Metaullics Pumps - Pyrotek

MOLTEN METAL PUMP SYSTEMS

METAULLICS SYSTEMSEstablished for over 50 years, Metaullics Systems has become a global leader in pumps and pump based systems for processingand handling molten aluminium, zinc, magnesium and their respective commercial alloys.Metaullics has a strong technical and innovative focus and is dedicated to providing practical solutions, service and support tothe non-ferrous industry. Its products provide improved productivity, lower operating costs and enhanced quality to metallurgicalplants world-wide.The head office and manufacturing facilities are located in the United States of America.Metaullics Systems Europe with headquarters in The Netherlands provides warehousing, sales and distribution in Europe and theMiddle East supported by a network of agents and distributors able to offer direct technical support and service on a local basis.Africa, Asia, and Australia are supported by a combination of distributors and agents.Electromagnetic pumping technology is supplied worldwide by the group company EMP Technologies Ltd., located in the U.K.Metaullics’ pump products are used by non-ferrous foundries, secondary smelters, primary smelters, die-casters and recyclersthroughout the world. New materials and proprietary designs have allowed the introduction of new products, systems andservices to a wide spectrum of aluminium, zinc, lead and magnesium operators world-wide.

MOLTEN METAL PUMP SYSTEMSMolten metal pumps are used for three major industrial applications.These are to CIRCULATEand to TRANSFER liquid metal and to MIX PROCESS GASSES with molten aluminium.Circulation Pumps use mechanical technology to stir liquid metal in a furnace. They arealso an integral part of systems designed to melt light gauge aluminium scrap.Continuously stirring a furnace with a circulation pump can increase production by 15 to50%, reduce energy consumption by 10 to 20%, reduce melt losses due to oxidation andextend furnace refractory life. Product quality is also improved since the alloy compositionand temperature of the metal in the furnace will be uniform.Transfer Pumps move liquid metal from one location to another.Their technology of operation allows them to work against gravity and the limitations itimposes on gravity fed systems.Transfer pump applications include furnace to furnace transfers, furnace to ladle transfers,furnace to casting machine transfers and for pouring large castings.Some pumps can be fitted with custom designed filters to deliver clean, filtered metal at theimmediate point of use. For galvanizers, pumps are used to empty galvanizing pots and kettlesin Hot Dip Galvanizing operations and to manage top dross accumulations in the snout ofContinuous Galvanizing Lines.Transfer pumps improve plant safety by eliminating the need for furnace taps, and provide aneconomic alternative to tilting furnaces. Productivity is improved by delivering metal directlyto the point of use and by pumping “on demand” with an easily controllable flow rate. Metalis pumped through refractory lined pipe which results in minimal heat loss during the transfer.

CIRCULATION PUMPSThe basic design of a mechanical circulation pump is shown.Most pumps are electrically driven, with the motor and motor mountbeing connected to the submerged pumping chamber by support legs.The motor turns a shaft fitted with an impeller in the pumping chamberand discharges metal from the base of the pump beneath the surface ofthe metal.Materials of construction include graphite for the drive shaft, impeller andbase, ceramic protection sleeves for the graphite drive shaft, and fullceramic support posts reinforced with high temperature steel rods.Graphite parts are treated by Metaullics’ proprietary treatment to retardoxidation.This technology, known as Tensor ® Technology is illustrated.Circulation pumps of this type and construction are usedin reverberatory furnaces that are usually equipped witha sidewell charging area. The primary benefit of this typeof furnace is high recovery rates when charging high surfacearea scrap.This allows scrap charging, alloy additions, dross removal, and metallurgicalsampling to be done in the open well thereby eliminating a need to openthe furnace doors except for periodic cleaning.Such a furnace requires forced circulation of hot metal from the hearth tothe charge well, with cold metal being circulated back into the hearth forreheating.

GAS INJECTION PUMPSA variation of the circulation pump is to equip it with a gasinjection feature. This allows degassing or magnesiumremoval from the melt to be carried out.The pump base is modified to accept a gas injection lancepositioned to introduce process gas directly into the highvelocity liquid metal exit stream. This causes the gas to bedisseminated into a mass of small bubbles with a largecumulative reactive surface area, offeringideal conditions for efficient interactionbetween the process gas and metal.Gas injection pumps can inject up to 250 kgof chlorine per hour into the molten bathwithout releasing pollution into theatmosphere.

TRANSFER PUMPSThe general layout of a transfer pump is shown. Pumps can be driven by an electricmotor or an air motor. Choice is generally determined by the sensitivity of controlrequired, the discharge volume needed or the metal head to be achieved. Severalsizes are available depending on the required flow rates and lift.The pumps sharemany common features with the circulation pumps but have their bases modifiedfor discharge to a hollow vertical cylinder known as the riser. Liquid metal ispumped above the liquid metal line of the furnace for discharge to the end usepoint.The pump remains in a furnace well and is activated whenever metal deliveryis required. Transfer pumps are used in the aluminium and zinc industries forfurnace to furnace transfers, furnace to ladle transfers, furnace to casting machinetransfers, and to pour sows or large castings. Flow rates for aluminium transfer canrange from 40 kg/minute to 5000 kg/minute. Most applications simply lift metalover the edge of the furnace. However, the high pressure capabilities of thesepumps have allowed some users to pump metal as high as 8 meters.

FILTER PUMPSSeveral transfer pump models are designed to befitted with molten metal filters over the pumpintake. This results in clean, filtered metal beingdelivered. This is especially useful to the die castingindustry where quality requirements demand the cleanestpossible metal.INSULATED PIPINGAn essential element for success in transferring liquid metal is to have asystem which ensures the metal is delivered to the point of use withoutfreezing. Refractory lined piping with low thermal mass linings has beendeveloped which has an optimum of good insulation properties and long lifefor various applications. Piping is available in straight and elbow sections sothat metal flow can be routed around or over obstacles if required. Althoughmost transfers are relatively short, distances of up to 25 meters are possible.

OTHER APPLICATIONSTRANSFER PUMPS FOR DROSS MANAGEMENTIN CONTINUOUS GALVANIZINGNew super alloys specifically designed for long service lifein liquid zinc alloys used in the Continuous Galvanizingprocess are making it possible to use all metal pumps tohelp the industry improve surface finish quality.Transfer pumps with specially modified inlets and outletsare able to remove the surface drosses which build up inthe inaccessible snout area where the hot steel strip entersthe liquid zinc alloy.It is essential for the zinc alloy surface to be kept clean sothat dross is not picked up by the steel strip as it enters thezinc.This is done as shown in the diagram.METAULLICS PUSH - PULL SYSTEM:IMPROVED COATING QUALITY BY REMOVING SURFACE DROSS

TRANSFER PUMPS FOR MAGNESIUMThe family of super alloys developed for ContinuousGalvanizing applications has a member with propertiesideal for use in liquid magnesium.Essential requirements of any system used in magnesiumare thermal stability and high strength at operatingtemperatures, especially when long pumps are used.Metaullics Systems’ super alloy for magnesium applicationsis dimensionally stable at 700°C. Furthermore, its tensilestrength is higher at 700°C than it is at room temperature.Finally, Metaullics’ 50 years of experience designing andbuilding pumps for molten metal applications insures thatthe pumps will be user friendly, work well, and be reliablein magnesium.NEW DEVELOPMENTSThe strong innovative focus of Metaullics Systems ensuresa steady and continuous stream of new developments,applications and improved systems for a wide range ofnon-ferrous metals.New pump and pump component designs, new materialsand new concepts for simply doing things better areevaluated continuously. Innovations such as gas injectionpumps, LOTUSS melting systems, Tensor Technology andnew super alloys for molten metal applications are just afew of the many products that Metaullics has introducedto the industry.

SYSTEMS FOR MELTINGLIGHTWEIGHT SCRAPA popular application for the circulation pump is to aid in melting light gauge, flowable scrap.Metaullics has developed a system, known as LOTUSS (LOw TUrbulence ScrapSubmegence), which operates in a reverberatory furnace fitted with a sidewell.The systemis comprised of a circulation pump and a specially profiled refractory melting chamberplaced downstream of the pump discharge.The system creates a vortex having sufficient downward force to quickly submerge thelightest metal scrap into the hot liquid metal which is supplied by the pump.Systems have been installed on furnaces ranging from 10 to 150 tonnes capacity and offerscrap melting rates of 1 to 18 tonnes/hour.

A SUMMARY OF THE USES,BENEFITS AND CAPABILITIESUSES BENEFITS CAPABILITIESTransfer pumps • Fill transfer ladles • Improved safety • Pumping rates up to 4,5 t/min (aluminium)• Furnace to furnace transfer • Increased productivity • Lift metal 7 meter• Pouring sows, ingot or large castings • Improved quality • Transfer metal up to 24 m through insulated pipe• Emergency pump-outs• Faster transfer• Less heat lossFilter pumps • Fill transfer ladles • All the benefits of transfer pumps • Pumping rates up to 1.5 ton/min (aluminium)• Pouring sows, ingot, or large castings • Delivers clean, filtered metal • Lift metal up to 2 meters• Protects pump from contaminates in the metalCirculation pumps To circulate: • Increase metal yield • Pumping rates up to 20 t/min (aluminium)• Sidewell furnaces • Increase furnace production by 15 to 50% • Continuous operation• Direct charge melters • Energy saving of 10 to 20% • Operating temperatures to 870°C• Tilting furnaces• Improved quality• Holding furnaces• Longer refractory life• Homogeneous metalGas Injection Pumps • Furnace circulation • All the benefits of circulation pumps • Pumping rates up to 20 t/min (aluminium)• Degassing • Pollution free demagging • Can be used with N2, Ar or Cl2• Demagging • Excellent mixing of process gas and metal • Cl2 Injection rates up to 250 kg/h• Alkali metal reduction • Continuous process • Continuous operation

Metaullics Systems Europe B.V.Ebweg 142991 LT BarendrechtThe NetherlandsTel: +31 (0)180 590 890Fax: +31 (0)180 551 040www.metaullics.come-mail: info@metaullics.nlMetaullics Systems Co. LP.31935 Aurora RoadSolon, Ohio 44139United StatesTel: +1 440 349 88 00Fax: +1 440 248 34 32www.metaullics.come-mail: info@metaullics.comM5100E© Metaullics 2004