Aluminium Recycling Furnaces

Used Aluminium Recycling Furnaces Remelting and Recovery Furnace Systems and Recycling Equipment

Aluminium scrap is not an endpoint. It is the raw material for the next melt.

Aluminium recycling furnaces remelt sorted scrap, chips, production returns, dross and other suitable aluminium residues. Depending on the material form, contamination and production objective, rotary drum furnaces, chip-melting furnaces, induction furnaces, crucible furnaces or tilting melting furnaces may be used.

Charge material Scrap, chips, production returns, dross or ingots

Main process Prepare, charge, remelt and recover metal

Furnace technology Rotary drum, chip-melting, induction, crucible or tilting furnace

System boundary Charging, exhaust treatment, holding, transport and ingot casting

Different recycling materials place different demands on the furnace

Not every aluminium return material can be processed economically and safely using the same furnace technology. Form, surface, moisture and foreign-material content influence charging, heat transfer and metal recovery.

Ingots

Defined geometry and comparatively consistent material quality Ingots and clean master alloys can be charged in a controlled manner. Furnace selection is based primarily on throughput, alloy, melting capacity and material flow.

Consistent charging

Returns

Runners, rejected castings and internal production residues Component size, alloy separation, coatings, deposits and possible steel parts must be considered before remelting.

Keep alloys separated

Chips

Large surface area combined with low bulk density Chips may contain cooling lubricants, moisture and high oxide levels. Drying, deoiling, compacting and controlled feeding substantially influence the recycling process.

Preparation required

Dross

Metal-containing mixture with a high proportion of oxides and residues The objective is to recover the remaining metal content. Process method, temperature, movement and possible additives must be matched to the specific dross.

Optimise metal recovery

Aluminium recycling involves more than the melting process itself

The performance of the complete system results from material preparation, charging, furnace processing, metal cleaning and the subsequent supply of molten metal.

Sorted return material becomes a reusable metal flow.

Sort

Separate alloys and foreign materials Controlled material quality begins before the furnace. Steel parts, non-ferrous metals, plastics, moisture and unsuitable coatings must be identified and removed where required.

Prepare

Prepare material size and condition for charging Shredding, screening, drying, deoiling or compacting may be required so that the recycling material can be introduced into the furnace safely and in a controlled manner.

Melt

Transfer heat and movement to the charge material Furnace temperature, charging sequence, burner or induction power, drum movement and holding time determine how quickly and with what recovery rate the aluminium is melted.

Separate

Separate metal, oxides and process residues After melting, slag, dross and other residues must be separated from the recovered aluminium. Cleaning access and the discharge concept influence the required workload.

Supply

Process the molten metal further or cast new ingots The molten metal can be transferred to a holding furnace, transported to a casting system, metallurgically adjusted or returned to a solid commercial or production form using an ingot casting conveyor.

Which furnace design matches the recycling material?

The appropriate design depends on the material form, contamination, required throughput, available energy supply and the planned metal flow after remelting.

Tilting Rotary Drum Furnace

For bulky, oxide-rich or differently shaped recycling materials

The rotating drum moves the material during the melting process. Tilting allows charging, process control and emptying to be adapted to the relevant operating phase.

Typical charge materials Bulky aluminium scrap, dross, UBC material, production returns and suitable chips.

Important inspection points Drum, drive, bearings, tilting mechanism, burner, door system, refractory lining and moving exhaust system.

Chip-Melting Furnace

For lightweight aluminium chips with a large reactive surface

Chip-melting systems are designed for the continuous or controlled feeding of small material quantities. Pretreatment and controlled submersion can limit oxidation and material loss.

Typical peripheral equipment Centrifuge, dryer, briquetting system, conveyor equipment, dosing hopper and fume extraction.

Important inspection points Residual moisture, oil content, conveying behaviour, feeding system, melting zone and deposit formation.

Induction Furnace

Precise electrical heating for defined material qualities

Induction furnaces transfer electrical energy to the metal through an electromagnetic field. Power can be controlled quickly, while the induced bath movement influences the mixing of the molten metal.

Typical advantages Precise power control, rapid response and no direct combustion gases inside the melting chamber.

Important inspection points Coil, refractory lining, converter, transformer, cooling, electrical connected load and earth-fault monitoring.

Crucible and Tilting Furnace

For smaller batches and defined alloy changes

Crucible furnaces or compact tilting furnaces can be used for manageable metal quantities, frequent alloy changes or decentralised metal supply.

Typical application Clean returns, smaller batches and separated alloy families.

Important inspection points Crucible type, capacity, heating performance, tilting drive, temperature control and metal removal.

The tilting rotary drum furnace combines heat, movement and adjustable inclination

Furnace movement influences the contact between the charge material, metal bath, furnace atmosphere and refractory lining. In a used system, the drum and auxiliary units must therefore be inspected as one complete system.

Drum geometry Length, diameter, internal profile and refractory lining determine usable volume, material movement and heat transfer.

Rotational-speed control Drum speed must be controllable for charging, melting, process treatment and emptying.

Tilting range Inclination angle, tilting speed and end positions influence material distribution, bath position and complete metal discharge.

Burner and flame routing Capacity, control range, flame shape and arrangement must match the drum geometry and intended material throughput.

Furnace door and exhaust route The door, hood and exhaust duct must follow the furnace movements and provide controlled extraction in every operating position.

Weighing and process monitoring Depending on the design, load cells, temperature measurement, burner data and batch programmes may be used to document the recycling process.

The recycling furnace is only one part of the complete system

With a used recycling system, the scope of supply determines whether only the furnace or an almost complete material and metal flow can be reused.

Material reception

Storage, sorting and preparation Containers, bunkers, crushers, screens, magnetic separators, drying equipment and chip-processing systems determine the material quality before charging.

Charging

Introduce material into the furnace in a controlled manner Charging machines, skips, vibrating conveyors, cranes or conveyor systems must match the material form, batch size, charging height and furnace opening.

Melting process

Control heat, movement and atmosphere The furnace, burner or induction system, control equipment, temperature measurement, drum drive and possible additive dosing form the main process zone.

Exhaust

Capture and treat flue gases Hoods, ducts, afterburning systems, filters, fans, measuring points and the chimney must be matched to the material, furnace operation and local approval requirements.

Metal transfer

Transport molten aluminium safely Launders, ladles, transport crucibles, pumps or tilting transfer systems connect the recycling furnace to holding, correction or casting furnaces.

Final product

Use the molten metal directly or produce new ingots Depending on the production concept, the metal is used directly within the foundry or returned to solid form through an ingot casting conveyor, cooling, marking and stacking.

Which project data determine technical suitability?

The manufacturer and year of manufacture provide only an initial classification. The material analysis, throughput, recovery objective, energy supply and complete system peripherals are decisive.

Charge material, process objective and site determine the required recycling concept.

Material

Type and composition of the recycling material Alloy, piece size, bulk density, oxide content, moisture, oil, coatings and foreign materials should be documented as representatively as possible.

Throughput

Charge quantity per hour or batch Production volume, batch sequence, shift model and required reserve determine the necessary furnace and peripheral performance.

Recovery

Recovered metal quantity Assessable recovery results from material quality, oxidation, process control, residues and the quantity of molten metal that can actually be reused.

Capacity

Batch volume and molten-metal content Nominal volume, working fill, minimum quantity, residual metal and degree of emptying must be considered separately.

Energy

Gas or electrical supply Check the fuel type, supply pressure, burner capacity, electrical connected load, transformers and available site capacity.

Temperature

Operating range and measurement concept Document furnace-chamber, exhaust-gas and metal temperatures, measuring points, thermocouples, limits and the control strategy.

Emissions

Exhaust volume and treatment Assess material contamination, burner capacity, furnace atmosphere, air volume, filtration technology and legal requirements at the new location together.

Metal flow

Discharge and downstream processing Pouring height, tilting angle, launders, ladles, holding furnace, alloy correction and ingot casting equipment must match the layout.

Control system

PLC, recipes and process data Record batch programmes, rotational speed, tilting movement, burner control, temperature, weighing, fault messages and interfaces.

Installation

Dimensions, weight and foundation Consider the working position, tilting range, maintenance areas, foundation loads, steel structure, platforms and transport routes at the new location.

Metal recovery and molten-metal quality must be considered together

A high recovered metal quantity alone is not sufficient. The produced molten aluminium must also be suitable for the intended alloy correction and further processing.

Separate alloys in a controlled manner Different aluminium alloys should already be separated during collection and storage. Mixing can complicate subsequent correction or restrict how the molten metal can be reused.

Limit oxidation and metal loss Large surfaces, high temperatures, long holding times and an unsuitable furnace atmosphere can cause additional oxide formation. Material feeding and process parameters must be adapted accordingly.

Exclude moisture safely Wet or enclosed material can create serious hazards when it comes into contact with molten aluminium. Incoming inspection, drying and safe charging rules are therefore essential.

Remove residues in a controlled manner Dross, slag, filter dust and other process residues must be discharged safely, collected and processed further according to their composition.

Plan analysis and correction Sampling, spectrometric analysis, temperature inspection and targeted alloy correction may be required before reuse.

Technical inspection of a used aluminium recycling furnace

A reliable condition assessment must include the furnace, mechanical movements, heating system, refractory lining, exhaust treatment, control system and all auxiliary equipment.

Furnace body and steel structure Inspect the drum, housing, frame, platforms, doors, covers, reinforcements and areas affected by corrosion, cracks or thermal deformation.

Refractory lining Check the layer structure, cracks, broken areas, joints, deposits, drum section, door area and pouring zone for remaining service life and possible renewal requirements.

Rotary drive and bearings Test the riding rings, rollers, bearings, gearbox, couplings, motor, frequency converter and concentric running under suitable conditions.

Tilting mechanism Document the hydraulics, cylinders, pumps, valves, bearing points, end positions, interlocks and controlled return movement.

Burner and gas train Check the burner, ignition, flame monitoring, blower, gas fittings, pressure control, tightness and safety control system.

Exhaust and filtration system Record moving hoods, ducts, dampers, fans, afterburning systems, filter elements, discharge equipment and measuring points completely.

Temperature and weighing Inspect thermocouples, protective tubes, displays, load cells, calibration condition, limits and process recording.

Charging and emptying equipment Inspect the charging machine, skips, lifting units, launders, outlets, ladle positions and available transport equipment for condition and completeness.

Control system and documentation Secure the PLC, operator panel, programmes, recipes, circuit diagrams, gas diagrams, hydraulic documentation, parameters and operating manuals as completely as possible.

Dismantling and reassembly form a separate system project

Recycling furnaces are heavy, thermally stressed systems with extensive peripheral equipment. Successful reuse therefore begins with complete documentation at the existing location.

Survey

Document the system and interfaces Record dimensions, weight, foundations, steel structure, energy supply, exhaust routing, charging, metal transport, control system and safety areas completely.

Shutdown

Remove metal and process residues Empty the furnace, secure residues, separate media, switch off the energy supply and prepare contaminated areas for dismantling.

Dismantling

Separate the main system and peripheral equipment clearly Label cables, lines, steel structures, exhaust equipment, hydraulics, burners, charging equipment and transport components and dismantle them securely for transport.

Transport

Plan weights and centres of gravity at an early stage Consider lifting points, crane capacity, vehicle dimensions, transport securing, road permits and access routes at the new location.

Reassembly

Reconfigure the foundation, exhaust system and energy supply Coordinate installation, refractory lining, burner adjustment, filtration technology, control system, safety functions and trial operation as one integrated project.

Used aluminium recycling furnaces and complete systems

Depending on availability, the range may include individual melting furnaces, rotary drum furnaces, holding furnaces and complete recycling systems with charging equipment, molten-metal transport, correction furnaces or ingot-casting equipment.

Current system type Complete recycling system Possible scope of supply including a rotary melting furnace, aluminium casting furnace and downstream holding or correction furnace.

Currently represented manufacturer FUMITHERM Depending on inventory, gas-fired rotary drum melting furnaces with associated holding furnaces may be available.

Availability, manufacturer, year of manufacture, furnace type, capacity, heating system and scope of supply can change continuously. The information in the individual machine listing is authoritative.

Additional furnace technology for metal supply and foundries

Aluminium recycling systems are frequently combined with additional melting, holding, dosing or induction furnaces.

Used Furnaces Overview of melting, dosing, crucible, recycling, induction and special-purpose furnaces. View overview →

Melting Furnaces Systems for melting and supplying larger quantities of molten metal. View category →

Dosing Furnaces Holding and reproducible dosing of aluminium or magnesium molten metal. View category →

Crucible Furnaces Compact melting and holding furnaces for different alloys and batch sizes. View category →

Induction Furnaces Electrical furnace systems for melting, holding and casting through electromagnetic induction. View category →

Other Furnaces Additional furnace systems for special alloys, heat treatment and industrial processes. View category →

Furnace Reconditioning Technical inspection, repair, refractory relining and adaptation of used furnace systems. View service →

Buy or sell used aluminium recycling furnaces

FISS supports the search for a suitable aluminium recycling furnace and its technical assignment based on the charge material, alloy, throughput, batch volume, furnace design, heating system, metal recovery, exhaust treatment, charging equipment and downstream metal flow. If no suitable system is currently listed, FISS can conduct a targeted search through its international network for an appropriate solution.

When selling equipment, FISS supports condition assessment, technical documentation, dismantling planning and international marketing of individual recycling furnaces and complete aluminium recycling systems. In addition to brokerage and international marketing, direct purchase by FISS may also be an option depending on the project.

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