Aluminum Melting Operations Explore Regenerative Combustion for Improved Waste-Heat Utilization

Regenerative Combustion in Aluminum Melting

In aluminum melting operations, the combustion system affects both the heating process and how waste heat from flue gas is utilized. For a natural gas aluminum melting tilting furnace, recovering heat from exhaust gas and reusing it for combustion-air preheating is a key feature of regenerative combustion.

The furnace described in the PDF is a rectangular, single-chamber tilting aluminum melting furnace equipped with a regenerative natural gas combustion system. It is designed for melting aluminum and aluminum alloy scrap, followed by skimming, refining, and temperature adjustment of molten aluminum.

How the Regenerative System Recovers Heat

The regenerative aluminum melting furnace uses a pair of burners that alternate between combustion and exhaust. While one burner heats the furnace, the other absorbs heat from the flue gas through a regenerator. After the reversing cycle, the stored heat is used to preheat incoming combustion air.

The proposal specifies combustion-air preheating to around 1000°C, main exhaust temperature around 200°C, and stated heat recovery efficiency above 85%. These parameters describe a system designed to reuse part of the flue-gas heat within the combustion process.

Linking Heat Recovery with Melting Performance

The performance guarantee specifies a melting rate of ≥4 t/h and unit gas consumption of ≤65 Nm³/t-Al. The acceptance test uses 100% aluminum ingots, with the melting test ending when molten aluminum reaches 720°C.

For buyers comparing a natural gas aluminum melting furnace, these conditions are important because fuel consumption and melting rate should be evaluated together with the defined testing method.

PLC-Based Combustion Control

The regenerative combustion system uses PLC control for purging, ignition, flame monitoring, and burner reversing. The proposal specifies a Siemens S7 PLC and continuous flame detection; in the event of flame failure, the system is designed to shut off the main flame and generate an alarm.

The combustion and exhaust fans also use variable-frequency control for airflow and furnace-pressure adjustment according to operating requirements.

Technical Parameters for B2B Evaluation

For overseas buyers evaluating an aluminum melting tilting furnace, regenerative combustion can be assessed through combustion-air preheating, exhaust temperature, heat-recovery specifications, gas consumption, melting rate, and defined testing conditions.

These measurable parameters provide a clearer technical basis for furnace evaluation than broad claims such as “energy saving” or “high efficiency.”