Tilting Rotary Furnace

A quantum leap in melting technology

 The Tilt Rotary Furnace
Melting Solutions Limited offer the TR range of advanced Tilting Rotary
Furnaces available in capacities from 1- 21.5 tonnes aluminium (0.5 - 11 m3).
TR furnaces provide state-of-the-art technology for melting a wide range
of scrap and for processing drosses. Complete melting plant solutions are
also available from Melting Solutions Limited , including charging machines,
holding furnaces, casting equipment and pollution control to meet the very highest environmental
standards. All from one experienced supplier built on proven results from our users.
The Melting Solutions Limited TR Furnaces offer great flexibility. One furnace able to process drosses,
mixed scrap, contaminated scrap (with iron) chips, UBC and foils. For companies looking to upgrade
from fixed axis rotary melting or reverberatory melting the TR Furnaces offer significant advantages with
attractive pay back.

n Low energy melting at 750 kW per tonne. The advantages are:

n High production rates, unrivalled n 25% fuel saving
melting speed n 50% increase in throughput
n Full automation PLC and SCADA n 30% saving on slag disposal
n Minimum labour costs n 50% saving in salt flux
n Quality engineering ensures long service n Reduced labour, fully
life with minimum maintenance automated process
n High metal recovery
n Integrated ‘turn-key’ solutions from a world
leader in melting technology TR MELTER WITH 5 YEARS
24/7 OPERATION, QUALITY
ENGINEERING IN ACTION

TILT ROTARY PROCESS

Tilt Rotary Furnaces have significant advantages compared to fixed axis A high salt-to-oxide ratio is required to ensure the slag is liquid to run
rotary furnaces. The diagrams above compare the operation of fixed axis through the small tap hole.
rotary furnaces with tap holes to the OTTO JUNKER (UK) Ltd hydraulic 1. Furnace is charged very quickly using the
lip axis Tilting Rotary Furnace: much larger charge opening.
Conventional fixed axis single pass (blue aluminium / red slag) 2. Melting by double pass burner arrangement.
Saving energy - faster melting.
1. Scrap and salt are charged into the furnace. Charging is restricted
by the small charge hole. 3. The furnace is tilted to pour out the aluminium. The dry slag remains
in the furnace - no time wasted opening tap hole.
2. The charge is melted by a single pass burner arrangement, limiting
efficiency. 4. Finally the furnace is rotated and tilted simultaneously to tip out the
dry salt slag for disposal. Amount of slag greatly reduced because a
3. Aluminium is run out through a tap hole. Opening and closing the
liquid slag is not needed - no time wasted opening slag hole.
tap hole is slow and labour intensive.
5. Faster rotation - better separation of aluminium from slag.
4. Slag is run out through a second tap hole. Slow and labour
intensive.
FURNACE SPECIFICATION TECHNICAL SUPPORT
The Melting Solutions TR range of Tilt Rotary All Melting Solutions furnaces are backed by full
Furnaces are available in a standard range of engineering and technical support to help plan the
capacities from 1,000 kgs to 21,500 kgs. furnace installation, for example, we usually provide
Options of oil firing or gas firing are available. design and drawings for furnace extraction hoods
On furnace capacities of 5 tonnes and above, and ductwork connecting to filter plants allowing
oxy-fuel burners firing either oil or gas are available. the client to manufacture these items locally saving
Please refer to the specification chart and individual transport costs.
drawings of the furnace range attached. Where required, Melting Solutions can provide
Normally the standard Melting Solutions Limited a complete turn-key solution including charging
scope of supply includes: machines, holding furnaces, casting and pollution
control usually using bag filters.
n The main furnace assembly
n Complete hydraulic system Turn-key projects are backed by on-site installation
n Burner system supervision, commissioning and operator
n Supply of refractory lining training where required. Assistance is given with
n PLC control environmental applications and liaison with local
environmental authorities which is a key part,
Furnaces up to 2,000 kgs size are supplied particularly for new melting facilities.
complete from Melting Solutions Limited with the
refractory lining already installed. Up to 2,000 kgs
the furnaces ship within an open top container, or by
road, requiring minimal installation and connection to
adequate services. Refractory linings on larger sizes
are installed on site.

TR 2 SUPPLIED
COMPLETE, MINIMUM
INSTALLATION TIME
INTEGRATED MELTING PLANT
Melting Solutions offer Tilting Rotary Furnaces
as combination ‘turn-key’ melting plants for
production of specification alloyed ingot and
di-oxidant production from scrap and drosses.
At the heart of the system is an advanced
technology Tilting Rotary Furnace that will melt
anything from iron castings to UBC, bales,
and drosses in the same furnace. Operators
have seen metal recovery improve by 5% on
average over the same type of scrap melted in
traditional reverberatory melting furnaces.
n Average of 5% extra metal recovery
n Lower energy cost, 25% saving in fuel
n Increase output
n Fully automated to reduce labour
n Very flexible to change alloys
n Iron content in melt closely controlled
at low levels
n Melting Solutions offer a turn-key
package with pollution control
n Range of furnace sizes
and outputs available

TILTING HOLDING / ALLOYING FURNACE

FULLY AUTOMATED
SYSTEM WITH ADVANCED
PLC PROCESS CONTROL
WITH SCADA
Tilt Rotary Furnaces
WORLDWIDE REFERENCES

ALUSERV TR 21 gas fired melting plant with 10 tonne tilting holding furnace, ingot
Bahrain casting machine and filter plant. Processing high volumes of drosses.

BALTICAL TR 10 gas fired. Melting plant complete with 2 x 20 t tilting melting/holding

Kaunas, Lithuania furnaces with 2 x ingot casting machines. Melting low grade scrap, castings
with iron and drosses.

BLAYDON METALS TR 3 gas fired. Complete melting plant with 3.5 m3 vibratory charging
Newcastle-Upon-Tyne, UK machine, 5 t tilting holding furnace and di-ox cube casting machine.
Dedicated plant for melting taint tabor (old rolled) mixed scrap producing
di-ox products for steel works.

CAST ALUMINIUM TR 5 with oxy fuel firing (oxy – oil). Dedicated dross melting plant
INDUSTRIES Dubai, UAE 15,000 t/year.

CHALCO TR 15 with oxy fuel firing (oxy – gas). A flexible melting plant for all types
(CHINA ALUMINIUM) of scrap, turnings, drosses, UBC etc. Automated 10 m3 charging machine,
Tsingdao, China automated slag moulds and pouring launder. 100 t per day melting plant.

F.E. MOTTRAM Project to upgrade furnace door on a 9 t MDY/ALTEK furnace.

Congleton, UK

FORUM TR 1 natural gas fired. Part of a melting plant 2 x 5 t reverberatory furnaces

Zaporozyhe, Ukraine with casting machine. For melting drosses and low grade scrap.

HONG POH METALS TR 1 oil fired. Dedicated melting plant for drosses. Supplied with
Melaka, Malaysia 10,000 m3/hr filter plant.

KRASAINIE TR 3 natural gas fired. Melting low grade scrap and drosses.
Lejumi Riga, Latvia

NORTON ALUMINIUM TR 5 natural gas fired. Melting mixed low grade scrap. Special 1.8 m extra
Cannock, UK large diameter door with latest side tilt feature.

NORTON PVT 2 x TR 6 dual fuel oil/gas fired furnaces with enlarged door 1.8m.
Mumbai, India Processing mixed scrap and drosses.

RMC CUSIANA TR6 gas fired with enlarged door 1.8m. Processing mixed scrap and
Italy drosses.

RUSAL TR 5 natural gas fired. Melting plant for drosses and low grade scrap with a
TSVETMETOBRABOTKA casting line for 500 kgs sows. Including a 30,000 m3/Hr filter plant.
Samara, Russia

SPONTEX TR 3 natural gas fired. Specialist plant for di-ox production for steel works.
Wjesnia, Poland Melting UBC and drosses.

TR 1: HONG POH METALS TR 5: CAST ALUMINIUM INDUSTRIES TR 5: TSEVETMETOBRABOTKA TR 10: BALTICAL

MALAYSIA DUBAI UAE RUSSIA LITHUANIA
 Specifications
Tilt Rotating Furnace 1 t - 21.5 t (0.5 - 11.0 m3)

'D'

'F' 'F'

'E'

TR1-3 OIL OR GAS FIRED AIR FUEL

'E'
'B'
Model kgs A B C D E F V m3
'A'Ø
Alu
'B' TR 1 1,000 850 2,540 1,100 4,450 2,235 2,250 0.5
TR 2 2,000 1,100 3,050 1,400 5,400 3,200 2,885 1.0
'C'Ø 'A'Ø TR 3 3,000 1,300 3,200 1,700 6,750 4,500 3,200 1.6

LIQUID VOLUME IN
CUBIC METRES 'V'
TR5-21 OIL OR GAS FIRED AIR OR OXY
FUEL OPTIONS.
Model kgs A B C D E F V m3
Alu
LIQUID VOLUME IN
TR 5 5,000 1,400 3,200 2,100 5,710 5,700 3,665 2.5
CUBIC METRES 'V'
TR 8 8,000 1,500 4,000 2,300 6,510 5,700 4,000 4.0
TR 10 10,000 1,800 4,700 2,400 8,040 6,760 5,000 5.0
TR 15 15,000 2,000 6,000 2,800 8,675 7,000 5,460 7.5
TR 21 21,500 2,000 6,000 3,000 8,675 7,250 5,660 11.0

UNIQUE DOOR WITH SIDE TILT FEATURE

1. CLOSED POSITION FURNACE 2. SIDE TILT PARTLY OPENS DOOR 3. DOOR PIVOTS FULLY OPEN FOR
CAN TILT WITH BURNER FIRING TO VIEW THE CHARGE WITH BURNER ACCESS WITH CHARGING MACHINE TO
DURING THE MELT INCREASING ON. CASTING CAN BE DONE IN PARTLY THE EXTRA LARGE CHARGE HOLE UP TO
MIXING AND HEAT TRANSFER. OPEN POSITION SAVING ENERGY 2 M DIA.
AND OXIDATION.
Performance Data
Notes Model TR 1 TR 2 TR 3 TR 5 TR 8 TR 10 TR 15 TR 21
1 Nominal rated aluminium capacity [kgs]. 1,000 2,000 3,000 5,000 8,000 10,000 15,000 21,500
Door opening inside diameter [mm]. 850 1,100 1,300 1,400 1,500 1,800 2,000 2,000
2 Liquid capacity [volume in m3]. 0,5 1 1,6 2,5 4 5 7,5 11
3 Maximum liquid aluminium capacity [kgs]. 1,150 2,300 3,680 5,750 9,200 11,500 17,250 25,300
4 Maximum charge weight (including salt) [kgs]. 1,150 2,300 3,680 5,750 9,200 11,500 17,250 25,300
5 Melt rate [kgs/hr]. 575 1,150 1,840 2,875 3,066 3,834 5,750 7,229
Melting time hours for one charge as (4) above. 2 2 2 2 3 3 3 3,5
6 Non melting time charging, casting and discharging
1 1 1 1 1 1 1 1
slag hours.
Cycle time ‚tap to tap‘ hours. 3 3 3 3 4 4 4 4,5
No. of cycles per day (24 hrs). 8 8 8 8 6 6 6 5,4
Maximum charge weight (including salt) per 24 hrs [t]. 9 18 29 46 55 69 104 137
Input per year (322 x 24 hr days) [t]. 2,962 5,925 9,480 14,812 17,774 22,218 33,327 43,992

ENERGY USING AIR-FUEL BURNER

Burner energy kW per tonne of charge (input). 750 750 750 750 750 750 750 750
Natural gas consumption per tonne of charge (input).
75 75 75 75 75 75 75 75
[m3]
Oil consumption per tonne of charge (input). [litres]. 75 75 75 75 75 75 75 75
Burner power (air fuel) [MW] 0,4 0,9 1,4 2,2 2,3 2,9 4,3 5,4

ENERGY USING OXY-FUEL BURNER

Burner energy kW per tonne of charge (input). ~ ~ ~ 400 400 400 400 400
Natural gas consumption per tonne of charge (input).
~ ~ ~ 40 40 40 40 40
[m3]
Oil consumption per tonne of charge (input). [litres]. ~ ~ ~ 40 40 40 40 40
Oxygen consumption (either oil or gas). [m3] ~ ~ ~ 80 80 80 80 80
Burner power (oxy fuel) [MW] ~ ~ ~ 1,2 1,2 1,5 2,3 2,9

MECHANICAL

Drive power [kW] 5,5 7,5 11 30 50 63 110 125

Variable melting angle 0 - 15 degrees of tilt (subject to

x x x x x x x x
capacity).
Rotation speed (variable direction and speed inverter
0-6 0-6 0-6 0-6 0-6 0-6 0-6 0-6
controlled) [RPM]
Nominal filter plant volume [Nm3/hr] (approximate only). 10,000 15,000 20,000 30,000 35,000 45,000 65,000 80,000

Notes:
1. Capacity rating. The advantages of the
2. Max. volume in the furnace body for liquid aluminium. Melting Solutions Limited
Tilting Rotary Furnace are:
3. Max. capacity liquid aluminium density of 2,300 kgs/m3.
4. Max. charge weight ‚input‘ including salt flux. n 25% fuel saving.
5. Based on ISRI grades of scrap, no excessive contamination n 50% increase in throughput.
and reasonable density of approx. 800 kgs/m3. n 30% saving on slag disposal.
6. Assumes efficient automated charging and handling. n 50% saving in salt flux.
n Reduce labour, fully
automated process.
Performance data given is an indication of typical performance.
Data does not constitute a guarantee. Subject to revision and change
without notice. Cycle times for lightweight and material with contamination
and combustibles will be extended. Please consult Melting Solutions
Limited for more information.
Oxy fuel firing may reduce filter capacity depending on hood configuration.
Please consult Melting Solutions Limited for further information.
Melting Solutions Limited is a leading British manufacturer of electric process heating
and melting equipment.
The company has over 30 years experience offering users a unique consulting and
manufacturing service for all makes and types of custom built induction heating and melting
equipment. In addition to this the company also offers upgrading, modification and spares
replacement of a wide range of induction process equipment and also offers project
management capabilities and sub-contract machining to large manufacturers.
Our philosophy is to enter into a unique partnership with the customer right from the initial
stages, through concept, design, manufacture to final installation, ensuring that each and
every project is delivered on time and on budget.

Melting Solutions Limited Phone: +44 (0)1675 470 551

Unit E, Dunton Park Fax: +44 (0)1675 470 645
Kingsbury Road
Curdworth E-Mail: [email protected]
Sutton Coldfield B76 9EB Web: www.meltingsolutions.co.uk
United Kingdom