennung erhöht, so dass die Schmelzleistung von 1,4 t/h (bei Einsatz von Luftbrennern, Chargierung 50%Kreislauf/ 50%Masseln) auf 3,5 t/h gesteigert und der Energieverbrauch mehr als halbiert werden konnte.Through the use of oxygen, the thermal efficiency is increased during combustion, so that the melting rate of 1.4 t / h (using air burners, charging 50% cycle / 50% piglets) increased to 3.5 t / h and the Energy consumption could be more than halved.

Die hohe Schmelzleistung und weitere Verbesserungen am Ofen verminderten die Metallverluste um ca. 50 %. Ein Vergleich verschiedener Parameter bei einem Luftbrenner, einem Luft/Sauerstoff- Brenner und einem erfindungsgemäßen Sauerstoff-Brenner + Heißgasgebläse bei einem 15-Tonnen-Schachtschmelzofen sind in der folgenden Tabelle 1 zusammengefasst: Tabelle 1 Luftbrenner Luft/ Sauerstoff-Brenner Sauerstoff-Brenner + Heißgasgebläse Schmelzleistung [t/h] 1,4 2,1 3,5 Schmelzleistung [%] 100 150 250 Erdgasverbrauch [Nm3/t] 100 45 43 Sauerstoffverbrauch [Nm3/t] 0 75 86 Produktion [t/a] 10080 15000 25200 Krätzemengen [%] 100 71 45 Aluminiumgewinn [t/a] 150 554 The high melting rate and further improvements to the furnace reduced the metal losses by about 50%. A comparison of various parameters in an air burner, an air / oxygen burner and an oxygen burner according to the invention + hot gas blower in a 15-ton shaft melting furnace are summarized in the following Table 1: <b> Table 1 </ b> air burner Air / oxygen burner Oxygen burner + hot gas blower Melting power [t / h] 1.4 2.1 3.5 Melting power [%] 100 150 250 Natural gas consumption [Nm 3 / t] 100 45 43 Oxygen consumption [Nm 3 / t] 0 75 86 Production [t / a] 10080 15000 25200 Etching amounts [%] 100 71 45 Aluminum gain [t / a] 150 554

Die Energieerspamisse und das höhere Metallausbringen garantieren trotz der Kosten für Sauerstoff eine erhebliche Kostenersparnis durch die Reduzierung der Energiekosten, eine Verringerung der Krätzemengen und Einsparung an Personalkosten.The energy savings and higher metal yield, despite the cost of oxygen, can save a significant amount of money by reducing energy costs, reducing the amount of scratching and saving labor costs.

Claims (6)

  1. Method for melting down aluminium, comprising the method steps of: supplying a starting material containing aluminium to a furnace, preheating the starting material by furnace flue gas in an upper region of the furnace, and heating the starting material by means of at least one burner to form an aluminium melt in a lower region of the furnace, the burner being supplied with an oxygen-rich gas and fuel, and thereby creating a burner flame that acts on the starting material in the melting region and contributes to the furnace flue gas, the furnace flue gas being extracted in the upper region of the furnace by means of a blower and returned at least partially as recirculated, heated gas to the burner in the lower region, a characteristic variable that is characteristic of the furnace atmosphere also being detected and the output of the blower controlled in dependence on the characteristic variable.
  2. Method according to Claim 1, characterized in that the oxygen content or the temperature is detected as the characteristic variable.
  3. Method according to Claim 2, characterized in that the oxygen content of the furnace atmosphere is measured and the measured value is used as a manipulated variable for a closed-loop control of an oxygen supply to the burner.
  4. Method according to Claim 1, characterized in that an afterburning of combustible constituents of the furnace atmosphere takes place in the blower.
  5. Method according to one of the preceding claims, characterized in that the recirculated gas is introduced into the furnace above and/or below the burner flame.
  6. Method according to Claim 5, characterized in that the recirculated gas is introduced into the furnace in such a way that it envelops the burner flame.
EP02780764A 2001-06-19 2002-06-12 Method for melting down aluminium Expired - Lifetime EP1402078B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE10129219A DE10129219A1 (en) 2001-06-19 2001-06-19 Process for melting aluminum
DE10129219 2001-06-19
PCT/EP2002/006472 WO2002103067A2 (en) 2001-06-19 2002-06-12 Method for melting down aluminium in a shaft furnace

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EP1402078A2 EP1402078A2 (en) 2004-03-31
EP1402078B1 true EP1402078B1 (en) 2008-02-27

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AU (1) AU2002345607A1 (en)
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DE102010029648A1 (en) 2010-06-02 2011-04-07 Kutzner, Dieter, Dipl.-Ing. Method for melting e.g. aluminum scrap or glass, for heat treatment of steel in hearth furnace, involves operating burners of furnace using radiant flame, and supplying oxygen to combustion air flow to enrich air on pressure side of blower

Family Cites Families (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3759702A (en) * 1971-04-07 1973-09-18 Chemetron Corp Method of melting aluminum
DE2315748A1 (en) * 1973-03-29 1974-12-19 Wests Manchester Ltd Gas fired vertical furnace - with exhaust partly recycled to burners to produce even combustion
US3982889A (en) * 1975-07-14 1976-09-28 Olson Benjamin F Preheating system for aluminum remelt furnace
IT1132249B (en) * 1980-07-24 1986-06-25 Meccaniche F B M Spa Costruzio SYSTEM TO RECOVER THE LATENT AND SENSITIVE HEAT OF THE EFFLUENT GASES FROM A MELTING GROUP, IN ORDER TO OBTAIN ELECTRIC AND / OR THERMAL ENERGY
SU972202A1 (en) * 1981-04-13 1982-11-07 Пензенский Политехнический Институт Shaft furnace for smelting aluminium alloys
US4664702A (en) * 1985-02-04 1987-05-12 Southwire Company Method of melting aluminum in a vertical shaft furnace
DE3938090C1 (en) * 1989-11-16 1991-04-18 Viessmann Werke Gmbh & Co, 3559 Allendorf, De
JPH04160123A (en) * 1990-10-22 1992-06-03 Daido Steel Co Ltd Method for controlling combustion of burner in aluminum melting furnace
DE4324111A1 (en) * 1993-07-20 1995-01-26 Feustel Hans Ulrich Dipl Ing Process and apparatus for burning mineralogical and petrographic compounds and mixtures
US5542839A (en) * 1994-01-31 1996-08-06 Gas Research Institute Temperature controlled low emissions burner
JPH10311688A (en) * 1997-05-09 1998-11-24 Nippon Sanso Kk Method for melting metal
DE19732867A1 (en) * 1997-07-18 1999-01-21 Linde Ag Method and device for operating gas burners
DE19917128C1 (en) * 1999-04-15 2000-12-28 Hans Ulrich Feustel Production of crude iron in a blast furnace comprises injecting oxygen at the injection sites through burners, sucking the required partial streams of the contaminated blast furnace gas using a partial vacuum, and burning the gas

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ATE387510T1 (en) 2008-03-15
AU2002345607A1 (en) 2003-01-02
WO2002103067A3 (en) 2003-11-27
DE50211788D1 (en) 2008-04-10
EP1402078A2 (en) 2004-03-31
WO2002103067A2 (en) 2002-12-27
DE10129219A1 (en) 2003-01-09

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