How to Save Money When Buying Low-Temperature Pyrolysis Furnace

Aluminium die-casting operations are notoriously energy intensive. In fact, approximately 25% of the total cost of die cast parts is associated with energy consumption. Identifying and tackling energy ‘hot spots’ can therefore make a huge difference to overall cost-efficiency and profitability.

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Which is exactly why this guide takes a closer look at melting and transferring liquid aluminium. Energy intensive processes are by no means limited to this specific area, but a substantial amount of energy is required to melt scrap and ingots and keep the molten metal at the right temperature. So much so that evidence suggests the melt-shop alone can account for as much as 77% of the overall energy consumption in a die casting foundry.

To help you make savings that could make a big difference to your business - here are 5 things to consider when it comes to cutting energy consumption and carbon emissions in your aluminium foundry:

Most foundry equipment, including melting and dosing furnaces, now leaves the production line Industry 4.0 ready meaning machines are pre-equipped to collect and provide informative data on performance. For legacy equipment that doesn’t fall into the ‘4.0 ready’ category, so-called gateway technology exists - Norican’s NoriGate solution being one example - which can be retrofitted to any machine in order to leverage the same information. A data-driven view of the entire die casting line is now possible and practical to achieve.

Crucially data ready to be unlocked in this way – and, with tools like Monitizer, displayed and analysed in real time - includes production KPIs which can be matched against energy consumed in order to identify potential issues and/or technology not performing to its full efficiency potential.

2) Check your shaft fill is optimized

Shaft melting furnaces, particularly with regards aluminium, are widely regarded as the most energy efficient furnace on the market. This is because they combine preheating, heating and liquefaction in one unit and function to a favorable counter flow principle: exhaust gas from melted charge material at the bottom of the shaft gradually heating up cold raw material as it travels down from being loaded at the top, minimizing the time it needs to spend at (energy-intense) high temperature to complete the melting process.

Quick fact: With an energy consumption level of 540kWh/t, a StrikoMelter shaft melting furnaces with an annual melting capacity of about 14,000 t creates 860 t less CO2 emissions every year than the melting furnace technology otherwise available on the European market.

But even shaft furnaces can be made more efficient. Particularly by looking at shaft fill and material distribution in the shaft. Wasted space is wasted energy. Here are 3 things you might want to look at to make sure your fill is as efficient as possible:

Pyrolysis furnace is a very popular machine used in the waste treatment and recycling industry to recycle tires, plastics and sludge into valuable fuel oil. To buy such a pyrolysis furnace, you need to prepare enough funds. But the detailed cost of a pyrolysis furnace can vary depending on factors such as machines type, capacity and configuration. DOING pyrolysis furnaces are divided into three types according to the form of equipment: batch type, semi-continuous type and fully continuous type.

DOING pyrolysis furnace three types

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For batch type pyrolysis furnace, the capacity is 100KG/500KG/1TPD/2TPD/5TPD/10TPD/12TPD/15TPD/18TPD/20TPD. The price is from $ to $. The batch type pyrolysis furnace can be fed with complete raw materials and needs to be shut down continuously to input raw materials and output products, and repeatedly cool and heat, completing a pyrolysis cycle in an average of 22 hours.

DOING batch type pyrolysis furnace details

For semi-continuous pyrolysis furnace, the capacity is 5TPD/10TPD/12TPD/15TPD/18TPD/20TPD. The price is from $ to $. The semi-continuous furnace needs to be fed with crushed raw materials, which are transported to the reactor through a conveyor screw. While feeding, slag is discharged, which effectively saves cooling time and achieves the production efficiency of two days and three furnaces. Compared with batch type pyrolysis furnace, the operation is more automated.

DOING semi-continuous type pyrolysis furnace for sale

For fully-continuous pyrolysis furnace, the capacity is 15TPD/20TPD/30TPD/40TPD/50TPD. The raw material need to be strict, under 5mm rubber powder, so expect the tyre further process line, only the fully continuous pyrolysis furnace price need about 500,000$ to 1,100,000$. The fully continuous pyrolysis furnace adopts PLC control operation, with a high degree of automation, continuous feeding, continuous oil discharge, and continuous slag discharge. It runs 24 hours a day and can run continuously for 30-40 days.

DOING fully-continuous pyrolysis furance

The above is an approximate cost. The specific price of the pyrolysis furnace also depends on the specific configuration: raw material pretreatment device, environmental protection device, safety device, etc.; the material of the reactor: Q245R, Q345R, stainless steel; the type of raw material is determined: the plastic pyrolysis furnace is necessary to match equipment to remove the wax produced during the pyrolysis process; the oil sludge pyrolysis furnace is necessary to match equipment to prevent sludge from sticking on the pyrolysis furnace.

DOING environmental protection device

DOING pyrolysis furnace technology is very mature in whole market, which have been exported to more than 100 countries. Every day we have clients gave us good feedback, also almost every week we have clients come for visiting. If you have time, you are welcome to make a video appointment or come to visit our office and factory in person. Welcome your coming!

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