Blog Information

• Posted By : Christina Wang
• Posted On : Jun 17, 2025
• Views : 1
• Category : NFL
• Description :

Overview

• In the aluminum and aluminum alloy casting production line, aluminum liquid filtration, purification, and degassing (usually referred to as rotary jet degassing) are key links that ensure the performance of the final product and improve the yield rate. The core issues that aluminum plants pay great attention to in this process are directly related to their production costs, efficiency, and market competitiveness.

  1. Purification efficiency and stability:

  Inclusion removal: Can all kinds of non-metallic inclusions (oxides, flux, furnace lining materials, etc.) be efficiently removed to prevent them from becoming the source of product cracks or reducing performance

  Hydrogen removal effect: Can the dissolved hydrogen content be quickly and stably reduced to the target level (usually less than 0.15ml/100g Al or even lower) to prevent the casting from producing pores and looseness

  Alkali metal control: Can harmful alkali metal elements such as sodium, lithium, and calcium be effectively removed to prevent hot cracking and processing brittleness

  Process stability: Is the equipment performance stable and reliable, and is the treatment effect small between batches to ensure consistent product quality

  2. Operating cost and economic benefits:

  Equipment and consumables life: Is the ceramic foam filter durable, and how often is it replaced? How long is the life of key components such as degassing rotors and degassing box linings? Frequent replacement leads to huge downtime losses.

  Energy consumption: Is the nitrogen/argon consumption and power consumption of degassing equipment (especially large equipment) optimized?

  Metal loss: Does the processing process cause excessive aluminum liquid to oxidize or remain in the equipment (such as filter plate tanks, degassing boxes), causing waste?

  Maintenance cost: Is the equipment easy to maintain, and is the downtime associated with maintenance too long?

  3. Production efficiency and ease of operation:

  Processing flux: Can the equipment meet the increasing production line speed and large tonnage processing needs?

  Online time: Is the alumina ceramic foam filter replacement and degassing equipment maintenance quick and convenient, minimizing production line downtime?

  Automation and integration: Is the equipment easy to integrate with the existing production line automation system? Do you know if the operation interface is friendly?

  Safety: How to ensure the safety of the equipment in the high-temperature aluminum liquid operation environment?

  4. Product quality assurance:

  Secondary pollution risk: Will the filter medium or degassing equipment components themselves shed particles and contaminate the aluminum liquid?

  Temperature control: Is the temperature drop of the aluminum liquid controllable during the treatment process? Avoid affecting the subsequent casting process.

  Process traceability: Can the equipment provide records and monitoring of key process parameters (such as gas flow, rotor speed, pressure difference, processing time, etc)

  As a professional manufacturer of alumina ceramic filter plates and aluminum liquid degassing equipment, we deeply understand these pain points and are committed to providing efficient and reliable solutions that meet the core needs of aluminum plants:

  1. Improve purification efficiency and stability:

  *Advanced ceramic filter plate technology:

  Gradient pore structure design: Our alumina ceramic filter plates adopt a unique gradient pore size design (such as 30/50/50ppi) to achieve efficient deep filtration, maximize the capture of inclusions of different sizes, and significantly improve the purity of the melt.

  High purity and excellent corrosion resistance: Selected high-purity raw materials (Al2O3 > 90%) and optimized sintering process ensure that the filter plate has excellent chemical stability and corrosion resistance in high-temperature aluminum liquid, avoids self-contamination of the melt, and ensures long-term stability of the filtering effect.

  Excellent thermal shock resistance: The special formula and structural design give the filter plate excellent thermal shock resistance, and it is not easy to crack when the temperature rises rapidly, which improves the service life and operational safety.

  * Efficient degassing equipment technology:

  Optimized rotor design: The use of fluid-dynamically optimized graphite or ceramic rotors (with impeller shape and opening design) produces small, uniform, and dispersed bubbles, thereby significantly increasing the gas-liquid contact area and bubble rising distance, and improving the dehydrogenation efficiency and alkali metal removal rate.

  Accurate gas control system: Equipped with high-precision flowmeters, pressure regulating valves, and automatic control systems to ensure correct and stable inert gas (N2/Ar) flow, avoid gas waste, and achieve the best degassing effect.

  Optimized degassing box design: The internal flow field is reasonably designed to ensure that the aluminum liquid is fully mixed and has sufficient residence time in the box, thereby improving the purification efficiency; the high-performance refractory material lining is used to resist the erosion of aluminum liquid and extend the service life.

  2. Reduce operating costs and improve economic benefits:

  * Extend the life of key components:

  High-durability filter plate: By improving material strength and optimizing microstructure (such as introducing reinforcement phase), our alumina ceramic filter plate has a longer service life, significantly reducing the consumable cost and replacement frequency per unit output, and reducing downtime.

  Long-life rotor and lining: The rotor is made of high-quality graphite or special ceramic materials, and the optimized degassing box lining material and structural design are used to greatly extend the life of key wearing parts, reduce spare parts consumption, and maintenance costs.

  Optimize energy and metal loss: Efficient gas utilization: The precise gas control system and optimized rotor design ensure that the consumption of inert gas is effectively reduced while achieving the same or even better degassing effect.

  Low stagnation design: The degassing box and filtration system design focuses on reducing the aluminum liquid retention, reducing metal loss, and minimizing cleaning difficulty.

  Insulation performance: Good equipment insulation design reduces the temperature drop of aluminum liquid during the treatment process and reduces the energy consumption of remelting.

  3. Ensure efficient production and convenient operation:

  * High throughput design:

  Provide filter plates and degassing units of various specifications and sizes to meet different processing throughput requirements from laboratory to large-scale industrial production.

  * Quick replacement and maintenance:

  Modular design: The degassing equipment adopts a modular design, and key components (such as rotor lifting mechanism, heater) are easy to disassemble and replace, shortening maintenance time.

  Convenient filter plate replacement system: Design an easy-to-operate filter box structure, with special tools, to achieve fast and safe replacement of filter plates.

  * Automation and intelligence:

  Integrated control system: The equipment is equipped with an advanced PLC/HMI control system to achieve accurate setting of process parameters, real-time monitoring, data recording and traceability, and facilitate quality management and process optimization.

  Remote monitoring and diagnosis (optional): Provide remote support options for fast fault diagnosis and maintenance guidance.

  Strengthen safety design: The equipment is equipped with complete safety protection measures (such as emergency stop, liquid level alarm, aluminum leakage detection, protective cover, etc.) to ensure the safety of operators.

  4. Ensure the quality of the final product:

  "Zero" pollution commitment: High-purity, high-stability alumina ceramic filter plates and carefully designed internal structures of degassing equipment minimize the risk of secondary pollution introduced by the equipment itself.

  Process stability guarantee: The high reliability of the equipment and the precise controllability of process parameters are the basis for ensuring high consistency of product quality between batches.

  Temperature stability: Effective insulation measures and (optional) heating systems help maintain the stability of aluminum liquid processing temperature.

  We are well aware that technological development is endless. To continue to meet and exceed customer expectations, we are committed to:

  Material R&D innovation: Continuously explore higher-performance ceramic composite materials and more durable graphite/ceramic rotor materials to pursue longer service life and better purification effects.

  Design optimization: Using CFD simulation and other means, continuously optimize the degassing box flow field, rotor structure, and filter plate pore distribution to pursue efficiency limits.

  Intelligent upgrade: Deepen the intelligence level of equipment, develop process optimization and predictive maintenance functions based on big data and artificial intelligence, and help customers achieve "smart smelting".