In-Line Degassing Process - Pyrotek

In-Line Degassing Process
In-Line Degassing Process
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supplement
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Jonathan prebble,
pyrotek’s manager of
aluminium process
Technology
Page 2
In-line
degassing
performance
itself benefits
from good
upstream
processing
activities in
the furnaces,
and in turn
benefits other
downstream
in-line
processes such
as filtration.
In-Line Degassing Process
ImprovIng performance:
In-lIne DegassIng
Today, in-line degassing systems are
often installed between the holding
furnace and casting station to remove
impurities. Many degassing systems
function automatically, efficiently
and without much attention by the
operator. Even so, reviewing degasser
fundamentals will help to optimize
performance and to assess equipment
features that are important when
choosing a new degassing system.
Degassing is increasingly being seen
as an essential part of the integrated
melt treatment, degassing and filtration
process. In-line degassing performance
itself benefits from good upstream
processing activities in the furnaces, and
in turn benefits other downstream inline
processes such as filtration. These
systems are mutually complementary
and their combined effect is greater
than their individual performance
contributions. These in-line treatments
and processes should be selected based
upon the specific quality specifications
for the cast products to be produced
when using them.
Why Degas
As its name implies, the primary purpose
of the in-line degasser is to remove
dissolved hydrogen from the melt prior
to and as close as practicable to the
casting station. Hydrogen is the only
gas that can dissolve significantly in
molten aluminium. The major source of
hydrogen is the combustion of natural
gas or oil in holding furnaces. High
ambient humidity is another source
of hydrogen, especially during the hot
summer months experienced in many
localities. The problem is that hydrogen
solubility decreases rapidly as the metal
freezes during casting, and the hydrogen
comes out of solution, causing such
casting problems as twisting and flaking
in thin section extrusions and blisters on
cast product. Target dissolved hydrogen
content depends on the final product
application, and can range from 0.20
pyrotek
supplement
ml / 100g Al for general 6xxx extrusion
billet down to 0.10 ml / 100g Al for
rolling slab for aerospace applications.
Hydrogen is removed from the molten
aluminium by bubbling an inert gas
through the metal. Argon and nitrogen
are typically used, but argon is preferred
for the best metal quality because of the
tendency of nitrogen to form aluminium
nitride inclusions and more dross. By
adding a small amount of chlorine
to the inert process gas in degassers,
non-wetted inclusions and alkali metal
impurities can also be removed more
efficiently from the metal.
Inclusions in molten aluminium can
come from smelting operations, furnace
remelting, or intentional additions (e.g.
grain refiners). Inclusions can lead to
tears and surface defects in rolling sheet,
pinholes in foil, and increased die wear
during extrusion. Fifty percent (50%)
reduction of non-wetted inclusions is
a typical target in degassing systems.
Additional mechanical filtration down
stream of the degasser (e.g. Ceramic
Foam Filter, Rigid Media Filter, etc.) may
also be required to meet quality goals.
Excessive alkali metal (sodium, calcium,
lithium) concentrations can cause edge
cracking during slab rolling, and bar /
rod breaks. Typical maximum alkali
metal concentrations should not exceed
5 ppm for each element.
hoW Degassers Work
An inert gas, typically argon, is injected
into the chamber using one or more
spinning nozzles or other type of
injection device (Figure 1). The injector
shears the gas into bubbles that saturate
the molten metal. As the bubbles of
the process gas rise to the melt surface,
dissolved hydrogen is desorbed from the
melt (Figure 2). Adding a small amount
of chlorine (usually 0.5% or less) to the
process gas breaks the bond between
the aluminium and any non-wetted
inclusions present, allowing the rising
gas bubbles to stick to the inclusions
and float them to the melt surface.

Figure 1: In-line degasser fundamentals
Figure 2: Hydrogen removal theory
In-Line Degassing Process
Additional chlorine may be added to
chemically react with incoming alkali
metals (sodium, lithium, calcium, etc.)
to form chloride salts that are also floated
to the surface. Inclusions and solid salts
that float to the surface to form dross are
skimmed from the degasser between
casts.
opTImIzIng DegassIng
performance
Effective degassing depends on the capability
of the in-line system to completely
saturate the melt with small bubbles to
maximize residence time while maintaining
a “flat” bath surface that allows
inclusions and salts to float to the surface
and separate from the liquid aluminium.
Nozzle (injector) design, process
gas flow rate, and vessel chamber geometry
are factors that must be matched
to achieve optimum results. The nozzle
(or nozzles) must be capable of injecting
sufficient process gas throughout
the vessel chamber without
causing metal vortexing.
Excessive rotor speeds
without adequate chamber
baffling can cause the melt
to vortex, potentially allowing
hydrogen and dross
that has been floated to the
melt surface to be remixed
into the melt.
Adequate bubble reaction
time in the refining chamber
is another parameter
that contributes to effective
degassing. Metal flow rate,
and thus calculated residence
time in the vessel,
is one factor to consider
when choosing a degasser,
but a deeper vessel also
positively influences degassing
performance. The
deeper the gas is injected
into the melt, the longer
it takes for the bubble to
rise to the surface, and the
greater the residence time
of that bubble. It is also
easier to achieve a “flat”
bath surface with deeper vessels that
enhances inclusion and salt removal.
The headspace of a newer degassing
system is often sealed using positive
pressure venting of the inert process
gas to improve operating performance
and lower operating costs. Maintaining
an inert headspace reduces dross
generation caused by bubbles breaking
the melt surface and exposing liquid
metal to oxidation. Keeping air out of
the degasser headspace can significantly
extend graphite nozzle life when
compared to older, unsealed systems.
There is little cost justification for
investing in expensive ceramic nozzles
in sealed systems.
Summarizing, general guidelines to
optimize degasser performance are:
• Inject sufficient inert gas (argon)
to obtain desired hydrogen outlet
levels.
pyrotek
supplement
scott simmons,
Division manager,
snIf ® Division
Typical
maximum
alkali metal
concentrations
should
not exceed
5 ppm for
each
element.
Page 3

Dr. robert frank
pyrotek’s manager of
Technology for
snIf ® systems
maintaining
an inert
headspace
reduces dross
generation
caused by
bubbles
breaking the
melt surface
and exposing
liquid metal
to oxidation.
Page 4
In-Line Degassing Process
• Set the nozzle speed to minimize
bath turbulence and vortexing while
maximizing bubble distribution.
• Maintain an inert headspace to
minimize dross formation and
graphite nozzle oxidation.
guIDelInes for aDDIng
chlorIne
Within limitations, the amount of chlorine
that should be added to the degasser
is based on incoming inclusion
and alkali metal levels from the holder.
Typically, only a very small amount of
chlorine (no more than 0.5%) should be
added to the process gas to dry the dross
within the degassing system and to assist
in inclusion removal. Additional chlorine
may be added to the process gas to
chemically react with incoming alkali
metals; the recommended amount based
on stoichiometric calculations plus a
small safety factor to ensure complete
reaction. However, regardless of incoming
alkali metal concentrations, total
chlorine addition should not exceed 5%
of the gas phase per nozzle. The presence
of a “chlorine odor” around the
degasser when processing with chlorine
could well indicate that excessive chlorine
is being added.
Metal treatment in the holding furnace
with either chlorine or a refining agent
should be considered in cases where
the incoming alkali metal concentration
to the degasser cannot be reduced
sufficiently by adding less than 5%
chlorine.
Furthermore, MACT (Maximum Achievable
Control Technology) regulations in
the USA limit the amount of HCl emissions
from a degasser to 0.04 lbs/ton of
Al refined. Limiting the amount of chlorine
addition to the in-line degasser ensures
compliance with this regulation.
In a multiple nozzle system, splitting the
chlorine evenly between the nozzles
promotes reactions that are more
effective. However, introducing the total
chlorine flow through the first nozzle,
and argon only through the remaining
pyrotek
supplement
nozzles, allows the final chambers
to remove any excess chlorine and
prevent liquid chloride salt carryover
that might occur, especially when
casting high magnesium alloys. Such
salts remain liquid and pass through the
downstream filter, creating the real risk
of them solidifying in the cast product
as inclusions.
In cases where the degasser would be
required to treat foundry alloys that
have been modified with strontium,
it is important to remember that
chlorine gas reacts with the strontium
addition and reduces its effectiveness
as a modifier. In this situation, furnace
treatment with a suitable refining agent
and then the subsequent use of argon
in the in-line degasser should achieve
the performance levels required for
alkali metals, inclusions and hydrogen
removal.
It is also worth noting that the addition
of chlorine gas to a degasser does not
improve the unit’s hydrogen reduction
efficiency.
Summarizing, general guidelines for adding
chlorine to an in-line degasser are:
• Adding more than the minimum
amount of chlorine required for
inclusion removal and alkali metal
control will not improve in-line
degassing system performance.
• Consider holding furnace treatment if
alkali metal reduction targets cannot
be met with less than 5% chlorine
addition or if HCl emissions could
exceed local regulatory limits.
commercIally avaIlable
In-lIne DegassIng sysTems
For DC casting applications, degassers
can be generally categorized as either
“trough” or “deep vessel”.
In trough degassers, injectors (nozzles)
are installed along the length of the
trough section. The number of injectors
is determined by metal flow rate.
The trough degassing section may be
separated into stages by using baffles

In-Line Degassing Process
to improve performance. There is no
heating arrangement, so at the end of
each cast most of the degassed metal is
cast into the product. Metal depth and
bubble residence time is limited, so
hydrogen reduction performance may
suffer, or process gas flow rates may
need to increase to counter the shortfall.
Trough degassers are particularly well
suited for billet casting lines where alloys
are frequently changed and superior
hydrogen reduction levels may not be
required. Most trough degassers do not
maintain an inert headspace above the
metal level at all times during casting,
potentially leading to accelerated wear
of the graphite rotors above the metal
line during operation and increased
dross generation.
Deep vessel degassing systems typically
have one, two or three nozzles installed,
depending on metal flow rate. The vessel
may be separated into chambers, and
baffled to ensure complete mixing without
vortexing. Most deep vessel systems
have a heating system to maintain metal
temperature between casts.
Advantages of deep vessel systems are:
• Better system process performance
due to increased bubble residence
time and mixing,
• Reduced holding furnace temperatures
because the metal is held in the
degassing vessel at or above casting
temperature, and
• Reduced temperature variation at
the casting station.
Disadvantages of deep vessel
systems are:
• Additional tilting equipment
may be required in
cases where frequent alloy
changes are planned;
• They may require a larger
footprint compared to
trough degassers, and
• The heating system equipment
adds capital and
maintenance costs.
snIf ® In-lIne refInIng sysTems
Pyrotek offers the SNIF ® SHEER aluminum
refining system. SNIF ® stands for
spinning nozzle Inert flotation. SNIF ®
Systems are deep vessel units, employing
1 to 3 nozzles depending on the
user’s metal flow rate and hydrogen reduction
requirements. A typical SNIF ®
SHEER refining furnace with two chambers
is pictured in Figure 3 and illustrated
in Figure 4. The refining furnace is
a well-insulated vessel, complete with
insulated cover, spinning nozzles (1
per chamber), and multiple inlet / outlet
ports (labeled as ports 1 through 4
in Figure 4). The cover may be raised
between drops, as required, using the
cover lifter.
Figure 3: SNIF® Sheer refining furnace assembly with cover up
pyrotek
supplement
pete flisakowski
pyrotek’s aluminium
metallurgical engineer
Figure 4: SNIF® Sheer hB (graphite block) furnace illustrating chamber design and variable
inlet / outlet port arrangements
Page 5

volker Dopp
snIf ® sales manager,
europe
Page 6
The
patented
snIf ®
sheer
nozzle is
unique in
the industry,
in that it has
two graphite
components,
a stationary
outer
sheath (the
stator), and
a rotating
piece (the
shaft / rotor
assembly).
In-Line Degassing Process
Multi-nozzle SNIF ® units are separated
into distinct chambers (stages) by
refractory plates. Openings in the plate
direct the aluminum from the inlet
port, through the vessel, and exiting
through the outlet port.
The multiple ports allow
varying configurations
in the casting line. For
the SNIF ® pictured in
Figure 3, front ports 2
and 3 are connected to
the inlet/outlet troughs,
while side ports 1 and 4
are closed.
The rib located at the
bottom of each refining
chamber stabilizes the
metal flow patterns and
further reduces the potential
for vortexing.
SNIF ® SHEER “P” model
furnaces feature a patented
pre-fired refractory
cartridge lining that
can be replaced at the end of its life.
The cartridge comes complete with internal
baffling and surrounding insulation.
The cartridge sits on an integral
structural frame for handling. A “P” furnace
cartridge can be replaced in one
or two days, possibly without removing
the steel shell from the casting line.
The relined SNIF ® P furnace can be
placed in service after a 30-hour
pre-heat.
SNIF ® furnaces may be heated by
either a graphite heater block or immersion
heaters. The graphite block
heating system, illustrated in Figure
4, is an effective, low maintenance
solution recommended where the
furnace is drained infrequently. Immersion
heated systems may be a
better choice when the unit will be
drained frequently for alloy changes.
snIf ® sheer spInnIng nozzle
The patented SNIF ® SHEER nozzle
is unique in the industry, in that it
Figure 5: SNIF® Sheer nozzle
with bottom plate
pyrotek
supplement
has two graphite components, a stationary
outer sheath (the stator), and a rotating
piece (the shaft / rotor assembly).
See Figure 5. The graphite is treated to
reduce oxidation. Process gas is transported
between the stator
and shaft, and is injected
into the melt at an opening
between the bottom edge of
the stator and the top edge
of the spinning rotor.
The SNIF ® SHEER stator
provides two unique advantages
for optimizing the
performance of inline refin-
ing systems: It:
• Reduces the potential for
metal vortexing around
the shaft and
• Allows an effective stationary
ceramic seal to be
installed where the nozzle
enters the SNIF ® degasser
through the cover.
The metal circulating action
of the SNIF ® SHEER nozzle is detailed
in Figure 6. Without the bottom ring,
the lower density gas exiting the nozzle
would immediately begin to float to the
surface. The bottom ring restricts metal
from entering from beneath the nozzle.
A downward metal circulation pattern
Figure 6: SNIF® Sheer nozzle circulation patterns

In-Line Degassing Process
is established across the nozzle blades,
countering the natural flotation effect.
Gas ejected from the nozzle is therefore
directed outward radially and dispersed
evenly throughout the melt.
The SNIF ® SHEER nozzle and rib work
together to reduce melt agitation,
reduce surface splashing, and increase
the process efficiency of the refining
system.
sealeD sysTem Technology
sealing covers and Trough
airlocks
Keeping air out of the in-line
furnace headspace improves system
performance by:
• Preventing graphite nozzle “burn”
at the melt line, which is a frequent
cause of nozzle failure.
• Reducing dross generation during
both processing and idle periods
between casts, which reduces the
need for aggressive cleaning.
Air can enter the furnace through
openings in and around the cover,
and through the inlet / outlet ports of
“unsealed” systems.
SNIF ® sealed systems employ a solid,
one-piece cover with perimeter
gasketing and trough airlocks to close
these openings. Positive pressure
venting and the process and idle gas
prevent air infiltration, establishing an
inert atmosphere the headspace.
A cover lifter is provided for raising
the cover between casting drops when
necessary for cleaning and dedrossing.
While there is complete access to the melt
surface when the cover is lifted, there is
no access to the melt surface when the
cover is down. Dross generation during
casting is reduced to the degree that
skimming during processing is neither
needed nor desired.
Trough airlocks are shallow ceramic
under pour baffles which fit into the
inlet / outlet ports, thus preventing air
infiltration during both casting and idle
periods. Trough airlocks are illustrated
in Figures 7 and 8.
The sealing cover and trough airlocks
work together to prevent air from entering
the furnace headspace. Furnace
sealing is so complete that nozzle failure
due to stator burn is effectively eliminated,
and for many applications the cover
only needs to be raised once or twice
weekly for cleaning. Dross generated by
the inert bubbles breaking the melt surface
and exposing the metal to oxygen
in the vessel headspace has been measured
to be less than 0.1 kg / MT metal
cast in low magnesium alloys.
snIf Trough aIrlock
before anD afTer
InsTallaTIon
Figure 7: Trough airlock schematic
Figure 8: Trough airlocks installed in furnace ports
pyrotek
supplement
mike mattocks,
snIf ® sales manager,
asia and latin
america
furnace
sealing is so
complete
that nozzle
failure due to
stator burn
is effectively
eliminated.
Page 7

mickey mccollum
snIf ® sales manager,
north america
Page 8
In-Line Degassing Process
snIf ® rac (rapid alloy change)
sysTems
SNIF ® RAC system can reduce operating
costs for those users who change alloys
frequently. The RAC system consists of
an immersion heated vessel that can be
hydraulically tilted, and lifting / rotating
cover. At the end of the cast, the metal
remaining in the SNIF ® deep vessel can
be emptied into a sow, returned to the
holding furnace, or cast into the end of
the cast product.
• Silicon carbide elements (one per
chamber) encased in Sialon ceramic
sheaths are suspended from the SNIF ®
cover.
• A “swivel” mast cover lifter raises and
rotates the cover / heaters / nozzle
apparatus to the side between casts.
Figure 9: SNIF immersion heating system and rotating cover lifter
Figure 10: SNIF® Sheer P140 illustrating the optional rotating mast
and backwards furnace tilt into a sow
pyrotek
supplement
• Hydraulic cylinders permit furnace
tilting for draining through the inlet /
outlet ports into a sow, back either to
the holding furnace, or downstream
into the cast, at the user’s choice.
Figure 10 shows a system where the
troughs are connected to ports 2 and 3.
The furnace is tilted backwards into a
sow for alloy changes.
snIf ® TD unheaTeD sysTems
The SNIF ® TD (Tilting
Degasser) system features
an unheated deep vessel designed for
casting environments where alloys
are changed frequently, such as small
billet or ingot casting operations. A mast
installed along side the unit both lifts the
cover and tilts the vessel, allowing metal
to drain either downstream into the end
of the cast or upstream back to the holder
(Figure 11). For added flexibility, metal
can be held in the vessel for the next
cast if an alloy change is not required. If
the lapse time between casts is less than
one hour, TD systems can keep molten
aluminum at a temperature that is high
enough to start the next cast.
The TD 1500 (2 chamber) and TD
1000 (1 chamber) systems are based
on conventional SNIF ® technology.
The TD units employ SNIF ® spinning
nozzle and sealed system technology.
Hydrogen, alkali metal and inclusion
reduction performance is comparable to
that achieved in standard, heated SNIF ®
Systems.
Figure 11: SNIF® TD 1500 tilting to drain metal at
the end of a cast

case sTuDIes
In-Line Degassing Process
Case Study 1 – Improving process
performance while lowering operating
costs
Operating performance of a new SNIF ®
with sealed system technology installed
at a rolling plant producer in the U.S.A.
was compared to their older non-sealed
SNIF ® systems. This user found that their
sealed system generated substantially
less dross while nozzle life increased
dramatically. They raised the cover of
their SNIF ® sealed system once or twice
weekly to lightly scrape the wall and
remove about 10 kg of dross. Previously,
this user would de-dross after every drop
(on average, six times a day, every day
of the week) removing approximately
100 kg of dross each time they skimmed
the bath surface. Nozzle life in the new
sealed SNIF ® system averaged 5 months,
compared to 12.5 days with their older
unsealed systems. This customer has
since upgraded other older
unsealed SNIF ® systems to
take advantage of sealing
technology.
Case Study 2 – Improving
process performance while
reducing chlorine addition
to meet environmental
regulations
A continuous caster in the
U.S.A. was looking to upgrade
their casting line and at
the same time meet the U.S.A.
MACT standards for chlorine
emissions. Their previous process
called for furnace treatment
using 100% chlorine,
and a primitive in-line degassing
box where chlorine was
bubbled into an accumulating
chamber. The primary purpose
for adding chlorine in the
furnace was to remove inclusions
in the metal and to dry
dross. Chlorine was added to
the in-line box for degassing.
Their upgrade called for rotary nozzle
in-line treatment and the elimination
of the furnace fluxing. After looking
at various options, they selected a twonozzle
SNIF ® SHEER P-60HB system.
Though their flow rate could have been
easily handled by a single nozzle system,
the two-nozzle system was chosen
for redundancy in case they lost a nozzle
in the middle of a 10-day cast. After
installation and start up of two SNIF ®
SHEER P-60HB systems, metal quality
improved with respect to inclusion and
degassing removal; overall chlorine use
was reduced more than tenfold; and the
upgraded casting facility was able to
meet MACT standards for chlorine emissions.
The total chlorine input to their
process was less than 0.04 lbs. chlorine
/ton of aluminium throughput. The efficiency
of the SNIF ® SHEER P-60HB with
respect to hydrogen and inclusion removal
enabled this user to consistently
produce quality thin gauge foil.
snIf ® sheer p-60hb
pyrotek
supplement
Dave busch
snIf ® field engineering
manager
The primary
purpose
for adding
chlorine in
the furnace
was to
remove
inclusions
in the metal
and to dry
dross.
Page 9

pyroTek’s
mIssIon
“providing
innovative
solutions to
customer
needs utilizing
Page 10
our global
resources.”
In-Line Degassing Process
Case Study 3 – Improving process
productivity and performance using an
unheated SNIF ® TD System
An eastern European producer casting
high silicon (13%) foundry alloy for
the automotive market was looking
to improve their process. Their mixing
furnace capacity is 12 MT. The casting
rate is up to 3 MT / h and each cast
averages 4 to 5 hours. Degassing
previously was accomplished by
injecting process gas from bottom plugs
installed in a refractory box. The bottom
plugs frequently required maintenance
and approximately 1 MT metal had to
be drained from the degassing vessel
after each cast. After studying various
options, this user selected a SNIF ® SHEER
TD-1000 unheated system with tilt-todrain
capability to replace their plug
degasser and to improve productivity.
The static capacity of the SNIF ® SHEER
snIf ® sheer TD-1000
snIf ® sheer TD-1000
pyrotek
supplement
TD-1000 is 450 kg. In addition to
the immediate productivity gains
captured by eliminating the bottom
plugs and reducing degasser static
capacity, this user also realized
improved hydrogen removal.
Incoming hydrogen levels to the inline
degasser averaged 0.25 ml/100g
Al. Outlet hydrogen from the SNIF ®
SHEER TD-1000 was measured at
less than 0.10 ml/100g Al, far better
than required. As a result, the SNIF ®
SHEER TD-1000 process argon flow
rate was reduced to further lower
operating costs.
conclusIon
The in-line degassing system is an
integral part of today’s casting operation.
Understanding and optimizing
process parameters are necessary to
achieve intended metal quality and
improve casthouse production efficiency.
Pyrotek’s SNIF ® systems feature a variety
of solutions to meet cast house
production and performance criteria.
Pyrotek’s experienced technical personnel
are ready to work with aluminium
companies to determine the
best product selection for improving
performance in their operation.

In-Line Degassing Process
pyrotek
supplement
pyroTek’s maJor locaTIons pyrotek is
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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/inline_degassing
See the previous supplements at www.pyrotek.info/furnace_operations
and www.pyrotek.info/melt_treatment
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
Page 11

In-Line Degassing Process
pyrotek
supplement