5460 Horning Road
Pittsburgh, PA 15236
Phone: 412-653-3500
Fax: 412-653-2253

Aluminum Industry

Aluminum Industry

Bloom Engineering Company utilizes its vast application experience and tailored flame characteristics to provide combustion solutions for the aluminum industry. Our burners and controls are engineered to optimize furnace efficiency and product quality. Additionally, Bloom burners and controls are designed to provide low NOx emissions along with maximizing efficiency based on each customer's application. Bloom offers many advantages including the ability to provide a flame to suit the application, ability to provide spark ignition, low noise burners, and excellent support and customer satisfaction. Bloom provides rugged burner construction to minimize maintenance costs.

Aluminum Industry Case Studies
The Next Generation Of Combustion Technology For Aluminum Melting

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Eliminating the Drawbacks of Regenerative Burner Systems

Original Source : TMS Organization (www.tms.org)

A User's Experience With Retrofitting An Aluminum Melting Furnace With Low NOX Regenerative Burners

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Prepared by:Charles R. Lied, Bloom Engineering Company, Inc. and Robert W. Klein, Vulcan Aluminum

CS0103 Low NOx Radiant Tube retrofit for Aluminum Aging Furnace

CS0103 Low NOx radiant tube burner for Aluminum aging furnace

To meet a more stringent emissions limit, Bloom engineered a radiant tube burner that required minimal modifications to the existing system.

CS0108 Regenerative System with Oxygen Lance

CS0108 Regenerative System with Oxygen Lance

Equipping the regenerative system on an aluminum melting furnace with an oxygen lance allowed for safe thermal oxidation of volatiles from dirty scrap with minimal alterations to the rest of the system.

CS0109 Regenerative System with a Common Manifold

CS0109 Regenerative System with a Common Manifold

In order to fit a new combustion system into a small physical space on and aluminum melting furnace, Bloom designed a unique regenerative system with a common manifold for air and exhaust shared between three burners.

    Frequently Asked Questions

      Question: How can I increase my furnace efficiency?

      Answer:

      A number of variables must be looked at. Burner air preheat is one – a cold air burner is less efficient than a hot air burner. Regenerative burners offer the highest air preheats, often within 300°F of the furnace temperature. Recuperative burners offer lower air preheats.

       

      Burner placement on the furnace is another – appropriately positioned burners help to maximize heat transfer to metal and minimize heat loss out the flue.

      Furnace pressure control also affects efficiency.

      A thorough analysis of each furnace design must be done to optimize its efficiency.


      Question: What is typically required for maintenance on a cold air system?

      Answer:

      For a melter, check the port and baffle for pluggage due to metal splash. For all furnaces, verify that safety systems (shut off valves etc.) are functioning properly. Periodic lubrication of valves should be performed per manufacturer’s specifications. Check that air to fuel ratio is within operating specifications. Check flame safety system is operating properly per manufacturer’s specifications.


      Question: What is a regenerative system?

      Answer:

      A regenerative system is comprised of one or more pairs of burners which alternately fire and exhaust furnace gases and the accompanying control system. The burners, when firing, act much like a recuperative burner with extremely high air preheat temperatures. When exhausting, the burner air and gas flows are shut off and a suction fan pulls exhaust gases through the burner and through the attached media case which acts as a heat retention device. The media within the case then acts as a heat exchanger in the firing cycle, providing the high air preheats. Regenerative burners are available with lower NOx emissions than comparable cold air burners; overall NOx production can be reduced significantly through reduced fuel used due to increased efficiency (from the 40% range for cold air firing to the 70-80% range for regenerative firing).


      Question: What is Bloom's recommended method of air to fuel control?

      Answer:

      Bloom recommends an electronically linked valve arrangement to maintain low excess air operation throughout the burner operating range.


      Melting Furnaces

        Bloom offers combustion and controls solutions for a wide variety of aluminum melting furnaces. Bloom has significant experience with both round top charged melters and rectangular melters (sidewell and direct charge).

        The optimization of each furnace is achieved through proper burner selection and placement in the furnace. Bloom combustion systems offer excellent melt rates, reduced fuel consumption and dross formation.

        Bloom’s patented baffle and rugged burner design contribute to reduced maintenance costs. Bloom leads the industry in development and application of low NOx emissions burners. There is no compromise of high CO generation for low NOx emissions with our burner designs.

        Bloom offers a complete array of process control systems {link to controls}, ranging from complete systems for our cutting edge regenerative systems to pre-piped, pre-wired pipe racks to combustion control for pressure balance or mass flow control depending on customers needs.

        Our highly experienced sales staff and service staff are renowned throughout the providing combustion solutions, not just combustion hardware and services.


        Additional Melting Furnace Information:
        Holding Furnaces & Crucible Heating Stations
        Holding Furnaces:

        Bloom Engineering combustion systems provide consistent control of bath temperature uniformity. Bloom can simultaneously reduce fuel consumption and improve bath temperature uniformity through the careful application of appropriate burners in optimized furnace locations. Bloom’s engineered burner designs provide the low turndown firing rates required to offset furnace losses when holding hot molten aluminum.

        Additional Holding Furnaces Information:

        Crucible Heating Stations:

        Bloom offers prepackaged crucible heating stations. These systems include a pre-piped gas train, startup panel, and process temperature controls tailored to the customer’s requirements.

         

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        Homogenizing Furnaces

          Bloom offers both direct and indirect fired burners for application to homogenizing furnaces.

          For products that require a non-oxidizing furnace atmosphere to maintain product quality, Bloom offers indirect fired burners. Years of experience and extensive laboratory development of our radiant tube burners with strong emphasis on tube temperature uniformity and NOx reduction yields optimum furnace performance.

          Products that are not affected by products of combustion utilize direct-fired burners in the furnace. Furnace efficiency is increased for a direct-fired furnace when compared to an indirect fired furnace due to a decrease in flue gas losses and faster heat up of the recirculation gases at the start of the cycle in a direct-fired furnace. Bloom’s burner and port designs provide excellent burner stability despite the quenching effect of the high recirculation rates within the furnace. Bloom also offers the option of pulse fired (high/low/off) or high turndown burners for temperature control.

           
          Annealing Furnaces

            Bloom offers combustion solutions for annealing furnaces. Controlled combustion permits the recrystallization of metals to resolve residual strain hardening due to cold working. Bloom’s indirect fired burners prevent quality problems that can be caused by water condensation on product. Bloom has devoted significant resources to developing radiant tubes with uniform temperatures and low NOx. High turndown burners are available for exceptional furnace temperature control through the range of furnace temperature cycles.

            Filterbox Applications

              Bloom burners offer a number of advantages for filter box applications. We offer a low noise natural gas burner that is easily ignited with a pilot or spark igniter. The burner is stable at stoichiometric ratio as well as excess air throughout its operating range. The flame burns out in the tube for more efficient heating. The temperature distribution is at the bottom of the tube, but there is no flame out the tube.

              We also offer a high thermal release (HTR) burner with excellent stability that uses high radiation from the port block to transfer heat to the process.

              The HTR burner is available with spark ignition or pilot ignition.