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Melting furnaces of the highest possible efficiency and quality
The performance range of StrikoMelter sets new standards. At a metal yield of virtually 100%, it is extremely energy-efficient and of unequalled durability. It also provides a metal quality which meets the highest possible demands. In many ways, the StrikoMelter is a unique melting and holding furnace which offers foundries especially economical production conditions.
The shaft geometry of the StrikoMelter and its special burner technology combining preheating, heating and melting in one furnace shaft. After the charge material has been melted in the lower part, the exhaust heats up the cold raw materials in the upper part of the shaft. The counterflow of melting material and gas allows for an extremely effective use of the exhaust heat according to the regeneration principle. For process reasons, this means that fuel consumption and metal loss are considerably lower than they are with all known products of the competition. The molten metal is transferred to the holding bath free of turbulences and with little dross formation. The melting volume in the holding area is independent of the melting process. As a result, liquid metal with a homogenous composition, a constant tap out temperature with the highest quality and purity is available for your production.
The world is spared 44,520 t of CO2
Even just the StrikoMelters delivered worldwide in the year 2014 have a total melting capacity of 1,113,000 t of aluminium per year. We are well aware of the responsibility signified by the associated energy consumption. This is why we work daily on reducing it still even further. The result? StrikoMelter shaft melting furnaces installed in 2014 create 44,520 t less CO2 emissions every year than the melting furnace technology otherwise available on the market. This means that the environment is spared greenhouse gases corresponding with the CO2 emissions of a fleet of 23,400 vehicles.
Lower unit costs for the light metal industry
When you invest in a furnace, energy consumption and metal loss over the service life account for more than 95% of the total costs. This is why our developers are constantly working on new cost-saving technologies. For example, a holistic analysis of furnace body, fire-proof lining and burner design allowed the efficiency of the well-known Strikomelter to be improved even further. Reduced energy consumption, maximum material yield, low wear, simplified lining concept: the PurEfficiency product line offers unique advantages for efficient production.
The shaft geometry of the StrikoMelter and its special burner technology combining preheating, heating and melting in one furnace shaft. After the charge material has been melted in the lower chamber, the exhaust heats up the cold raw materials in the upper part of the shaft. The counterflow of melting material and gas allows for an extremely effective use of the exhaust heat according to the regeneration principle. For process reasons, this means that fuel consumption and metal loss are considerably lower than they are with all known products of the competition. The molten metal is transferred to the holding bath free of turbulences and with little dross formation. The melting volume in the holding bath is independent of the melting process. As a result, liquid metal with a homogenous composition, a constant removal temperature and maximum quality and purity is available for your production.
750 - 20,000 kg: Holding the melt at a constant temperature
In contrast to immersion melting, the size of the holding bath in our StrikoMelter is independent of the melting performance and can be selected exclusively according to the requirements of your production process. The sizes begin with only 1.5 times the hourly melting performance. This makes extremely compact furnace systems with low space requirements possible. However, it is also feasible to hold up to 20 t of melt at a constant temperature.
7,300 days: Extremely durable
A service life of 20 years is not unusual for our melting furnaces: the impressive durability of the StrikoMelter is one of its most outstanding performance features. This makes it the most robust melting furnace in its class.
The melting furnace for structural parts
The new StrikoMelter BigStruc also allows extremely large structural components to be remelted. This new melting furnace was specially designed for melting large-volume, thin-walled parts as well as small-sized returns while ensuring a very low metal loss and energy consumption.
To make full use of the potential of lightweight construction in passenger car body design, an increasing number of structural components are manufactured using the die-casting process. The trend towards aluminium structural components with the aim of reducing the number of joining and assembly steps lead to considerably larger, flatter cast parts, which creates both complex sprue structures and small, thin-walled returns. Both types of returns pose new challenges for foundries.
The new StrikoMelter BigStruc is suitable for melting large-volume parts as well as small-sized returns with a low metal loss and energy consumption. The sometimes extremely thin-walled cast parts are preheated in the shaft without direct exposure to the flames and rapidly melted at the foot of the shaft. The metal flows directly from the melting bridge into the holding bath.
Optimization for structural parts
In contrast to a conventional StrikoMelter shaft melting furnace, the StrikoMelter BigStruc has a special shaft design allowing returns with an area of up to 2.5 m² to be loaded into it. The height of the shaft can remain unchanged in comparison with the standard StrikoMelter. After loading, the shaft is closed with a cover (“hot gas baffle”). Due to the bulky and large-volume components, there is a larger void volume with a lower bulk density. However, the closed hot gas baffle keeps the heat in the shaft and prevents the energy from escaping unused. With BigStruc, the preheating and melting of the charge material takes place in the closed shaft. In order to load the StrikoMelter at the best possible time in the melting process and keep the shaft well-filled, the filling level is monitored constantly using a new laser system – even when the shaft cover is closed. In addition, constant checks are made as to whether the hot gas baffle is able to close the furnace shaft without problems.
All in all, the tried and tested concepts StrikoMelter Plus+ and StrikoMelter Purefficiency were only partially modified to meet the new requirements: a modified and enlarged shaft geometry, a hot gas baffle and the new options of near-stoichiometric combustion and self-sealing doors. Of course, the BigStruc can also process material and returns of the kind usually occurring in foundries.
Using returns profitably and in an environmentally sound way
In times of rising prices for raw materials and energy, the recycling of valuable raw materials becomes highly economical. Besides the existing systems for melting returns, the melting of aluminium chips is becoming more and more important. In the production of cast aluminium parts, the in-house recycling of chips is an extremely economical alternative: for example, costs such as those for the acquisition of raw materials (ingots) can be reduced considerably.
Challenge and solution:
To remelt chips, you need an efficient technology which carries out remelting under the exclusion of air. This is the only way to ensure maximum metal yield and an environmentally sound melting process. StrikoWestofen has developed melting systems for recycling chips which meet these requirements. These aggregates have a chip melting capacity of between 300 and 2,000 kg/h. The combined Strikomelter with the option of chip recycling is used for smaller quantities or where there is only an occasional need for recycling.
The StrikoMelter ramp melting furnace has been adapted to meet the requirements of customers who use T-bars and sows. As the EtaMax® shaft is not suitable for the melting of T-bars, these are melted on the melting ramp. The EtaMax® shaft is used to melt the returns in order to guarantee the customary high energy yields at a low energy consumption.