Aluminum Calcium DC Furnace Equipment
Price:
The price will be negotiated based on the technical requirements and supply scope of Party A
MOQ:
1 unit
Delivery Time:
2 months
Brand:
Shaanxi Chengda
Product Description
Aluminum Calcium DC Furnace Equipment Introduction
1. Equipment Positioning & Core Applications
The aluminum calcium DC furnace is a custom-designed DC arc furnace dedicated to the production of calcium aluminate. It is mainly used for high-temperature melting treatment of aluminum-containing solid wastes such as aluminum dross and aluminum slag to produce high-purity pre-melted calcium aluminate products. Widely applied in steel metallurgy, building materials, and solid waste resource utilization fields, it serves as an upgraded alternative to the traditional rotary kiln process.
2. Core Working Principle
- Electrical-to-Thermal Energy Conversion: Powered by a DC power supply system, a stable DC arc is generated between the top graphite electrode and the furnace bottom anode. The arc core temperature reaches up to 10,000°C, with the outer flame temperature around 4,000°C. The high temperature of the arc completely melts raw materials such as aluminum dross and lime.
- Electromagnetic Stirring Effect: The DC current generates a constant magnetic field, driving directional flow in the molten pool. This enhances mass and heat transfer, resulting in more uniform material reactions and significantly improving the purity and composition stability of calcium aluminate.
- Continuous/Semi-Continuous Smelting: Raw materials are fed from the furnace top feeding port, and molten calcium aluminate is discharged from the furnace taphole. This enables efficient continuous production, with power consumption per ton of finished product as low as 700 kWh.
3. Equipment Structure & Components
| System Module | Core Components | Function Description |
|---|---|---|
| Furnace Body System | Steel furnace shell with refractory lining, water-cooled furnace roof, taphole/tapping spout | Contains the high-temperature molten pool, withstands thermal loads and mechanical stress. The water-cooled furnace roof effectively reduces heat loss. |
| Electrode System | Top graphite electrode, electrode lifting mechanism, conductive cross arm | Serves as the cathode for arc generation. PLC intelligent control of electrode position ensures stable arc power. |
| Power Supply System | High-power DC rectifier power supply, transformer, control cabinet | Outputs stable DC power with a power factor ≥ 0.95, causing no harmonic interference to the power grid. |
| Control System | PLC automatic control system, temperature/pressure sensors | Enables fully automatic control of electrode lifting, power regulation, and smelting rhythm. |
| Auxiliary Systems | Dust collection system, cooling system, feeding system | Treats smelting flue gas, ensures stable equipment operation, and achieves clean production. |
4. Key Technical Advantages (vs. Traditional AC Furnaces/Rotary Kilns)
✅ High Efficiency & Energy Saving: Saves over 15% electricity compared to AC furnaces, reduces electrode consumption by 35%, and increases output by 20% at the same power. The power consumption per ton index is far lower than traditional processes.
✅ High Product Purity: High-temperature melting above 2,500°C enables complete reaction of raw materials, allowing precise adjustment of alumina content without the under-firing/over-firing issues common in rotary kilns.
✅ Stable & Reliable Operation: DC arc eliminates power fluctuations in AC systems, ensuring uniform electromagnetic stirring in the molten pool. The risk of furnace bottom burn-through is significantly reduced, leading to low equipment failure rates.
✅ Strong Environmental Adaptability: Can be equipped with high-efficiency dust collection systems to treat flue gas generated during smelting, meeting environmental requirements for solid waste resource utilization.
✅ Adaptable to Solid Waste Treatment: Directly processes aluminum-containing industrial solid wastes such as aluminum dross and red mud, achieving reduction and resource utilization of hazardous waste with both economic and environmental benefits.
5. Typical Technical Parameters (2000-4000 kVA Models)
| Parameter Item | Specification Range |
|---|---|
| Rated Capacity | 2000~4000 kVA |
| Working Voltage | 120~300 V (adjustable) |
| Working Current | 6000~15000 A (adjustable) |
| Smelting Temperature | 2000~2500 °C |
| Power Consumption per Ton | 700~900 kWh/ton |
| Electrode Diameter | 300~500 mm |
| Furnace Diameter | 3~5 m (customizable) |
| Control Mode | PLC Fully Automatic Control |
6. Application Scenarios & Process Value
- Production of Steelmaking Auxiliary Materials: High-purity calcium aluminate acts as a refining slag for desulfurization and dephosphorization in steelmaking, significantly improving molten steel purity and serving as a high-quality metallurgical auxiliary material.
- Resource Utilization of Aluminum Dross Solid Waste: Converts secondary aluminum dross into high-value calcium aluminate products, turning waste into treasure and solving the problem of solid waste disposal in the aluminum industry.
- Raw Materials for the Building Materials Industry: Pre-melted calcium aluminate can be used as a raw material for cement and refractory materials, improving product performance while reducing production costs.
7. Comparison with Traditional Processes
| Comparison Dimension | Aluminum Calcium DC Furnace | Traditional Rotary Kiln | AC Submerged Arc Furnace |
|---|---|---|---|
| Product Purity | High (Complete melting reaction) | Low (Prone to under-firing/uneven composition) | Medium (Poor arc stability) |
| Energy Consumption | Low (700-900 kWh/ton) | High (Large coal/natural gas consumption) | Medium (15% higher than DC furnaces) |
| Electrode Consumption | Low (Stable DC arc) | No electrode consumption | High (High three-phase electrode wear) |
| Environmental Performance | Easy to equip with dust collection systems | Difficult flue gas treatment | Harmonic interference to the power grid |
| Production Efficiency | High (Continuous smelting) | Low (Intermittent/semi-continuous) | Medium (Power fluctuations affect production rhythm) |
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Company
Shaanxi CHENGDA Industry Furnace MAKE Co., Ltd.
Location
Room 1201, Greenland Blue Ocean Building, Zhanba Yi Road, Yanta District, Xi'an City, Shaanxi Province, China
Contact Person
Du