Aluminum Ash Treatment Electric Furnace (Calcium Aluminate Furnace)

1. Equipment Composition (Furnace Body + Auxiliary Systems)

1.1 Furnace Body (Core)

• Furnace Type: Three-phase AC arc furnace / DC plasma arc furnace (dual-electrode bottomless anode, anti-piercing).
• Shell: 20–35mm thick steel plate with annular stiffeners, high deformation resistance and rigidity.
• Lining: High-alumina bricks + magnesia-carbon bricks + corundum castable, refractoriness ≥1850℃, excellent aluminum slag corrosion and thermal shock resistance, service life ≥12 months.
• Roof: Fully sealed water-cooled roof with electrode holes + temperature/feeding/flue gas ports, suppressing dust and fluoride escape, meeting environmental standards.
• Tapping Openings: Water-cooled + refractory lining; lower metallic aluminum outlet, upper calcium aluminate slag outlet; tapping temperature 1550–1650℃.

1.2 Electrode System

• Electrodes: High-purity graphite electrodes, φ350–600mm, high temperature resistance, low consumption, excellent conductivity.
• Cross Arm: Water-cooled copper alloy, high current capacity, low impedance, stable power supply.
• Lifting: PLC fully automatic closed-loop control for precise arc length/temperature regulation, fast response, small fluctuation.

1.3 Power Supply & Electrical System

• Transformer: 3000–20000kVA, multi-voltage gears (180–450V) for melting/reaction/clarification.
• Rated Current: 8000–35000A, low short-network impedance, high thermal efficiency.
• Control: PLC + touch screen, integrating temperature control, power regulation, automatic feeding, fault alarm, data traceability, fully automatic operation.

1.4 Raw Material Pretreatment & Batching

• Pretreatment: Aluminum ash screening + magnetic separation + ball milling (80% ≤100 mesh), removing iron impurities, improving reaction efficiency.
• Automatic Batching: Aluminum ash + limestone/slaked lime, Al₂O₃/CaO molar ratio 1:1–1:1.2, PLC dynamic metering, error ≤±0.5%.
• Mixing & Homogenization: Twin-shaft mixer, mixing 30–45min, uniformity CV ≤5%.

1.5 Environmental Protection & Auxiliaries

• Water Cooling: Forced cooling for shell, roof and cross arm; surface temperature ≤35℃, safe and reliable.
• Flue Gas Treatment: Sealed + baghouse dust removal + fluorine & denitration + waste heat recovery; dust ≤10mg/m³, fluoride compliance.
• Hydraulic Tilting (Optional): 0–45° tilting, easy for slag removal, cleaning and maintenance.

2. Main Technical Parameters (Standard Models, Customizable)

2.1 Processing Capacity

• Raw Materials: Primary/secondary aluminum ash, aluminum slag (moisture ≤5%)
• Capacity: 10–60t/h (240–1440t/d)
• Power Consumption per Ton: ≤680kWh/t (DC furnace ≤600kWh/t)

2.2 Smelting & Product Indicators

• Working Temperature: 1500–1800℃ (peak 1850℃)
• Calcium Aluminate Composition: CaO 45–50%, Al₂O₃ 35–40%, SiO₂≤5%, S/P≤0.5%
• Metallic Aluminum Recovery Rate: ≥92% (aluminum grade ≥98%)
• Fluorine Fixation Rate: ≥98% (solid waste harmless)
• Product Form: Block/granular (5–35mm), pre-melted dense, non-porous

2.3 Furnace Body Parameters

• Hearth Size: φ2800–5000mm × H3200–5500mm (circular)
• Transformer Capacity: 3000/6000/10000/16000kVA
• Electrode Diameter: 350/400/500/600mm
• Control Mode: Fully automatic PLC + manual dual mode

2.4 Environmental Protection & Energy Consumption

• Dust Emission: ≤10mg/m³
• Fluoride Emission: ≤3mg/m³
• Tailings Utilization Rate: 100% (calcium aluminate products for sale)

3. Core Advantages

1. Hazardous Waste Detoxification, High-Value Conversion: High-temperature melting fixes fluorine/nitrogen/salt, aluminum ash becomes steelmaking pre-melted slag, value increased by 3–5 times per ton.
2. High Efficiency & Energy Saving, Low-Cost Operation: DC furnace saves 15% power, 35% electrodes, 20% capacity vs AC furnace; electromagnetic stirring for more complete reaction.
3. High-Temperature Melting, Stable Quality: Pre-melted at 1500–1800℃, uniform composition, low melting point, fast melting, high deoxidation/desulfurization efficiency.
4. Sealed & Eco-Friendly, Safe & Reliable: Fully sealed + high-efficiency fluorine & dust removal, no leakage, low emission; intelligent monitoring + safety interlock, reliable long-term continuous operation.
5. High Customization & Wide Adaptability: Customized by aluminum ash composition, capacity and environmental requirements, suitable for small to large aluminum plant solid waste treatment.

4. Application Fields

• Aluminum Smelters: Primary/secondary aluminum ash, aluminum slag harmlessness & recycling
• Aluminum Processing Enterprises: Casting aluminum ash recovery & high-value utilization
• Metallurgical Auxiliary Plants: Pre-melted calcium aluminate refining slag large-scale production
• Hazardous Waste Disposal Centers: Aluminum ash hazardous waste reduction, detoxification, recycling
• Steelmaking Industry: Ladle deoxidation & desulfurization, steel purification refining slag

5. Models & Services

• Standard Models: 10t/h / 25t/h / 40t/h / 60t/h Calcium Aluminate Electric Furnace
• Customization: Hearth size, transformer capacity, automation level, environmental accessories
• Turnkey Service: Design, manufacturing, installation & commissioning, training, after-sales support