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The Ingot Casting Line Applies to Recycled Aluminum Recovery.1
Assembly Line Production Line, Metal Production Line, Custom Ingot Casting, Aluminum Ingot Production
Shandong Yantong Energy Saving Equipment Co., Ltd
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Product Description The ingot casting line applies to recycled aluminum recovery. Working Principle and Technology of the Production LineBased on the composite technology of "bottom-pour continuous casting + electromagnetic stirring directional solidification", waste aluminum (containing over 95% can materials) is heated to 720±15oC in a dual-frequency induction melting furnace. The molten aluminum is injected into the crystallizer through a PID intelligent flow control system (accuracy ±0.5L/min). The crystallizer adopts a beryllium bronze inner wall with spiral water channel design, ensuring the molten aluminum crystallizes into a shell at a speed of 0.8-1.2m/min. The billet drawing system is equipped with servo motor synchronous control technology, achieving speed stability of ±0.05mm/s to effectively reduce crack defects. The secondary cooling zone uses zoned water mist cooling technology, with 8 independent temperature control modules regulating the cooling rate at 5-15oC/s to ensure columnar crystal structure accounts for ≥85%. The whole line has an automation rate of 92%, processing 120-180 tons of waste aluminum daily with a yield exceeding 98.5%.Parameter TableLength of ingot casting lineNumber of moldsNumber of moldsNumber of molds6.5KG10KG15KGMelting time is 40 - 90 minutes per batchCasting speed is 4 - 6 meters per minute (adjustable)Motor power of ingot casting line4M48PCs300Kg2.2KW5M60Pcs500kg3KW6M72PCs3W8M96Pcs1Ton4KW9M108PCs 4KW11M132Pcs2Ton4KW13M156Pcs5KW17M206Pcs3Ton5KW21M-26M245-314PCs6KW Core Equipment and SystemsMelting Unit: Adopts dual-frequency induction melting furnace (500Hz+3000Hz composite frequency), combined with supersonic gas spray gun (thermal efficiency ≥88%), which increases melting speed of light materials like cans by 30%. The intelligent feeding system achieves ±0.3kg feeding accuracy via laser ranging and weight sensors, and real-time monitoring of molten aluminum composition by a spectrometer ensures high-quality ingots with Si≤0.2% and Fe≤0.35%.Cooling System: Innovatively applies a plate heat exchanger + cooling tower closed-loop system, with 96% cooling water recycling rate. The crystallizer cooling water inlet temperature is controlled at 25±3oC, outlet temperature rise ≤12oC, and infrared thermal imaging monitors the crystallizer surface temperature to ensure temperature difference ≤15oC, reducing defects like cold shuts and shrinkage pores.Customized Solutions: Provides modular design, with production line length customizable between 12-28m, ingot mold quantity supporting 30-120 configurations, and producing 6kg-25kg ingots of different specifications to meet demands of die-casting, profiles, forging and other industries.Production Advantages and EffectsEnergy Consumption Data: Power consumption per ton of aluminum ≤480kWh (industry average 550-620kWh), gas consumption ≤85m3 (industry average 100-120m3), with comprehensive energy saving rate over 18%.Quality Stability: Chemical composition fluctuation of ingots ≤±0.03%, physical properties meeting GB/T 1196-2017 standards, and internal flaw detection qualification rate ≥99.2%.Typical Customer Cases:A regenerative aluminum enterprise in Zhejiang: After adopting the line, labor cost decreased by 40%, defect rate dropped from 3.2% to 0.8%, saving over 3 million yuan annually.A die-casting factory in Guangdong: Using customized small-specification ingots (6kg/block), melting efficiency increased by 22%, and mold life extended by 15%.
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