Aluminum Ash Treatment Equipment with 1550-1650℃ Melting Temperature, 750-850kWh/t Power Consumption, and 60-160t Daily Treatment Capacity

Introduction to Equipment and Parameters

I. Process Principle

• Main reaction: 3CaO + Al₂O₃ → 3CaO·Al₂O₃ (calcium aluminate)
• Side reactions: Oxidation/reduction conversion of AlN and metallic Al; volatilization and removal of salts
• Product: Pre-melted calcium aluminate (steelmaking refining slag, deoxidizer/desulfurizer)

II. Core Equipment Composition (Complete Production Line)

1. Pretreatment System

• Crushing and Screening Machine: Crushes aluminum ash to ≤50mm, removes iron and impurities
• Batching Station: Automatic metering of aluminum ash, CaO, reducing agent (coke) and modifier (MgO)
  • Ratio: Aluminum ash 40–65%, CaO 35–45%, MgO 0–15%
  
  
• Mixer/Briquetting Machine: Mixes materials evenly; briquetting is available to increase melting speed

2. Core Equipment: Calcium Aluminate DC Electric Arc Furnace

• Furnace body: Round/square, steel shell + composite refractory lining (corundum-mullite/magnesia-chrome brick)
• Electrode: Graphite electrode (double/three electrodes)
• Power supply: DC rectifier power supply (1000–10000kVA)
• Furnace tilting mechanism: Hydraulic tilting (for slag discharge)
• Cooling system: Water cooling for furnace shell and electrode chuck
• Flue gas system: Purification of high-temperature flue gas, fluoride and salt mist

• Electrode consumption reduced by 40%
• No reactive power compensation required, lower investment
• Noise reduced by 10–20dB
• Strong electromagnetic stirring, uniform composition and fast melting speed
• Insulating shell easily formed in case of power failure, protecting furnace lining

3. Post-treatment System

• Slag Discharge/Cooling: Tapping of hot slag → water quenching/air cooling → crushing
• Crushing and Screening Line: Jaw crusher + roller crusher + vibrating screen
  • Finished particle size: 1–10mm, 10–50mm (for steelmaking)
  • Overscreened powder returned to furnace for remelting
  
  
• Storage and Packaging: Finished product silo, automatic packaging (25/50kg/bulk bag)

4. Environmental Protection Supporting Facilities

• Flue Gas Purification:
  • Quench tower (temperature controlled below 200℃)
  • Bag filter (fluoride adsorption)
  • Alkaline washing tower (removal of HCl, F⁻ and salt mist)
  
  
• Wastewater: Cooling circulating water + small amount of acid-base neutralization
• Solid Waste: Almost no secondary waste residue (full conversion)

III. Product: Calcium Aluminate (Finished Product Indexes)

• Main phases: 3CaO·Al₂O₃, 12CaO·7Al₂O₃
• Typical composition (wt%):
  • Al₂O₃: 55–65%
  • CaO: 30–40%
  • MgO: 2–5%
  • SiO₂: ＜3%
  • F⁻, S, P: ＜0.1%
  
  
• Application: Pre-melted refining slag for steelmaking, high-efficiency desulfurizer, deoxidizer

IV. Technical Features

• Resource utilization: Turns aluminum ash into treasure, Al₂O₃ utilization rate >90%
• Harmless treatment: Decomposition of AlN, removal of salts, solidification of heavy metals
• High efficiency: Short single-heat cycle, high continuity and automation
• Low consumption: Significantly lower power and electrode consumption of DC furnace than traditional processes

V. Selection Suggestions

• Small-scale line: 1250–3000kVA DC furnace, daily treatment capacity 30–80t aluminum ash
• Medium-scale line: 3000–6300kVA DC furnace, daily treatment capacity 80–160t aluminum ash
• Large-scale line: 6300–10000kVA DC furnace, daily treatment capacity 160–300t+ aluminum ash