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2002 TMS Annual Meeting & Exhibition: Commercial Mini-Sessions
ANNUAL MEETING MENU
As a complement to the 2002 technical program, presentations featuring new technologies, equipment, and processes will be featured in the Mini-Commercial Sessions.
At these sessions you will have the opportunity to
The mini-sessions will be held Monday, February 18, 2002 and Tuesday, February 19, 2002
PRESENTATION SCHEDULE AND ABSTRACTS
Topic: SESSION I: FURNACES, MELT TREATMENT, CASTING
Time: 11.40 PM
Schmitz+Apelt LOI is featuring the Twin-Chamber melting furnace, for state-of-the-art melting of contaminated aluminum scrap without using salt, resulting in low energy and fuel consumption, minimal metal loss, and reduced dross accumulation in the bath. Also, Single Coil Annealing furnaces which optimize the heating and cooling of individual coils to maximize shop production and minimize handling and floor space requirements.
Time: 12:00 PM
The presentation will discuss the basic considerations made when designing an Electromagnetic stirring (EMS) installation. Fluid flow simulations are used for the choice of stirrer size and for optimizing the position of the stirrer with respect to the actual furnace geometry. Results from flow simulations will be shown.
The use of EMS in aluminum melting and holding furnaces will dramatically improve furnace operations. This presentation will discuss the results achieved, to include:
A typical payback calculation for an EMS installation will be outlined.
Time: 12:20 PM
The secondary aluminum producer has available a variety of scrap types which can be utilized to produce secondary alloy. While light gauge scrap is usually less expensive to purchase, often by a wide margin, it presents operational challenges which may offset the low purchase price. In recent years, two similar systems have become available that aid the melting of turnings, borings, UBC and other light scrap while achieving high recovery rates, excellent production rates and low energy consumption. Both systems, designed for use in aluminum reverberatory furnaces, feature quick scrap submergence to minimize melt loss and strong circulation of molten metal within the furnace to enhance production rates and energy efficiency, one powered with an electromechanical pump, the second with an electromagnetic pump.
Time: 12:40 PM
Lithium, sodium, calcium and magnesium may be all reduced efficiently to very low levels of ppm, within a few minutes, in the pot room crucible, before transfer to the melter/holder furnace; no chlorine is required, only the use of aluminium fluoride salt. The TAC process is the most frequently used and has been well described in several journals when it was first introduced by Alcan. Some removal, particularly of sodium, may also be obtained by simply transferring from one crucible to another for transport or delivery of molten aluminium, without the use of either gas or salt. On the other hand, these same elements may be also reduced in the casthouse in the holder, using either salts or gases by means of manual addition of fluxes or chlorine lances, or more recently, rotary gas/flux injectors. Degassers may also be used for removing alkalines with the use of chlorine.
Time: 1:00 PM
The PECHINEY JETCLEANER is a in-line trough degassing system which removes hydrogen with "jets" of inert process gas at a high velocity and without the conventional rotary type impellers. The refining process in a dense distribution of gas bubbles discharged into the melt, creating a high turbulence which reduces the required metal residence time for effective degassing. Hydrogen and particulate reductions are maintained at levels comparable to spinning impeller systems and the industry requirements.
The PECHINEY JETCLEANER process provides production flexibility without metal retention between casting periods and no downtime or scrape loss during alloy changes. The JETCLEANER is a sealed reactor with no moving parts in the bath resulting in lower capital and operating costs. Today's JETCLEANER will process metal flow of up to 30 Metric Tonnes per hour.
Time: 1:20 PM
The Wagstaff StopCastTM Automatic Bleedout Detection System provides billet casters with the latest innovations in safety and automation. The key features of the StopCast system are sensors to detect a bleedout and automated dams to stop metal flow to specific molds.
This presentation will include a brief explanation of the operation of the StopCast system and its availability as an option with Wagstaff billet casting equipment. Investment and operating costs of the system will also be discussed.
Time: 1:40 PM
Today's energy crisis has forced aluminum producers to search for materials
and processing solutions that allow them to meet or exceed existing
productivity requirements while reducing overall energy consumption.
One such solution is Rex Roto's High Performance Metal Delivery System
utilizing the Pyroform HP refractory technology. These delivery
systems allow producers to eliminate launder pre-heating, eliminate
"super-heating" for cast starts, and lower furnace temperatures
by as much as 25-50o C. Case histories are reviewed that demonstrate
the impact of these factors on reduced energy consumption.
Time: 11:40 AM
Anodes of any size can be vibrated or pressed. Anode presses have some distinct advantages compared to vibrators (especially when the paste conditioning system and the press are optimally adjusted to each other):
The presentation illustrates the concept and design of a modern anode press center including paste conditioner, dosing and mould filling system and hydraulic anode press as manufactured by Laeis Bucher.
Time: 12:00 Noon
BROCHOT has already supplied 26 rodding shops of different types (from manual, semi to fully automated systems) to the aluminium industry worldwide, among which 13 complete rodding shops. BROCHOT will take advantage of the next TMS Show to present the latest developments achieved for two main types of aluminium casting stations which are the rodding benches and the carousel systems.
Time: 12:20 PM
In furnace loading and tending, the use of efficient mobile vehicles, connected to detachable hydraulic tools or rigid scrapers reduces significantly the capital cost for the aluminum producer. A new generation of cylindrical loading boxes makes it possible to fill the furnace without damaging the refractory. The operator can do his work easily, more productively and in total safety.
The drive bi-directional vehicle helps much during transportation, of liquid bath, of alumina silos or large scrap boxes. Ergonomics played a significant role in the design of the Vallee equipments.
Time: 12:40 PM
This presentation will combine all the strategic and economic goals that work together to make a safety program not only succeed for a company but to actually be a benefit and asset as well.
Topics to be covered include:
Time: 1:00 PM
Fluent Inc., the world's leading CFD software provider, announces the latest release of its flagship product, FLUENT 6.0. As the use of computational fluid dynamics (CFD) software becomes more commonplace in the metals industry, we are responding with many new features ideal for modeling the performance of metals processes and equipment.
FLUENT enables metals engineers to simulate a wide range of processes, such as DC, CC and ingot casting, mold and tundish flows, pumps, filters, steel refining, mixing, oxygen-steel making, scrap melting, electric arc furnace and various reheat furnaces. Its many new capabilities ideal for metals industry applications include an enhanced volume-of-fluid (VOF) capability with heat transfer that provides accurate simulation of melting, casting, solidification and metal drawing processes and even Toxic Release Inventory (TRI) tracking.
Time: 1:20 PM
The aim of this paper is to present the advantages of simulation in
the modern casting environment. The application of casting simulation
is demonstrated through industrial examples, in the field of continuous
casting, direct chill casting and strip casting.
Anode paste preparation by means of intensive mixers has become a proven technology. It represents an alternative to the conventional process technology which has remained almost unchanged for decades.
The new process is based mainly on the electric heating of the dry substances as well as on the subsequent separate homogenizing and cooling in an intensive mixer and a mixing cooler. The new technology is characterized by drastically reduced energy consumption, exact temperature control, minor wear and tear and little maintenance expenditure, low investment cost and finally an optimum anode quality.
The plant operation is possible in continuous or batchwise mode.