Tilting Rotary FurnaceWorld Class Melting Technology

Melting Solutions offer the TR range of advanced Tilting RotaryFurnaces available in capacities from 1-21.5 tonnes aluminium (1.5-11m3) 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, 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 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 Furnacesoffer significant advantages with attractive pay back.

The Tilt Rotary Furnace

• Low energy melting at 350kW per tonne.

• High production rates, unrivalled melting speed

• Full automation PLC and SCADA

• Minimum labour costs

• Quality engineering ensures long service life with minimum

maintenance

• High metal recovery

• Integrated ‘turn-key’ solutions from a world leader in melting

technology

Tilt Rotary Process 1. 2. 3. 4. 5. 6. 7.

Tilt Rotary Furnaces, Double pass burner firing. (blue aluminium / red slag)

1. Furnace is charged very quickly using the large charge opening.

2. Melting by double pass burner arrangement. Saving energy-faster melting.

3. The furnace is tilted to pour out the aluminium. The dry slag remains in the furnace-no wasted time opening tap holes.

4. The furnace is rotated at high speed for 5 minutes in each direction-using burner if required.

5. More aluminium is poured out of the furnace. Repeat steps 4 & 5 until no further aluminium is obtained.

6. The furnace is tilted and rotated simultaneously to tip out the dry salt slag. Amount of slag greatly reduced because a

liquid slag is not needed. Faster rotation-better separation of aluminium from slag.

7. After each cycle furnace is quickly cleaned, avoiding the need for a weekly salt wash.

WHY CHOOSE MELTING SOLUTIONS?For more than fifteen years Melting Solutions have pioneered tilt rotary design, working closely with our customers, and leading companies in the secondary aluminium industry worldwide.Our furnace designs strive to continuously improve the key objectives of the aluminium industry;-

Highest metal recovery.Lowest energy consumption.Maximum productivity.

The Melting Solutions tilt rotary with it’s innovations set the standard for the industry and deliver high profit margins for our customers.We have proven time and again our tilt rotary furnaces deliver profitable melting plants for our customers using the cumulative benefits of our innovative designs;SUPER EFFICIENT MULTI DIRECTION DOORMinimises door open time, metal is poured and slag removed with the door substantially closed.Unrivalled operator viewing access to optimise the melting process, without losing melting time or efficiency.Latest development – SIMULTANEOUS CHARGING AND MELTING UNDER THE DOOR.Result – significant reduction in energy cost and improvements in metal recovery and productivity HEAVY DUTY ENGINEERINGOur proven pin drive system – more than 15 years success in the field. Customers report little maintenance – maximum production time.FE stress analysis backed by our experienced engineering team modelling in 3D.Advanced and proven bearing technology.Our engineering tradition, skills and proven track record mean your investment will pay back quickly and last for years to come.COMBUSTION TECHNOLOGYMelting Solutions offer a wide range of combustion solutions with efficient combustion of all liquid and gaseous fuels.Air gas / oil.Oxy gas / oil.HYBRID COMBUSTION.Air / oxy fuel burners often deliver the ultimate solution, balancing energy cost and maximum melting performance.We look forward to discussing and advising our customers on the most efficient and effective combustion systems.PROVEN REFRACTORY SOLUTIONSWe have supplied both monolithic and brick linings successfully for many customers. Pre cast ready to install monolithic lining systems are also available.meltPRO™Our interactive software developed for the rotary melting plant, which has been highly successful. meltPRO™ can be retrofitted to existing furnaces and is capable of expansion to allow for future growth. Total foundry management, reported data is tailored to individual customer requirements

INTEGRATED MELTING PLANT

OPERATOR CONTROL

MONTHLY PRODUCTION

(t)

ANNUAL PRODUCTION (t)

DAILY PRODUCTION

(t)

TILT ROTARY CAPACITY / MODEL

HOLDING FURNACE(S) CAPACITY

CASTING CAPACITY FILTER PLANT VOLUMEm3/hr.

1,000 12,000 40 TR8 7t 5t/hr 40,000

1,500 20,000 60 TR12 10t 5t/hr 60,000

2,500 30,000 90 TR15 15t 8t/hr 80,000

4,000 50,000 150 TR21 25t 10t/hr 100,000

CHARGING MACHINEWITH WEIGH CELLS

TILT ROTARY FURNACEWITH SIDE TILT DOOR

INTEGRATED MELTING PLANT

INTEGRATED MELTING PLANT

MONTHLY PRODUCTION

(t)

ANNUAL PRODUCTION (t)

DAILY PRODUCTION

(t)

TILT ROTARY CAPACITY / MODEL

HOLDING FURNACE(S) CAPACITY

CASTING CAPACITY FILTER PLANT VOLUMEm3/hr.

1,000 12,000 40 TR8 7t 5t/hr 40,000

1,500 20,000 60 TR12 10t 5t/hr 60,000

2,500 30,000 90 TR15 15t 8t/hr 80,000

4,000 50,000 150 TR21 25t 10t/hr 100,000

POROUS PLUGS

TILTING HOLDING FURNACE

INGOT CASTING MACHINE

FILTER PLANT

ROBOTIC INGOT STACKING MACHINE

UNDERDOOR CHARGING

CHARGING MACHINES AND MATERIAL HANDLING

The efficient charging of the furnace is one of the most important considerations in creating a modern and efficient melting plant.

Melting Solutions lead the industry, in effective charging and handling equipment.

MOBILE VIBRATORY FEEDER

We supply a range of Charging Machines from 1 – 10 m³ hopper capacity rated from 1T – 6T per charge and above.

Using powerful vibratory motors a wide range of scrap can be rapidly charged into the furnace at a nominal 1T/minute and often with dense and shredded scrap this charging rate is much faster.

Our machines are heavy duty for years of trouble free service. We match the correct capacity machine for your furnace and scrap characteristics. The machines are fully integrated into the plant controls. We can include energy chains and machines that have long travel for crane loading.

Operations by remote controls are also available to optimise productivity.

Notes MODEL REFERENCE TR1 TR2 TR4 TR6 TR8 TR12 TR15 TR21

1 Maximum Charge Weight (Including Salt) - Kg 1,150 2,300 4,600 6,900 9,200 13,800 17,250 25,300

Door Opening Inside Diameter - mm 850 1100 1500 1800 1800 2000 2000 2000

2 Liquid Capacity - Volume in m³ 0.5 1.0 2.0 3.0 4.0 6.0 7.5 11.0

3 Melt Rate - Kg/Hr 575 1,150 2,300 3,450 4,600 4,600 5,750 7,229

Melting Time for one Charge Above - Hours 2 2 2 2 2 3 3 3.5

4 Non Melting Time, Charging, Casting and Discharging - Hours 1 1 1 1 1 1 1 1

Total ‘cycle time’ tap to tap - Hours 3 3 3 3 4 4 4 4.5

Number of Cycles per 24 hours 8 8 8 8 8 6 6 5.4

Maximum Charge Weight (Including Salt) per 24 hours - Tonnes 9 18 37 55 74 83 104 137

Input per year (322 x 24 Hour days) - Tonnes 2,962 5,925 11,850 17,774 23,699 26,662 33,327 43,992

ENERGY USING AIR-FUEL BURNER

Burner Energy kW PER Tonne of Charge 750 750 750 750 750 750 750 750

Natural Gas Consumption per lb of Charge (Input). - m³ 75 75 75 75 75 75 75 75

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 1.8 2.5 3.5 3.5 4.3 5.4

ENERGY USING OXY-FUEL BURNER

Burner Energy kW PER Tonne of Charge ~ ~ 350 350 350 350 350 350

Natural Gas Consumption per Tonne of Charge (Input). - m³ ~ ~ 35 35 35 35 35 35

Oil Consumption per Tonne of Charge (Input). - Litres ~ ~ 35 35 35 35 35 35

Oxygen Consumption (Either Gas or Oil) - m³ ~ ~ 70 70 70 70 70 70

Burner Power - (Oxy Fuel) - mW ~ ~ 1.0 1.2 1.6 1.6 2.0 2.5

MECHANICAL

Dive Power - kW 7.5 10 22 37 45 75 110 125

Variable Melting Angle, 0-15° angle of Tilt (Subject to Capacity) x x x x x x x x

Rotation Speed (variable direction and inverter controlled.) RPM 0 - 6 0 - 6 0 - 6 0 - 6 0 - 6 0 - 6 0 - 6 0 - 6

Nominal Filter Plant Volume - (Nm³ /Hour) 10,000 15,000 25,000 35,000 40,000 45,000 65,000 80,000

PERFORMANCE DATA

Notes:1. Maximum charge weight input including salt flux.2. Maximum volume in the Furnace body for liquid aluminium.3. Based on ISRI grades of scrap, no excessive contamination and reasonable density of approx 800 Kg/m³4. Assumes efficient automated charging and handling.

SPECIFICATIONSMODEL kg Alu A B C D E F Vm³

TR1 1,000 850 2,540 1,100 4,450 2,235 2,250 0.5

TR2 2,000 1,100 3,050 1,400 5,400 3,200 2,885 1.0

TR4 4,000 1,600 3,200 1,850 6,800 3,800 4,500 2.0

TR6 6,000 1,800 3,350 2,300 6,800 4,400 5,100 3.0

TR8 8,000 1,800 3,850 2,300 7,800 4,400 5,200 4.0

TR12 12,000 2,000 5,000 2,700 9,100 5,500 5,800 6.0

TR15 15,000 2,000 5,650 2,800 9,500 6,400 6,500 7.5

TR21 21,500 2,000 6,000 3,100 11,500 6,400 6,600 11.0

250 Lichfield Road, Brownhills. WS8 6LH