improving performance in furnace melt treatment process - Pyrotek

In-Furnace Melt Treatment Process
PYROTEK
SUPPLEMENT

Jonathan Prebble,
Pyrotek’s Manager of
Aluminium Process
Technology
In-Furnace Melt Treatment Process
Pyrotek has
the expertise,
technology,
experience
and the
global
resources to
maximize the
performance
of your
aluminium
melt
treatment
systems.
Page 2
PYROTEK
SUPPLEMENT
IMPROVING PERFORMANCE IN
FURNACE MELT TREATMENT PROCESS
ANALYZING THE MELT
TREATMENT PROCESS
Quality is generally defined as
conformance to mutually agreed upon
customer specifications. This definition
matches well with any discussion around
aluminium melt quality and the related
molten metal treatment process. The melt
treatment processes addressed in this
article include alloying and furnace melt
refining. In-line degassing and filtration,
which are important components in
achieving final melt quality, will be
addressed separately in the next article in
this series titled, “Improving Performance –
Degassing and Filtration Processes.”
The five main melt quality culprits for the
casthouse are the following:
Trace elements, causing off specification
or inconsistent casts.
Alkali metals, causing cracking and
missed specifications.
Hydrogen, causing porosity and density
complaints.
Inclusions, causing downstream
processing complications.
Product inconsistency due to either
chemical or thermal variations during
casting.
The process of melt treatment starts with the
requirements of the finished product’s enduser.
These requirements vary widely and
need to be understood, agreed upon and
documented so that melt quality processes
can be managed to deliver this specification
with zero defects at the lowest possible
cost. While it starts with consistently
meeting customer specifications, it does not
end there. Other critical factors in managing
melt quality processes include operational
costs/cycle times, operational health and
safety, and environmental impact/
compliance.
To maximize casthouse performance in all
these critical areas, it is important that the
production team clearly understands the
marketing and operational objectives
involved. These defined objectives measure
the effectiveness of the melt quality
processes and practices upon the final cast
product. Typical challenges include, but are
not limited to, how to achieve the same
level of product quality consistency time in
and time out, combined with how to achieve
optimum performance in a practical
manner while, at the same time, minimizing
costs and maximizing productivity.
These challenges and issues vary greatly
depending upon whether processing
primary or secondary metals. It is important
to understand the melt quality and source
of impurities at the beginning of the casting
process in order to establish successful
operational processes that will deliver
consistent metal quality to the casting
station.
Pyrotek’s mission is to work with casthouse
managers to develop a coordinated, holistic
approach to a sustainable operations plan
for melt treatment. We bring all these
operational elements together in a
synergistic way that maximizes the
performance of each step of the melt
treatment process. Pyrotek’s approach
includes a process audit and situation
analysis with the customer to jointly
understand and document the customer’s
operational objectives, historical operating
performance, casting pit capabilities, end
user requirements, environmental
objectives and safety. Once these are
understood and agreed upon, a prioritized
list of performance improvement projects
(PIP’s) are identified. A Pyrotek technical
team is then organized to work with the
customer to execute, track and evaluate
each project’s results against preestablished
targets and world-class
operational norms for similar operations,
targeting similar melt quality specifications.

In-Furnace Melt Treatment Process
PRIMARY VS. SECONDARY
What are the different impurities?
Primary smelting can introduce the
following impurities:
From the refined alumina we obtain
elements such as Si, Fe, and traces of Ti,
Ca, V, B, etc.
From the coke blend used to make the
anodes we pick up further traces of Ti, V,
Ca, Si, Fe, etc.
From the carbon plant operations, we
attract traces of Si, P, Fe, Mn – mainly from
the anode but also from the cast iron
thimbles and the steel stubs on the anode
rod assemblies.
Recycled Secondary Ingot (RSI)
Dissolution of these impurities takes place
in the cell/pot at ~ 960°C. The chemical bath
also contributes alkali metals from the salts
used – K, Na, Ca and Li. Some cells operate
a high Li bath chemistry for added current
efficiency. Carbides and oxides are also
generated by the turbulent electro-magnetic
and chemical activity in the cells and the
reactions with the cell lining materials. The
bath is frequently tapped along with the
metal in the crucible delivered to the cast
house. Turbulence during the transfer leads
to oxide and dross inclusions in the metal.
Refractory wear in transfer ladles also leads
to a risk of increased inclusions.
Feed stock from secondary melting can
introduce an even wider range of impurities
depending on the material combination
used to charge the furnace. Recycled
Secondary Ingot (RSI) cast from metal
recovered from dross, saw chips, saw fines
and thermal fill scrap, can contribute alkali
metals as well as TiB and aluminium
2
oxides. Recycled scrap from internal or
external sources is an additional source of
hydrocarbons, paints, lacquers,
surface treatments, oils and
lubricants. Fumes, dioxins and
furans can be produced in large
amounts depending on the quality
and quantity of recycled material
that is melted. Customer returns
and in-house scrap can add Li and
Zn in 7000 series, Cu in 2000
series, Mn in 3000 series, Si in
4000 series, Mg in 5000 series and
Fe in 8000 series.
Alloying elements such as silicon
can introduce dusts, as well as
high levels of iron and calcium.
These can be slowly absorbed into
the solution. Magnesium additions
can contribute magnesium oxide,
Fe and Ca. Boron waffle, when
added to the furnace for EC
grades, fades in as little as 90
minutes developing into TiB , 2
which settles and turns the
furnace bottom into a sticky
sludge. Tibor rod, when added to
the trough outside the furnace in
route to the casting table, can
have a tendency not to mix well
in the trough, developing into
coarse TiB particles, which can
2
affect degassing efficiency and/or
clog the downstream filtration
systems in use.
PYROTEK
SUPPLEMENT
SECONDARY SOURCES
OF IMPURITIES
Recycled Scrap
Purchased Scrap
Uncoated Metal Tools
Processing practices are a
constant source of contaminates.
Poor handling and metal flow Inefficient or Poorly Adjusted
arrangements generate metal Burners
turbulence, which in turn,
generates dross and oxides. Iron pick up can
come from uncoated metal tools. Poor
housekeeping allows dirt, inclusions and
dusts to become entrained in the metal flow
as inclusions to the next cast. Waste burner
gases and poor burner efficiency allow
hydrogen to be absorbed. Open doors and/
or improper burner adjustments can
contribute to hydrogen pickup and to melt
loss due to direct flame impingement. In-line
degassing can be an unintentional source
of contaminates from rotor speed too slow
(large bubbles), rotor speed too fast
(vortexing), rotor particulate, oxide build up
and broken baffle plates.
Page 3

Alan Peel,
Managing Director
EMP Division
Page 4
In-Furnace Melt Treatment Process
Purchasing
pure
alloy elements
in a form
that can be
charged
directly
into the
vortex of an
EMP System
also can give
some
financial
benefits.
ALLOYING - A Critical First Step
In Improving Melt Treatment
Performance
Alloying is the modification of melt
chemistry to meet casting specifications. It
is typically done in the melting furnace and
adjusted in the holding furnaces or during
transfer. Alloying elements include, but are
not limited to: silicon, iron, magnesium,
manganese, copper and chromium. Stirring
and melt homogenization are key
components of the alloying process.
Alloying cycle times must allow for
adequate dissolution time as well as for the
time required to complete proper furnace
skimming, refining and settling. For certain
applications, there is a need to select highgrade
alloys (for example, low Fe and Ca
silicon metal for wheel/rim alloys).
To maximize efficiency, operating practices
must measure alloying recoveries, adjust
furnace temperatures and processing
techniques to optimise alloy additions. If
operating in conjunction with a primary
smelter, it is often possible to utilise the hot
metal superheat – a potential source of free
furnace energy. Use powders, flakes and
tablets rather than ingot or waffle to reduce
energy costs and to accelerate dissolution
rates when they can be efficiently stirred
into the metal.
The use of effective techniques to facilitate
forced circulation of the melt during the
melting and alloying phases of the process
demonstrates improvements in cycle times
and more efficient use of expensive alloying
materials.
The EMP and Metaullics division both offer
the LOTUSS vortex system which is a
highly effective method of submergence for
both scrap and alloying materials.
Traditional methods for alloying in the cast
house utilized pre-prepared master alloys.
These are charged directly into the melting
or holding furnace and ‘stirred in’ with the
assistance of the dross rake. The problem
associated with this technique is that it tends
to take longer for the alloy addition to
become fully mixed into the melt as the
mixing is reliant upon the drossing tool to
PYROTEK
SUPPLEMENT
fully mix the bath and master alloys. In an
attempt to overcome this problem of
effective mixing, the master alloys are
usually made with a special flux that
accelerates the mixing of the alloy addition
into the melt.
The EMP and Metaullics pumping systems
for light gauge scrap additions have the
advantage of the unique vortex well as a
medium for the addition of alloys into the
furnace. The furnace door is kept closed
during the entire process, with the following
three operating benefits:
Maintaining the heat transfer efficiency
of the furnace,
Minimising energy losses, and
Minimising environmental emissions to
the casthouse and operators.
The LOTUSS vortex system eliminates the
need to alloy directly through the furnace
doors or by using specially made alloy
tablets. The pure elemental additions Mn
flake, Fe splatter, Cu cuttings/swarf and Mg
bars can now be used in an effective way
by charging directly through the EMP
Vortex.
Fig. 1 Magnesium Ingots Charged Directly Into
the EMP Vortex
Economic Benefits to Alloying Through
The Vortex
With the appropriate feeding equipment,
alloys from lump silicon to magnesium have
been effectively charged into a furnace with
significant reductions in alloy losses and an
improved dissolution time of the alloy into
the melt.
The following graph demonstrates the fast
dissolution of magnesium ingots through a
vortex.

In-Furnace Melt Treatment Process
Fig. 2 Chemical Homogeneity
Yield Improvement
This reduction in alloy losses results from the
fact that the alloy addition is immediately
submerged sub-surface, minimising any
exposure to the air and to the burners in the
furnace. Typical yields on pure alloy additions
charged in this manner are shown below:
Alloy Yield By Yield When
Addition Charging Charged Directly
Through EMP To Furnace
Lump Silicon 97% 94%
Magnesium 98% 90%
10 Kg Ingot
Manganese Flake 98% 94%
Iron Splatter 98% 90%
(Powder/Tablet)
Copper 99% Only Tablets
Yield Improvement by Charging Pure
Alloys Directly Into EMP Vortex
Reduced Mixing Time
By charging the alloy additions in this
manner, they are immediately mixed in the
sub-surface aluminium movement within the
vortex. They quickly dissolve and are easily
mixed into the full aluminium bath by the
rapid sub-surface flow from the
electromagnetic pump.
Alloy Purchase Costs
Purchasing pure alloy elements in a form that
can be charged directly into the vortex of an
EMP System also can give some financial
benefits. Normally it is not possible to use
pure additions when charging directly into
the furnace due to their ability to go into
solution. The yield can also be a concern as
they tend to be small in size and oxidise
easily.
By using the LOTUSS vortex well, it
becomes practical to charge these pure
elemental additions directly through the
vortex. The result is a yield that is much
higher (depending upon the quality of the
alloy oil, moisture levels etc.) than when
charging through the main furnace door.
The use of pure elements offers additional
savings in the reduced cost of master
alloys and tablets.
Additional Benefits of EMP Systems
EMP now offers complete solutions to
melting furnace problems. EMP’s use of a
LOTUSS charge well offers casthouse
operations the following opportunities:
Reduced alloying costs
Ability to transfer from furnace to
furnace or to casting lines
Option to raise metal levels for transfer
Add flux additions directly into the melt
Reduced emissions when fluxing
Improved flux efficiency for Na and Ca
removal
Capability to incorporate gas injection
for hydrogen removal.
LOTUSS (Low Turbulence
Scrap Submergence System)
The LOTUSS (Low Turbulence Scrap
Submergence System) in conjunction with
a Metaullics mechanical pump or EMP
electromagnetic pump, has proven
especially effective for submerging and
blending silicon alloy additions and light
gauge scrap such as machining chips,
turnings, borings or “swarf” exhibiting a
high surface-area-to-weight ratio.
Typically, these types of materials include
oxides, lubricants and debris created
during the production process. The
propensity for aluminium to oxidise
increases the metal surface tension,
causing light gauge charge materials to
remain on the surface of the molten metal.
This causes further oxidation and
subsequent melt loss. The use of a forced
submergence technology, like
the LOTUSS system,
greatly reduces this effect,
permitting high metal
yield rates and increased
productivity.
Metaullics Tensor ® Circulation Pump in Combination
With a LOTUSS Charging System
PYROTEK
SUPPLEMENT
Dave Plant,
Project Engineer
EMP Division
Pyrotek’s
EMP,
Metaullics
and
SNIF ®
divisions
offer a
complete
line of
circulation
equipment.
Page 5

Paul Campbell
Marketing Manager
Metaullics Systems
Division
In-Furnace Melt Treatment Process
The
Metaullics
gas injection
pump is the
product of
choice
where
demagging is
required.
Page 6
DEMAGGING WITH CHLORINE
In order to produce foundry alloys,
secondary smelters often use chlorine gas
to demag, degas, or both. Foundry alloys
for sand, permanent mold, and die casting
require low magnesium levels. Wrought
alloys such as building materials,
extrusions, beverage containers,
and a wide variety of other
commonly recycled consumer
products contain substantially high
levels of magnesium. To the extent
possible, scrap is often blended
based on pricing, availability, and
composition to meet or approach
the magnesium specification for
the material being produced. In
many cases, however, the
specification cannot be met by
blending alone and smelters have
found that gas injection pumps are
an effective tool to achieve the
required result.
Demagging efficiencies are
dependent on thermodynamic and kinetic
considerations. Under favorable
conditions, magnesium can be removed
from molten aluminium alloys by adding
halogen compounds such as chlorine. The
reaction between magnesium and chlorine
occurs because there is a preferred
chemical affinity at normal molten
aluminium operating temperatures.
In accordance with the following reactions,
when gaseous chlorine is introduced into
molten aluminium, aluminium chloride is
produced as a gaseous product (see
equation below). When magnesium is
present, the aluminium chloride reactively
decomposes to form magnesium chloride
which rises to the surface where it can be
removed by skimming. Favorable
thermodynamics alone do not guarantee
efficient magnesium removal. Kinetic
factors such as rate of mixing, contact area,
and concentrations will all have dramatic
effects.
2Al + 3Cl 2AlCl (1)
2 3
2AlCl + 3Mg 3MgCl + 2Al (2)
3 2
The following graph represents typical
demagging results in the production of
foundry ingot in a 75 ton furnace with a 38
ton heel from the previous heat. Scrap
containing high percentages of magnesium
was charged into the furnace while the
pump was operating. The gas injection
pump was able to remove the magnesium
at essentially the same rate that it was
added to the furnace, maintaining the alloy
▲ ▲
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SUPPLEMENT
within the specification limit for the alloy
being produced.
It has always been necessary for chlorination
technology in aluminium recycling to meet
rigorous environmental standards. Current
MACT (Maximum Achievable Control
Technology) standards in the U.S. have
taken this requirement to an even higher
level. Compared to other chlorination
technologies, gas injection pumps provide
the safest and most efficient technology for
accomplishing this aspect of melting and
refining.
When demagging is required, the Metaullics
gas injection pump is the product of choice
due to its proven operating efficiency, low
maintenance, rugged construction and
reliability.
METAULLICS GAS INJECTION
PUMPS
Advanced technology, with the
revolutionary 6-barrel impeller design,
achieves longer life, higher efficiencies,
and reduced maintenance requirements.

PHD-50
In-Furnace Melt Treatment Process
Furnace Mounted HD2000 in the
Treatment Position Utilizing a
Spinning Rotor
STAR FIM5
EMP Charge Well With Gas Injection
IN-FURNACE REFINING - The Correct
North
America
Methods Can Benefit Your Melt Quality
Pyrotek’s early involvement in research programs
and technical partnerships with the major aluminium
companies aimed at eliminating chlorine usage has
improved the efficiency of fused refining agents in
in-furnace treatments. We have gained the
knowledge, products and practical expertise to
resolve most metallurgical problems related to the
presence of hydrogen, non-metallic inclusions and
alkali metals in aluminium cast products. Pyrotek
has proven over recent years that the use of
environmentally friendly refining agent injection
technology is a truly viable alternative to both
chlorine fluxing and fluoride based fluxes.
Fluxes and refining agents can
improve the quality of aluminium
alloys if they are treated while still
molten in the furnace. Originally,
this type of treatment was
restricted to dross reduction and
furnace cleaning. However, it
usually contributed to magnesium
loss in certain alloys (due to
chemical and thermal reduction)
as well as an increase in alkali
Fused Refining Agents
metals (from the salts used in the
products supplied in previous
years). Magnesium is an expensive addition to make
to any alloy, thus any treatments by salts or chlorine
gas, both of which remove magnesium, are therefore
expensive in terms of “hidden” costs. Alkali metals
(Na, Ca, Li) are also undesirable in certain foundry
alloys (for example, A356.2) due to the problems they
can cause in subsequent processing of the cast
products, as well as the undesirable effects that they
can have upon their grain structure (such as,
modification).
A range of fused refining agents has been developed
by Pyrotek to counter act these undesirable side
effects. They are a blend of fused, anhydrous MgCl 2
and KCl which allow them to be injected or
immerged, either through a lance, rotor or a vortex,
below the surface of the melt, where they melt before
coming into intimate contact with the molten
aluminium in finely-dispersed liquid droplet form.
Refining agents are particularly effective when
introduced below the melt surface because the
refining agent materials melt below 480°C (880°F).
The refining agent quickly becomes a liquid phase
in molten aluminium, facilitating the reaction which
(Continued on page 8)
PYROTEK
SUPPLEMENT
Robert Bridi
Pyrotek’s Global
Product Manager,
Fluxes, Refining Agents
& Lubricants
Refining
agents are
particularly
effective
when
introduced
below the
melt
surface.
Page 7

Proper furnace
refining with
Pyrotek’s refining
systems can
deliver
measurable,
repeatable
improvements in
metal quality by:
Reducing Alkali
Metals
Page 8
In-Furnace Melt Treatment Process
Reducing
Hydrogen Levels
– enabling the
downstream
degasser to
achieve a better
exit result
Reducing
Inclusion Levels
– better filtration
efficiencies and
product quality
downstream
Using the correct
injection method
to refine the melt
Optimises flux
consumption
Speeds up scrap
and hardener
melting
Minimises
variations in
chemistry and
temperature
through the melt
Reduces or
eliminates the
use of chlorine
gas or degasser
tablets.
removes the alkali metals. Reactions and
impurities removal take place in the liquidliquid
contact areas (Collision Theory). The
density of the liquid phase of the refining
agent is 2.17 and that of the liquid
aluminium is 2.35. Being relatively similar
in density, the droplets of refining agent can
remain within the liquid metal for some time
before floating out. During their period of
suspension, the droplets of the refining
agent react with Na, Li and Ca, while also
absorbing some of the inclusions and
hydrogen present in the melt.
This process also has valuable secondary
benefits. During and after the alkali metal
reaction stage, a fall in both hydrogen and
inclusion levels has been measured. This
indicates that during refining, degassing and
cleansing of the melt is also taking place.
These refining agents also assist in keeping
the furnace walls clean (thereby retaining
furnace capacity – often without the need
for additional cleaning fluxes), improving
the recovery of alloying additions. The
physical mixing process also promotes
chemical homogeneity and reduced
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SUPPLEMENT
thermal stratification within the body of the
melt.
The reaction efficiency of impurity removal
is enhanced by improving the metal
circulation within the furnace during
injection rather than adding the refining
agent flux in excess and/or on the melt
surface.
Pyrotek offers a wide range of flux injection
and circulation equipment to maximize the
efficiency of the flux refining agents. This
minimizes consumable costs, cycle times,
and environmental issues associated with
proper melt treatment. The product mix of a
particular casthouse and its related quality
specifications drive the correct choice and
combination of melt treatment technology.
The good news is that this type of flux
injection equipment, combined with the
proper refining agent and operating
practices, almost always has a rapid pay
back (typically 6 – 18 months) and adds
significantly to melt quality consistency,
operator safety and environmental
objectives with the use of PLC controlled
operating procedures.
NA REDUCTION IN A PRIMARY SMELTER CASTING HIGH MG
ALLOYS
The table below depicts a primary smelter that replaced 100-150 Kg MgCl2/KCl powder
blended flux with 30-50 Kg Pyrotek Promag RI fused refining agent addition in the furnace.
The objective was to bring the Na below 1ppm in casting, to reduce the treatment cost, to
reduce fume emissions associated with the excess of powder flux and to eliminate edgecracks
due to Na during hot rolling of high Mg alloys. Promag RI is the refining agent used
in all casthouses of this aluminium company. In a large number of primary plants the Promag
RI is being injected via a spinning nozzle system in the furnace. In 2006, tests of Promag
addition in the vortex of the EMP system will be performed at a primary smelter.
Product Quantity Na Before Furnace Na After Furnace Final Na In The
Treatment, ppm Treatment, ppm Casting Table, ppm
Powder Blend 150kg 6.6 2.3 0.4
Powder Blend 100kg 15.8 2.2 0.6
Promag RI 50kg 9.6 1.6 0.3
Promag RI 50kg 16.4 3.2 0.6
Promag RI 50kg 14.5 5.0 0.6
Promag RI 50kg 14.0 2.4 0.3
Promag RI 50kg 22.9 3.1 0.3
Promag RI 30kg 16.7 3.0 1.0
Promag RI 30kg 5.5 1.5 0.2
Promag RI 30kg 24.6 1.5 0.5
Promag RI 30kg 38.1 3.0 0.4

In-Furnace Melt Treatment Process
REDUCTION OF
HYDROGEN,
CALCIUM AND
INCLUSIONS IN
SECONDARY
PROCESSING
In 2004, Pyrotek presented
a technical paper at TMS
on the effective removal of
calcium and hydrogen in a
secondary remelt casting
billet for internal
consumption. The case
study was based on
sustained sampling and
testing. It clearly
demonstrated that the
combination of Pyrotek’s
HD-2000 with Pyrotek’s
FIF-50 can be used for
injecting solid fluxes and
refining agents along with
the standard process gas.
This process produced
significant reductions in
hydrogen, calcium, and
inclusion levels within the
furnace. It also
demonstrated that these
levels could be maintained
into the cast metal if proper
furnace controls were
maintained.
The Pyrotek system was
simple and reliable
performing with a minimum
of dross formation and
furnace disruption while
operating within current
environmental standards.
The system had the effect of
consistently improving
metal quality in the billet
with the unquantified
benefits of increased
extrusion speeds, extended
die life, reduced breaks and
defects.
Calcium & Inclusion Data Versus Time for Holder and
Casting Line During and After HD 2000 Treatment
Calcium Content (ppm)
9
8
7
6
5
4
3
2
1
0
0.0
-20 0 20 40 60 80 100 120 140
Calcium Removal Results
Removal (%)
Relative Time (minutes)
Total Inclusion Removal
Removal (%)
Hydrogen Removal Results
Removal (%)
100
90
80
70
60
50
40
30
20
10
100
80
60
40
20
-20
-40
-60
45
40
35
30
25
20
15
10
Mix Flux Mix Idle Cast
Calcium Inclusions
0
1a 3a 5a 7a 9a 11a 13a 15a 17a 19 23 27 31 35 39 43
Test #
OK Minimum Detection Limit Reached
0
1a 3a 5a 7a 9a 11a 13a 15a 17a 19 23 27 31 35 39 43
5
Test #
0
1a 3a 5a 7a 9a 11a 13a 15a 17a 19 23 27 31 35 39 43
Test #
AlSCAN 1 AlSCAN 2
-137
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
Total Inclusions (mm2/kg)
PYROTEK
SUPPLEMENT
Dr. Robert Frank
Pyrotek’s Manager of
Technology for
SNIF ® Systems
Pete Flisakowski
Pyrotek’s Aluminium
Metallurgical Engineer
PYROTEK’S
MISSION
“Providing
innovative
solutions
to customer
needs
utilizing
our global
resources.”
Page 9

Page 10
In-Furnace Melt Treatment Process
Dr. Neil Keegan
Pyrotek’s Metallurgical
Services Group
Manager
Dr. Dave Neff
Metaullics Molten
Metal Treatment
Manager
Pyrotek
is the
aluminium
industry’s
most
comprehensive
resource
for improving
in-furnace
melt treatment
performance.
PYROTEK
SUPPLEMENT
ELIMINATION OF CHLORINE IN THE FURNACE MELT TREATMENT
In 2002, a major producer in South America, recognized Pyrotek as “Supplier of the Year”
largely for its contribution to the elimination of chlorine in their melt treatment processes.
Pyrotek’s service after the sale, timely deliveries and fast, innovative solutions to their
technical needs, were also factors in Pyrotek receiving this distinguished award.
In North America, numerous primary and secondary processors have also been able to
improve their melt quality while significantly reducing or eliminating chlorine treatments,
including the ability to meet the MACT (Maximum Achievable Control Technology) standards.
The use of Pyrotek’s various refining agent injection techniques has allowed many facilities
in the U.S. to continue using dirty and painted scrap and to comply with the new MACT
standards for new and existing group 1 furnaces (dirty scrap or reactive agent in the furnace).
The following table shows the stack emissions achieved by a billet caster in the U.S. that
successfully switched from chlorine lance fluxing to the use of a refining agent with a
Pyrotek FIF-50 flux injection system (lance). Actual test results below demonstrate that
when the furnace treatment is performed with Pyrotek’s refining agent injection system, the
levels of HCl particulates and dioxin/furans fall well below the new MACT standards despite
the dirty and painted scrap added to the charge.
Run # Run #1 Run #2 Run #3 Three run avg.
Run time (sample time) 507 minutes 473 minutes 442 minutes 474 minutes
Molten metal, tons/hr 2.73 2.97 3.01 2.90
Particulate PM MACT Limit 0.4 lb/ton of feed
Concentration, gr/DSCF 0.00607 0.00754 0.00622 0.00661
Emission rate, lb/hr 0.819 1.13 1.07 1.01
Emission rate,
lb/ton of molten metal
0.300 0.380 0.355 0.345
Hydrogen Chloride MACT Limit 0.4 lb/ton of feed
Concentration, ppm 8.14 8.15 8.21 8.17
Emission rate, lb/hr 0.727 0.811 0.934 0.824
Emission rate,
lb/ton of molten metal
0.266 0.273 0.310 0.283
TEQ Three run average MACT Limit 15.0 μg/ton of feed
Total CDD/CDF lb/ton 1.56E-08
Total CDD/CDF μg/ton 7.07
CONCLUSION
From its early involvement in research programs and technical partnerships with major
aluminium companies to eliminate chlorine usage and to improve the efficiency of fused
refining agents in in-furnace treatments, Pyrotek has gained the knowledge to resolve
metallurgical problems related to the presence of hydrogen, non-metallic inclusions and
alkali and alkaline earth metals in aluminium castings. Pyrotek has proven in recent years
that the environmentally friendly refining agent injection technology is a viable alternative
to chlorine fluxing and to fluoride based fluxes.
As a partner to the industry, Pyrotek has worked with aluminium companies world-wide to
review and improve their melt treatment performance. From melting to casting and everything
in between, Pyrotek has experienced personnel to help increase productivity while meeting
customer driven quality goals.
Pyrotek is the aluminium industry’s most comprehensive resource for improving in-furnace
melt treatment performance. Pyrotek is unique in its ability to provide the integration of
innovative technologies, process expertise and a global perspective, all dedicated to assisting
customers in the optimization of their casthouse processes and practices.

In-Furnace Melt Treatment Process
PYROTEK’S MAJOR LOCATIONS
ASIA
CHINA, Shenzhen
Phone: (86) 755-26632324
e-mail: shenzhen@pyrotek.info
INDIA, Pune
Phone: (91) 21-375-6800
e-mail: pune@pyrotek.info
INDONESIA, Jakarta
Phone: (62) 21-563-8507
e-mail: jakarta@pyrotek.info
JAPAN, Kobe
Phone: (81) (0)78-265-5590
e-mail: kobe@pyrotek.info
KOREA, Daegu
Phone: 82 (0)53-523-5202
e-mail: korea@pyrotek.info
MALAYSIA, Kuala-Lumpur
Phone: (603) 5631-3096
e-mail: kualalumpur@pyrotek.info
TAIWAN, Kaohsiung City
Phone: (886) 7-224-8222
e-mail: taiwan@pyrotek.info
THAILAND, Bangkok
Phone: (66) (0) 2 361-4870
e-mail: bangkok@pyrotek.info
AUSTRALIA
AUSTRALIA (ANZ HEADQUARTERS)
Phone: (61) (0)2 9631-1333
e-mail: sydney@pyrotek.info
CANADA
QUEBEC, Drummondville
Phone: (819) 477-0734
e-mail: drummondville@pyrotek.info
EUROPE
CZECH REPUBLIC, Blansko
Phone: (420) (0) 516-527-111
e-mail: blansko@pyrotek.info
GERMANY, Grevenbroich
Phone: (49) (0)2182-8-10-20
e-mail: grevenbroich@pyrotek.info
SWEDEN, Ed
Phone: (46) (0) 534-62000
e-mail: ed@pyrotek.info
SWITZERLAND, Sierre
Phone: (41) (0)27-455-82-64
e-mail: sierre@pyrotek.info
UNITED KINGDOM, Milton
Keynes
Phone: (44) (0)1 908-561155
e-mail: miltonkeynes@pyrotek.info
MEXICO
MEXICO, Santa Catarina
Phone: (52) 81-8336-9117
e-mail: mexico@pyrotek.info
MIDDLE EAST
UNITED ARAB EMIRATES, Dubai
Phone: (971) (0)4-883-77-00
e-mail: dubai@pyrotek.info
NEW ZEALAND
NEW ZEALAND, Auckland
Phone: (64) (0)9 272-2056
e-mail: auckland@pyrotek.info
RUSSIA/CIS
RUSSIA/CIS, Moscow
Phone: (7) 095-230-71-63
e-mail: moscow@pyrotek.info
SOUTH AFRICA
REPUBLIC OF SOUTH AFRICA,
Richards Bay
Phone: (27) (0)35 7974039
e-mail: richardsbay@pyrotek.info
SOUTH AMERICA
BRASIL, São Paulo
Phone: (55) (0)11-4786-5233
e-mail: saopaulo@pyrotek.info
VENEZUELA, Puerto Ordaz
Phone: (58) 286-994 1894
e-mail: puertoordaz@pyrotek.info
U.S.A.
CALIFORNIA, Cerritos
Phone: (562) 623-0085
e-mail: cerritos@pyrotek.info
INDIANA, Columbia City
Phone: (260) 248-4141
e-mail: columbiacity@pyrotek.info
INDIANA, Evansville
Phone: (812) 867-6343
e-mail: evansville@pyrotek.info
NEW YORK, Canastota
Phone: (315) 697-8410
e-mail: canastota@pyrotek.info
NEW YORK, Elmsford
Phone: (914) 345-4740
e-mail: elmsford@pyrotek.info
NORTH CAROLINA, Salisbury
Phone: (704) 642-1993
e-mail: salisbury@pyrotek.info
OHIO, Solon
Phone: (440) 349-8800
e-mail: solon@pyrotek.info
PENNSYLVANIA, Carlisle
Phone: (717) 249-2075
e-mail: carlisle@pyrotek.info
WASHINGTON, Spokane Valley
Phone: (509) 926-6211
e-mail: spokane@pyrotek.info
WISCONSIN, Waukesha
Phone: (262) 524-9095
e-mail: waukesha@pyrotek.info
This supplement can also be viewed at www.pyrotek.info/melt_treatment
See the previous supplement at www.pyrotek.info/furnace_operations
PYROTEK
SUPPLEMENT
Pyrotek is
unique in its
ability to
provide the
integration of
innovative
technologies,
process
expertise and a
global
perspective.
CORPORATE OFFICE
9503 E. Montgomery Avenue
Spokane Valley, WA 99206
Phone: (509) 926-6212
Fax: (509) 927-2408
e-mail: info@pyrotek.info
Visit
Pyrotek
at
www.pyrotek.info
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In-Furnace Melt Treatment Process
PYROTEK
SUPPLEMENT