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Tower furnaces are loaded from the top of a vertical tower with aluminum, and burners at the bottom of the tower melt the aluminum. The primary mode of heat transfer in tower furnaces is through convection by direct impingement of the burner on the metal in the lower section of the tower, and by the combustion gases as they travel out the tower past the metal charge. A variation of the tower furnace uses a grate system which lowers the metal through four grates, gradually heating the charge through each grate until on the fourth and final grate, the charge melts and falls into the hearth.

The advantages of the tower furnaces are high efficiency (40%-77%) and low oxidation losses. The disadvantages of tower furnaces are their high capital costs and the furnace size is restricted by height limitations.

ECOMELT-EMT
Electro-Mech Tilting tower furnace
Fields of application 
Central melting in Die casting
Ingot manufacturing
Alloy making
Metal recycling
Bulk melting
General performance specs
Fuel Consumption - 60 ltr/ton at 720deg
Metal loss - 1.6% to 2%
Capacity - 300kg/hr to 4 Ton/Hr
Loading - By Auto charger
Fuel - LDO/FO/HSD/LPG/Propane
ECOMELT-EMT consists of
Stationary melting chamber
Electromechanical tilting holding chamber connected to melting chamber by a tunnel
Auto charger
Advantages
Minimum oil consumption. ( As low as 52 Ltrs/ton is recorded with fuel LDO )
Low melting losses ( As low as 1 % is recorded )
Low risk of hydrogen absorption.
Easy wall to wall access for through cleaning.
Minimum man power requirement. ( Only 2 nos )
Low operating cost.
Continuous supply of molten metal.
Capacity range – 300Kg/hr to 4000Kg/hr.
The high degree of automation, quality of the materials and simple construction of the equipment guarantees a reliable and efficient production with high degree of economy resulting in profitable production of molten metal.
Are you looking for the most cost-effective, highly efficient and Eco-friendly aluminum melting furnace?
You don’t need to search anymore. STEC ECOMELT series furnaces can dramatically reduce your aluminum melting costs by increasing energy efficiency and reducing melt loss. When compared to a crucible, barrel, rotary, or reverberatory (reverb) furnace, a ECOMELT can reduce energy consumption by 50% or more, reduce melt losses by up to 80% and reduce emissions while delivering better metal quality. In comparison to an electric aluminum melting system, energy costs are less than 1/3 with comparable results on metal cleanliness and melt loss.
RANGE OF TOWER FURNACE
ECOMELT-EMT - Electromech tilting tower melting furnaces
ECOMELT-HT - Hydraulic tilting tower melting furnaces
ECOMELT-ST -Stationary tower melting furnaces
ECOMELT-BL - Direct bale out type tower melting furnaces
Aluminum Melting Efficiency
60 ltrs per Ton fuel consumption for continuous melting 1.5 to 2% gross melt loss
Tapped metal temperature control to +/- 10º C
Higher quality metal with lower gas inclusion levels
How does an ECOMELT Furnace achieve these results?
Direct Waste Heat Recovery by charging material into the melting shaft without the high maintenance costs associated with add-on recuperation equipment.
Full pre-heating of charge is achieved via the waste flue gases in the melting shaft of furnace. This process of preheating burns off all impurities present on the charged material and removes the moisture content as a result of which the fuel consumption is reduced and any chance of explosion is eliminated.
Automated charging system ensures full level of melting shaft charge to get optimal efficiency.
Rapid aluminum melting in the melting zone of furnace in an oxygen deficient atmosphere reduces melt loss. Aluminum Metal melts near instantaneously.
Complete independence of melting and holding furnace functions reduces energy requirement for melting and reduces super heating resulting in reduction of hydrogen/gas pickup.
High quality insulation reduces the heat losses.
PLC controlled system makes the operation very user friendly.
Stoichiometric tuning of burner systems. Furnace is capable of being sealed to the extent that energy is not lost through charge wells or large furnace openings. Positive furnace pressure can be achieved through controlling out going flue gases. Wall to wall furnace access for ease of cleaning and maintenance by providing large doors. Full pre-heating of charge material eliminates explosion hazards. Automated charging eliminates hot metal splash risk to operators and reduces manpower required for loading. Limited operator exposure to furnace internals. Low shell temperatures prevent accidental contact burns and provides comfortable working environment. Optional automated tapping systems for furnace. Furnace is ergonomically designed.
 
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