1. How many 6.5kW Plasma Airtorch™ units do I need for reducing dross?

Start with one for a standard 1000lb melter (i.e. add to exisiting furnace).  The number of ions may be enough.  Later if you need more units they can be added modularly. 

2. Would like to know something about the control systems?

SCR based control systems. Several models available which offer control of energy through power or temperature settings.

3. How does the furnace prevent Al nitride- how do you prevent the interaction?

Temperature is not hot enough for aluminum nitride formation. We have not noticed any nitride formation in the melt or on crucible walls.

4. What is the cost of the low-ion plasma generator?

You will be surprised at the price when compared to plasma generators.  Please contact us for current prices and models.

5. Space limitation, how big can it be scaled up?

This is one of the lowest foot-print devices.  Controls are small and can be remotely located.

6. What if the the coverage is more than one unit can handle.

As units are modular you can easily add more should you require to do so.

7. How does the Al react and behave in the furnace?

Clean and not turbulent at all. Very low dross.

8. Questions about the induction melting numbers, they seem too low.

Please see full details on Aluminum Melting Furnace.

9 . Clarify the “low-ionization term”, what does it mean?

Good Question. Low Ionization is our patented method to avoid the huge energy penalty normally associated with ionization.  A technical article is posted on the site. Patents are under issue.

10. What are the power requirements, voltage amp etc?

Again please conatct us.  Several volages are possible.

11. What control system is used?

Same as question 2 above.

12. What kind of seal is required?

No seals. Open to air.

13. How do you introduce the scrap into the unit?

Please discuss with us for scrap.  Scrap can be gravity fed. Other ways of introducing the scrap with a conveyor or screw will be possible. We recommend that you construct the furnace you need and simply add the plasma generator.

14. How do you seal the chamber and prevent intrusion of O2?

No seal required. O2 is present but is blanketed away. (See technical article).

15. Clarify whether scarp is wet/dry/painted/oil and how to deal with each?

All can be used depending on your existing scrap furnace, sometimes with a pre-heater in the conveyor.

16. What kind of metal temperature is achieved?

Metal is estimated to be about 20-100°C above the meting point in mormal melting operations.

17. What do you mean by 'hot zones'?

Space inside the furnace.

18. Scrap size is very important, how much can be in the furnace?

You can continue to use your existing furnace.

19 . Why not a ceramic or graphite felt filter?

The filter material in the two page introduction referred to the filter scrap that comes from a sprue which had metal filters.  The furnace seperated the sprue and filter by a melting process.  . No filters are used required for normal melting.

20. Why is a steel mesh filter needed, and the chance of iron impurities?

Same as question 19 above. There is no filter in furnace. In the example used for the trials the sprue contained a metallic filter.

21. Where does the O2 go or consumed?

No oxidation. It is blanketed out by ions.

22. What is the largest furnace been made to?

Mostly use for tonnage furnaces when employed for dross reduction. 

23. Do you lose advantages when you scale up?

Larger furnaces give larger productivity advantage (see benefits). We do not anticipate loss of efficiency or more energy consumption per pound but do anticipate cost could reduce.

24. When tap furnace, use tap hole to plug drain.

Furnace can be run continuously or as a pit. These are different configurations both possible. Fan blown. Very gentle. No sound.

25. What is the best furnace lined with?

One can use alumina refractory made by Mattech Corporation.

26. What is the affluent seal or is there one, is it completely sealed, vent for gasses?

No Seal.

27. Does it work with solid Al?

You, mean can it be used for heat treating. The answer is yes.

28.  Whether the scalability of the design will allow for melting at rates of about 0.5 - 2.0 kg/s?

This depends on power and configuration. Rapid melting is possible because of the clean atmosphere and very enhanced heat transfer coefficient to the melt. Once again please see the web site for details.

29. What is the energy consumption (overall, including any necessary heat-up, holding time, etc), capital cost of equipment?

For blanketing a standard tonnage (one ton) furnace you should start with one unit. Each furnace is different.  Please see the Melt Rates table if melting is to be affected.

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