Hertwich Engineering - Stefan Pelech

The Hertwich multi-chamber melting technology versus conventional
delacquering – a status update
25th International Recycled Aluminium Conference

Requirements to Advanced Aluminium Recycling
 HSE – HEALTH, SAFETY, ENVIRONMENT
 High product value and quality, avoiding downgrading of scrap
 High yield / recovery, low metal loss
 Low energy consumption

• Oil, plastic and paint = hydrocarbons to energy
 Low carbon footprint
 Environmental compliance
• Minimizing emissions and pollutants like NOx, Dioxine, VOC
• No salt or only minimum addition of salts
 Low operating costs
25th International Aluminium Conference – 14.11. – 15.11.2017 2 All rights reserved © Hertwich Engineering GmbH
Conventional Hot Processing
Conventional Hot Processing – To discuss
Gasification of organic compounds
 shredding required for proper transport to / through the kiln
 shredding generates dust and fines again → danger of dust
explosions
 Rotary kiln, how to adjust to different scrap size, thickness /
different heat-up time:
i.e. thin scrap too long, thick scrap too short !? Scrap input
 VOC limited to ~ 2,5% - more VOC may cause excess of
energy, overheating, C-emissions
 O2 + VOC concentration, danger of explosions, emergency
shut down
The argument, carbon and paint residues are removed by
rotation / abrasion is hardly to verify
at 500°C
 Oxidation, above 200 °C the oxid layer doubles every 100 °K
→ consequently less yield
→ oxides support sludge formation +
→ melt cleanliness !?
 plant footprint, 2x - or more compared to multi-chamber
furnace 10% fines
Hertwich Furnaces ***BAT***
MULTI CHAMBER FURNACE TECHNOLOGY

DESIGN PRINCIPLE
SCRAP PREHEATING ENVIRONMENTALLY FRIENDLY

+ REDUCE NATURAL GAS CONSUMPTION
WITH VOC GASES FROM SCRAP
= RECOVERY MAXIMIZED
LOW ENERGY CONSUMPTION
+ SUBMERSION MELTING
Multi Chamber Melting Furnace with Preheat Shaft
 This furnace type is well-suited for scrap requiring rather long preheat times, like profiles
with thermal break and
→ best for baled UBC, swarf, litho, foil
→ no shredding required
 Suitable for scrap with organic impurities, VOC up to ~ 6 % - subject to caloric value,
single charges up to 15%
 Scrap melt rate even with low density scrap up to 250 tons/day
 Optimum preheating (> 45 min) for thorough gasification of VOC
 Low energy consumption (< 550 kWh/ton) with regenerative burners
 Minimum melt loss due to submerge-melting
Multi Chamber Melting Furnace with Preheat Ramp
 Suitable for scrap with organic impurities, VOC up to 3%, single charges up to 10%
 Scrap melt rate up to 160 tons / day
 Low energy consumption (< 550 kWh/ton) with regenerative burners
 Minimum melt loss due to submerge-melting
 Well suited for automotive industry
• Delivery of high quality melt for die casting machines
• Remelting inhouse scrap incl. large parts
Multi Chamber Melting Furnace with Preheat Ramp V
Multi Chamber Melting Furnace with Preheat Ramp V
- Melting Furnace with high speed co-flow drier
for small piece scrap and swarf
Swarf drying V
Swarf drying V
RESULTS
 Low metal loss, yield 2 – 3 % higher than with conventional hot processing
 High metal cleanliness, no carbide formation
 No salt / flux usage on melting
 Environmental compliance, no afterburner or thermal oxidizer
 Energy consumption
Energy Consumption – Furnaces
Specific Energy Consumption

at nominal melt rate
Hertwich Conventional
1. Clean Scrap < 600 kWh/ton 650 – 1000 kWh/ton
2. Contaminated Scrap
Scrap with paint, plastic, rubber, oil 200 - 600 kWh/ton 500 - 800 kWh/ton
Fuel consumption related to VOC calories
3. Organic content (VOC)

assume: average up to 6 - 7% max. 2,5%
caloric value of VOC ~ 8 kWh/kg
Compact Remelt Plant
The most economic solution for conversion of clean extrusion scrap and ingot into
extrusion billet and forging stock:
 Continuous and automated process integrating all production steps
 Production ranging from 2.000 tons/year to 40.000 tons/year
 Lean operating labour requirements (2 men per shift including scrap handling/charging)
 Low melt loss due to submersion melting process (0,5% of metal charged)
 Low energy consumption
 Competitive investment cost
Compact Remelt Plant
Inhouse remelting of turn-around scrap for extrusion and forging billet
Capacity: 5.000 – 45.000 tons per year
Service Center Metals, Virginia - USA
1st Compact Remelt Plant (2014) = 30.000 t / y + Ecomelt PR100
2nd Compact Remelt Plant (2017) = 45.000 t / y + Ecomelt PS160
Service Center Metals – Phase II (45.000 tpy)
Hertwich ECOMELT PS 160
Melt rate: 8 t / h
Melt content: 85 t
Including:
+ Skimming Machine
+ 3,5 t/h Co-Flow-Dryer
for Chip Pre-treatment
Service Center Metals – Phase II
Horizontal Casting Machines (HDC) – 2 off
Casting rate: 2 x 3,5 t / h
Diameter: up to 14“
Including:
Inline Melt Treatment
(Degassing, Grain Refining, CFF)
Horizontal Casting Machines (HDC) – 2 off
Continuous Homogenizing Furnace + Air Cooling Station

Capacity: 8 t/h (45.000 t/y)
Helical Ultrasonic Testing Unit

3 centre + 6 angle probes
Automation
+ Monitoring System
+ Automatic Restarting Program
+ Process Data Storage and analysing software
+ Log tracking
+ Integration into customers ERP system
Input Material Optimization
Level 4: Enterprise Resource Planning (ERP),
Industry 4.0 Accounting
Financial
Sales
Management
Purchasing
ERP
Customers
Planning Analytics
HERTWICH
MES
THANKS FOR YOUR ATTENTION!
THANKS FOR YOUR ATTENTION!

Hertwich Engineering - Stefan Pelech

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Hertwich Engineering - Stefan Pelech

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The Hertwich multi-chamber melting technology versus conventional

delacquering – a status update

25th International Recycled Aluminium Conference

 HSE – HEALTH, SAFETY, ENVIRONMENT

 High product value and quality, avoiding downgrading of scrap

 High yield / recovery, low metal loss

 Low energy consumption

 Low carbon footprint

 Low operating costs

MULTI CHAMBER FURNACE TECHNOLOGY

SCRAP PREHEATING ENVIRONMENTALLY FRIENDLY

Specific Energy Consumption

1. Clean Scrap < 600 kWh/ton 650 – 1000 kWh/ton

3. Organic content (VOC)

 Continuous and automated process integrating all production steps

 Production ranging from 2.000 tons/year to 40.000 tons/year

 Low energy consumption

 Competitive investment cost

Continuous Homogenizing Furnace + Air Cooling Station

Helical Ultrasonic Testing Unit

Continuous Homogenizing Furnace + Air Cooling Station

Continuous Homogenizing Furnace + Air Cooling Station

THANKS FOR YOUR ATTENTION!

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