Casthouse Equipment & Consumable Tools | 铸造车间装备与消耗性工装工程指南

A parameter-based directory of dross recovery hardware, high-temperature consumables and melt refining units

基于参数的目录：铝渣回收装备、高温消耗性工装与熔体精炼装置

1. Primary Dross Recovery Systems

Equipment	Engineering Function	Key Parameters	Detail
Hydraulic Dross Press 液压铝渣压榨机	A ribbed alloy press head compresses hot dross inside the pan, forcing entrained liquid metal out through the drain pan into the sow mould beneath, while simultaneously extracting heat from the mass.	Force: nominal ~100 tonnes (≈1,000 kN) on widely installed units; hydraulic systems commonly rated 138 bar operating / 160 bar design Cycle: 3–5 min (compact units) to 6–8 min per pan (full-size) Head: cast alloy steel with pressure ribs; cooled variants are patented on current models Pan set: two-piece cast steel — drain pan with flow apertures over sow mould	Specs →
Rotary Dross Cooler 回转式冷渣机	Reduces dross temperature under sealed, controlled conditions — arresting oxidation and thermite progression — before the material is tipped, stacked or dispatched for secondary treatment.	Construction: double-wall water-jacketed rotating drum Internals: abrasion-resistant flighting Services: integrated dust collection hood interface Note: cooling duration is installation-specific; figures quoted without a named installation are marked unverified	Specs →

1.1 Recovery Performance

Recovery is reported in two separate figures, and conflating them is the most common error in equipment comparison:

Metric	Typical Range	Meaning
In-house drain 厂内沥铝率	5–25%	Metal recovered on site at the press and returned directly to the melting furnace
Secondary recovery 二次回收率	40–70%	Metal recovered later from the pressed skull at a rotary furnace or third-party processor

Ranges as published by ALTEK for the TARDIS Gen III press range. Actual figures depend on dross type, skimming practice and time-to-press.

2. High-Temperature Consumables: Pans & Moulds

These items absorb repeated thermal cycling between ambient and molten-metal temperature. Service life is governed by thermal shock resistance, not by static strength.

• Dross pan & drain pan（主渣锅与沥铝锅）— Dross is skimmed into cast steel or alloyed cast iron pan sets; the drain pan carries base apertures sized to pass liquid metal while retaining solid dross, with a sow mould positioned beneath. Pan geometry is matched to furnace sill height and expected dross volume. Design metrics →
• Sow mould & ingot mould（大锭模与小铸锭模）— Sow moulds cast recovered metal into handling-sized blocks, typically 500–2,000 kg; ingot moulds produce standard commercial units commonly in the 5–25 kg range. Draft angles govern release; external ribbing influences convective heat extraction.

2.1 Operating Temperature Envelope

Condition	Temperature	Relevance
Aluminium melting point	660 °C	Lower bound for metal to remain drainable
Hot dross as skimmed	≈660–700 °C	Dross charged promptly sits near the melting point of aluminium
Rotary furnace processing	700–850 °C	Optimum separation window; patents cite 750–850 °C as preferred
Uncontrolled oxidation	>800 °C	Fine aluminium reacts rapidly with oxygen, then nitrogen — vigorous burning and metal loss

Equipment must tolerate the full envelope, including excursions above 1,000 °C under localised thermite conditions. Oxidation losses rise measurably with temperature, which is why cooling rate rather than peak capacity defines recovery performance.

3. Melt Refining, Filtration & Automation

Unit	Function	Performance Basis
Rotary degasser 旋转除气装置	Removes dissolved hydrogen by dispersing inert gas through a rotating rotor and shaft	Reported reduction from 0.3–0.4 ml/100 g Al down to ≤0.1 ml/100 g under good conditions. Multi-stage units with up to ten rotors are installed on high-throughput casthouses.
Ceramic Foam Filter (CFF) 陶瓷泡沫过滤板	Removes solid inclusions — oxides, refractory particles, carbides — by depth filtration as metal passes the pore network	Grade expressed in PPI: 30 PPI ≈ 0.65–0.90 mm mean pore; 50 PPI ≈ 0.30–0.45 mm. A correctly sized and seated filter is reported to cut inclusion area fraction by 50–80% on PoDFA / LiMCA measurement.
Skimming tools & automation 扒渣工具与机器人	Blades mounted on loaders, dedicated skimming vehicles, or articulated robotic arms — often combined with furnace charging duties	Sensor-guided systems (vision / laser) are deployed to reduce metal entrapment in the skimmed layer. Claims of a specific percentage improvement are treated as unverified unless traced to a named installation.

3.1 Two Distinct Problems

Degassing and filtration are frequently treated as interchangeable. They are not:

• Rotary degassing targets dissolved hydrogen — a gas in solution.
• CFF filtration targets solid inclusions — particles in suspension. It does almost nothing for dissolved gas.

The correct sequence is furnace → rotary degassing with fluxing → transfer → CFF at launder or mould entry.

3.2 CFF Grade Selection

Grade selection is a trade-off between filtration efficiency and flow resistance. Finer is not automatically better:

PPI	Mean Pore	Typical Application	Required Metallostatic Head
10–20	1.2–3.2 mm	Ingot, sow and remelt with heavy inclusion load	75–100 mm
30	0.65–0.90 mm	Structural castings, cylinder heads, general commercial work	100–150 mm
40–50	0.30–0.65 mm	Wheels, aerospace and critical thin-wall sections	≥150–200 mm

For most commercial aluminium casting a 30–40 PPI grade represents the balance point; 50–60 PPI is reserved for high-value, low-volume work. Dirty melts should run a coarse upstream stage to protect the finer downstream filter from premature bridging.

Verification Status

Parameters on this page carry one of three statuses, applied consistently across the site:

• Traced — figure attributable to a manufacturer datasheet, published standard, patent specification or named installation.
• Installation-specific — varies by site; reported as a range with the source noted.
• Unverified — cannot be traced to a primary source; marked inline rather than presented as established.

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中文摘要 · 车间装备与消耗性工装

核心约束：热渣中的金属持续氧化，业内数据约为每分钟损失 1%。因此装备价值取决于多快完成金属分离并抑制氧化，而非峰值能力。

1. 铝渣压榨机：带齿槽的合金压头在渣锅内压缩热渣，使夹带铝液经沥铝锅流入下方锭模，同时导出热量。广泛装机机型标称压力约 100 吨（≈1000 kN），液压系统常见 138 bar 工作压力 / 160 bar 设计压力；小型机循环 3–5 分钟，全尺寸机每锅 6–8 分钟；压头为合金铸钢带压筋，现行机型的压头冷却为专利技术；锅组为两件式铸钢（沥铝锅开孔 + 下方大锭模）。

回收率须分两项表述：厂内沥铝率（in-house drain）5–25%，指现场压榨回收并直接回炉的金属；二次回收率（secondary recovery）40–70%，指压榨渣块后续在回转炉或第三方处理厂回收的金属。两者混用是装备对比中最常见的错误。

2. 渣锅与锭模：铸钢或合金铸铁锅组承接扒渣，沥铝锅底部开孔按通过铝液、截留固态渣的原则设计，锅体几何匹配炉门槛高度与渣量。大锭模铸造 500–2000 kg 回收铝块；标准小锭模多在 5–25 kg 区间。拔模斜度决定脱模，外壁加强筋影响对流散热。

温度区间：铝熔点 660°C；出炉热渣约 660–700°C；回转炉处理 700–850°C（专利文献以 750–850°C 为优选）；超过 800°C 细铝先与氧、再与氮剧烈反应。装备须承受全区间，包括局部铝热反应超过 1000°C 的工况。

3. 除气与过滤是两件事：旋转除气针对溶解氢，良好条件下可从 0.3–0.4 ml/100g 降至 ≤0.1 ml/100g；CFF 过滤针对固态夹杂（氧化物、耐火材料颗粒、碳化物），规格以 PPI 表示——30 PPI 约 0.65–0.90 mm 孔径，50 PPI 约 0.30–0.45 mm。选型与安装正确时，PoDFA / LiMCA 测得的夹杂面积分数可下降 50–80%。CFF 对溶解气体几乎无效。正确顺序为：熔炼炉 → 旋转除气+精炼 → 转注 → 流槽或模入口处 CFF。

PPI 选型是权衡而非越细越好：10–20 PPI 用于重夹杂的铸锭与大锭；30 PPI 用于结构件、缸盖等一般商用件（需 100–150 mm 金属静压头）；40–50 PPI 用于轮毂、航空及薄壁关键件（需 ≥150–200 mm 静压头）。脏料应前置粗级过滤，保护下游细级滤板免于提前搭桥堵塞。

核验状态：本页参数分三级标注——可追溯（厂商数据表、公开标准、专利说明书或具名装置）、装置特定（随现场变化，注明来源的区间）、未证实（无法追溯一手来源，随文标注而非作为既成结论呈现）。