Aluminium

ESA is active mostly, but not exclusively, in secondary aluminum for remelters and refiners of aluminium scrap, as well as in downstream processing of finished and semi-finished products.
We supply: a complete range of long flame burners in cold air or regenerative (up to 5 MW) for holding/melting furnaces; complete oxy-fuels systems for rotary melting furnaces (up to 20 MW) as well as for holding reverberatory furnaces. We develop various burners and customized solutions (from simple torches to customized linear burners) for prehating systems for tundish/launders/channel applications, as well as sidewall burners for filter box or launders.
Finally, we offer high velocity cold air or self recuperative burners for reheating/homogenizing, heat treatments of seminfinshed products.

It is now widely accepted that oxy fuel system are optimal when melting low grade aluminium scrap into rotary furnaces, due to the high temperatures and the strong radiant component allowed. Our solutions include standard „High Turbulence“ oxy fuel burners in the single head version for small/medium size rotary furnaces, or, for bigger sizes, we suggest our multiheads solution, which provide a more concentrated flame penetrating quickly into the load and thus increasing melting rate and lowering oxides and wastes.

Ooxy-fuel-High Turbulence for-rotary-aluminium-furnace

Oxy fuel Multihead 20 Mw for rotary melting furnace.

For remelters using reverberatory holding/melting furnaces, static or tilting, there are products depending on volumes, kind of processed aluminum (scrap quality, ingots… ) and of course according to the wished level of energy saving.

ESA ENM Long Flame burner in Aluminium holding furnaces

This is why it is meaningless to provide an answer to one of the main listened question: is it better oxy fuel or regenerated air? it depends, case by case. from dozens of factors . We are not furnace manufactures and so we leave the choiche to the customer, who knows better than us end user requirements, while , being burners‘ manufactures we try to offer a wide range of solutions also for oxy fuel.

ESA-Regenerative-Burner-Low-Nox in reverberatory tilting furnaces

ESA-Regenerative-Burners-in-tilting-reverberatory Holding-furnaces.

For reverberatory holding furnaces, in particular, we offer at least two main solutions:
The Air/Oxy fuel „AGO“ , that has two main advantages:
1) a long „diffusive“ flame similar to air burners’one.
2) the possibilty to use oxygen during melting phase and switch to air during holding phase, given that molten aluminium requires much less energy to remain liquid.
If the main goal is to save oxygen (so money!), the possibility to switch to air is also appreciated where there is the risk of Oxygen shortages.

Air-Oxy-Fuel-ESA-Ago-Nxt-in-reverberatory-furnaces.png

The additional possibility is our „Flame Turning FT“ burner, thah, installed on the roof of a reverberatory furnace, can direct the flame in order to provide an evenly heated atmoshpere which avoid the formations of hot spots, as well as, during melting phase, of redirectinbg the flame toward the ingots (or scrap) just loaded into the bath.

ESA Oxy Fuel Flame Turning into reverberatory furnace

For further phases of casting and for transfer, degassing, filtering processes, we also provide different solutions, really according to the specific requirments and situation.
The burners used are often our torches or more sophisticated Pyroline linear burners in various configurations. or also our ESW flat flame burners.

ESA-Pyroline-in-channel-and-configured-to-preheat-in-line-filters

Finally, for the downsteram process of bars, ingots, in various kind of rehating and teratement furnaces, ESA boasts all its wide range of high/medium velocity burners in cold air: EMB, EMB SIC, recuperated air EMB SIC Nxt, or self recuperated air: REKO FF NxT.

ESA self recuperative burners „Reko“in-rehating furnace of alluminium bars