1. "Fully Automatic Environmentally Friendly Energy-Saving Aluminum Ash Machine", abbreviated as "Fully Automatic Aluminum Ash Machine" or "Aluminum Ash Machine"

2. Shape of aluminum ash machine

3. Floor area and usable area of aluminum ash machine equipment

Floor area ----- ≈75㎡ (length 13m X width 5.7m X height 6.9m)

Effective area - ≈117㎡ (length ≥ 23m x width ≥ 9m) - (forklift operation space)

4. Equipment operating conditions and consumption

Power supply: 380v/220v (three-phase five wire system 50KW)

Actual electricity consumption: 43Kw/hour; (Excluding supporting dust removal equipment)

Compressed air: pressure 0.5-0.6MPa 10m 3/h (used for cleaning the transfer trolley panel and track)

Cooling circulating water: at room temperature (groundwater) or entering the cooling tower system of Party A,

Water temperature ≤ 30 ℃, pressure 0.25MPa

Reference value for circulating water consumption (15T/h). Actual water consumption ≈ 100kg-200kg/h

The foundation of the aluminum ash machine is at a uniform elevation (horizontal plane), with a concrete thickness requirement of 200-250mm or more (bearing capacity of about 4-5 tons/square meter).

5、 Understand the components and functions of aluminum ash machine

1. Host

1.1 The host is the main mechanism for processing aluminum ash, the core of the entire equipment, the key to achieving efficient aluminum liquid recovery, and the main manifestation of equipment value.

1.2 The working mode adopts dual oil cylinder up and down drive, and the motor sprocket chain transmits torque;

1.3 Recovery rate of 85 ± 5%;

1.4 Processing time 5-7 minutes per pot;

The 1.5 blades adopt a positive "Δ" shape, with different cutting speeds for the inner and outer blades, achieving efficient cutting of aluminum ash while simultaneously stirring the bottom and upper parts of the pot;

1.6 Equipped with an electrical control system for the rising process of its internal mechanical room, including initial state, soup dispensing state, and termination state;

1.7 The pot is cast as a whole and should not break. The depth and shape of the pot benefit from our long-term experience in aluminum ash treatment. The special shape of the pot can maintain the temperature of the aluminum ash, which is not easily lost for a long time, and can ensure that the liquid aluminum quickly accumulates at the bottom of the pot during stirring, making it easy for the aluminum liquid to flow out. The feature of this machine is to process hot aluminum slag in one go without the need to transfer or exchange it;

When processing aluminum ash, special processes are used to ensure that the recovery rate of finished aluminum is increased by more than 10% compared to before, and by more than 20% compared to other methods;

The mechanical room and mixing shaft move up and down together, which can effectively overcome the problems of long main shaft length and limited rigidity that are prone to bending during mixing work;

1.10 Core components:

The main reducer and various component system motors use high-end motors (SEW, 11kw), the drive chain uses Donghua Chain, and all bearings use SKF (Sweden) series products. The torque of the reducer is transmitted through the chain, which is cleverly designed as a drive source for asynchronous rotation of the inner and outer blades. The reducer and spindle cannot be directly connected through a coupling or rely on gear transmission. Using chains to transmit torque effectively overcomes abnormal vibrations and strong impacts caused by foreign objects in the pot;

1.11 All bearing parts, chain wheels, and chain connections are equipped with automatic lubrication devices;

1.12 The entire mechanical room adopts positive pressure dust prevention measures. (1.1KW Roots blower)

2. Transfer Flip

This device system is a device that discharges and transfers the heat residue ash processed by the host;

It is one of the indispensable devices for aluminum ash processing equipment;

The structure is constructed using a flipping device that does not require pits or grooves;

Flip at an angle of 55 degrees to completely remove residual dust. (Transfer motor SEW-0.75kw)

3. Cooling screening

This component is a device for cooling and grading the residual ash after extracting aluminum liquid;

Adopting a simple cooling effect and a straightforward cooling structure;

Cooling efficiency of 80-95%, using circulating cooling to ensure no waste of water source;

Adopting a simple and easy to maintain sealing structure;

Natural steam emission method was adopted. (Cooling and screening power motor: SEW-7.5KW)

4. Spiral conveyor (angle dragon)

The horned dragon mainly plays a role in transit transportation, and fine particles are transported by the horned dragon to the bucket elevator before being bagged. Medium sized particles are transported to the next process (scraper) by medium sized particle ceratopsians

5. Scraper conveyor (scraper machine)

The scraper machine plays a role in transporting particles during transportation. The particles are transported by the scraper machine to subsequent processes, and the entire process is sealed. Each processing system is equipped with a dust removal port, effectively ensuring the cleanliness of the working environment and workshop environment. (The scraper conveyor power motor adopts SEW reduction motor: 4KW)

6. Cold ash feeding machine

The cold ash feeding machine is one of the key components of the complete equipment, and its main function is to store and collect the room temperature residue after cooling and screening; Secondly, neutralize the raw slag with excessively high temperature, reducing the temperature of the aluminum slag to a suitable working range. (The vibrating feeder consists of two 0.25kw vibration motors)

6.1 Have sufficient storage space;

6.2 Compact organization;

6.3 Simple maintenance without easy dust leakage;

6.4 The cold ash temperature is at room temperature and can significantly reduce the temperature of the hot aluminum slag to be treated in the next pot,

Facilitating the cooling process in the later stage.

7. Hydraulic system

The hydraulic system is also one of the core components. With it, the mechanical chamber can move up and down smoothly, and with it, the flipping body can smoothly pour the aluminum ash residue into the cooling bucket.

8. Centralized lubrication system

The bearings and other components in enclosed spaces require manual lubrication, which is inconvenient, labor-intensive, and may not be properly lubricated. Therefore, we have adopted a centralized lubrication system to address these shortcomings, greatly saving manpower and resources.

9. Cooling water circulation system

The cooling circulation system is also one of the important systems of this equipment. It mainly consists of two water pumps (one in and one out) and water pipes. It adopts a scientific cooling method to cool the aluminum residue at a temperature of several hundred degrees Celsius to room temperature (generally, the temperature can be grasped by hand at about 50-80 ° C), with a cooling rate of up to 95%. It adopts an external spray cooling method to cool while ensuring water quality, thus achieving a pollution-free and recyclable state of water quality, effectively reducing production costs. (Cooling water pump 1.5-2.2kw)

10. Control system

The control system is one of the indispensable cores of this device. Whether this device can operate and work automatically depends on this control system, which is like the human brain's command center.

So our electronic control system uses high-end electronic components from domestic and foreign products, such as frequency converters (Siemens/Mitsubishi), PLCs (Siemens/Mitsubishi), touch screens (Mitsubishi/Siemens), etc., all of which use international high-end brands. Some components also use domestic high-end brands such as Shanghai Schneider. In order to ensure the sustainable and normal operation rate of this equipment.

Note: Among the four series of reduction motors, R, F, K, and S, our SEW reduction motors all use R series reducers. The R series hard tooth surface reducers use high-quality steel cast iron housings, which greatly improve the hardness and impact performance of the housings. We adopt a series and modular design concept, with a finely graded transmission ratio, high transmission efficiency, low energy consumption, superior performance, and wide adaptability. There are numerous motor combinations, installation forms, and structural schemes, with finely graded transmission ratios to meet different operating conditions, achieving mechatronics integration, high transmission efficiency, low energy consumption, and superior performance.

6、 Process flow diagram of fully automatic aluminum ash machine

6.1 Explanation of Process Flow

1.1 Remove the aluminum ash from the melting furnace and place it in a specialized pot for the aluminum ash machine. Then use a forklift to transport the hot aluminum ash that needs to be processed to the main unit of the aluminum ash processing equipment, and start the equipment for high-speed processing. Separate metal aluminum and thermal residual ash with different densities through equipment stirring. Before starting the mixing process, the operator decides whether to directly mix or add a heating agent based on the temperature state of the hot aluminum ash, so that the hot ash is in a burning state for mixing. After being removed from the smelting furnace, the hot aluminum ash is stored for a long time, and the temperature of the aluminum ash drops below 650 ℃. It is necessary to add a heating agent for stirring and separation. The separated hot residual ash is automatically transferred and flipped to the super cooling machine for cooling through a transfer flipping device. After sufficient cooling, the hot residual ash is cooled from around 700 ℃ to around 60 ℃, and then enters the grading and granulation device, where it is divided into three products: one is a powder with a thickness of less than 2mm; One type is 2mm~10mm particles; One type is a block of 10mm or more. Powder and block like materials enter ton bags or iron boxes; The particles are sent to the cold ash feeding machine for recycling, and the excess is packed into ton bags.

6.2 Equipment Overview:

2.1. This device utilizes the thermite reaction of aluminum oxide (hot floating slag) generated in the aluminum dissolution furnace, and separates aluminum oxide ash (hot residual ash) and aluminum solution by stirring with blades using different specific gravities. The aluminum solution is then fed into the steel ingot mold. After the residual ash is cooled, it can be removed using an iron box (cloth bag);

2.2. This device consists of a pot for storing hot floating slag, a mechanical chamber with rotating blades, a transfer and flipping conveyor, a hydraulic power device, a cooling and grading device, related conveying devices, and a control box for controlling the transmission;

2.3 Characteristics of this device: The dual blades (one main blade and two auxiliary blades) used in the aluminum ash processing machine are a practical new solution to improve mixing efficiency, using two hydraulic cylinders to move the blades up and down. Changing the previous chain drive method, improving the material of the bearing and bearing shells, eliminating vulnerable parts, and achieving short-term and high-efficiency processing through advanced pot and blade structures. The residual ash after simultaneous processing is loaded into the cloth bag in the iron box through the grading mechanism. The equipment is installed entirely on the ground for easy cleaning of the entire device;

2.4. The concept of "stir frying slag+cooling+one-time screening+circulating stir frying slag" is adopted, which fundamentally changes the recovery rate of useful aluminum in aluminum slag and greatly improves the purity of coarse particles that need to be returned to the furnace;

2.5. There are maintenance ports for the interlocking, driving, and rotating parts of the equipment components, and dust collector interfaces are connected to areas that are prone to dust generation (five in total, including the host end, transfer flip end, primary screening end, scraper end, and bucket elevator end).

7、 Number of people operating the equipment

This equipment requires 1-2 people to operate, with one master operating the equipment and one master driving a forklift to cooperate with the operation. Two masters coordinating cross operation is enough to "play" with this equipment (forklifts are used to transport hot aluminum slag, transport replaced fine particle ton bags, etc.).

8、 Processing capacity and consumable usage time (410 type)

The 410 standard machine is named after the volume of the pot, which means 0.41m 3,

The weight of each pot of aluminum slag is approximately 0.41m 3=410kg. According to the safety operation manual, for safe operation, we require that each pot of hot aluminum slag only contains 80% of the pot volume. Therefore, the actual amount of aluminum slag in the pot is approximately (410 * 80% ≈ 330kg). Our host takes 5-7 minutes to process each pot of aluminum slag. Calculated based on 7 minutes, plus the transfer and flipping time and forklift operation time, each pot takes about 15 minutes. That is to say, processing 4 pots of hot aluminum slag per hour, with a processing capacity of approximately (330 * 4=1.3T) per hour. If calculated based on a daily workload of 10 hours, the calculation is as follows:

Daily ≈ (1.3 * 10 ≈ 13T), monthly ≈ (13 * 28 ≈ 364T), annual ≈ (364 * 12 ≈ 4000T+)

Performance guarantee values for the entire equipment set:

1) Processing capacity: 4000-6000 tons/year

2) Cooling capacity: greater than 900kg/time, residual ash temperature ≤ 60 ℃;

3) Single stir fry time: ≤ 10 minutes (usually 7 minutes)

4) Noise: ≤ 80 decibels (some dust collection outlets may exceed 80 dB)

5) Slag pot lifespan: 1-2 years (depending on actual usage)

Stirring blades:>800 times or 7-10 days (depending on the operation)

9、 Aluminum ash testing method

1. Take 50g to 100g samples from different locations in a bag of aluminum ash;

2. Retrieve approximately 300g-600g of aluminum ash per unit and crush it. The crushed aluminum ash is approximately between 100 and 200 mesh;

3. After crushing the aluminum ash, use a 20-40 mesh sieve to screen out the aluminum;

4. Sift out the aluminum (soak it in pure hydrochloric acid water), then wash it several times with clean water, air dry or bake it dry;

5. After drying, put it into a small melting furnace for melting. The melting temperature is around 740-760 degrees Celsius;

6. After reaching the melting temperature (melting agent can be added), stir with a steel chisel. After stirring, pour the aluminum water into a container for cooling;

During the aluminum water cooling process, clean the melting furnace thoroughly for easy use next time;

8. Weigh the aluminum water (divided by) and measure the amount of aluminum ash taken (multiplied by). 100% is equal to the percentage of aluminum ash content.