Aluminum Alloy Ingot Manufacturing Industry: . Outline of Manufacturing Processes

11.
Aluminum Alloy Ingot Manufacturing Industry

. Outline of Manufacturing Processes
I-1 Pretreatment process Turnings and can scraps being part of a raw material sometimes go through pretreatment of drying and roasting in a special facility in advance, in consideration of the operating environment, safety, etc., rather being injected into a melting furnace as they are. [1] Drying the turnings Turnings constitute a high ratio of the material used in the alloy industry. Some cutting oil attached to the turnings contains chlorine compound, and since the cutting oil tends to be incompletely combusted during drying time, dioxin is generated as an emission. The combination of rotary kiln drying furnace and a bag-filter type dust collector is common. Exhaust gas recombustion apparatus and rapid cooling apparatus are effective, and a cyclone type dust collector, etc. are sometimes attached to the front of bag filter type dust collectors. There is no special drying operation as a countermeasure against dioxin, but attention must be given to temperature control, leakage of exhaust gas, etc. [2] Coating removal roasting for can scrap Similarly to turnings, can scrap with coating is often roasted in a kiln to eliminate the problems in melting, and dioxin is generated in the exhaust gas caused during roasting because the coating contains chlorine compounds. Many facilities adopt a process in which the circulation gas through the kiln is reheated and excessive emission is released to air through a bag filter type dust collector. I-2 Melting process There are various kinds of melting furnaces, however, oil burner type reverberatory furnaces are the most common. If they are further classified, they are divided into melting furnaces with fore hearths (side-well, open-well) and closed furnaces (melting furnace without fore hearth). The former is a special furnace for melting aluminum scrap (use ratio in this field is about 70%). Since the scrap is generally small in size and thin-walled and aluminum itself is easily oxidized, the melting loss of raw material scrap is significant if it is directly put into the heating chamber, and is in contact with the flames of the oil burner. Thus, the scrap is put into the fore hearth and pressed into the molten metal, which is then passed from the heating chamber. [1] Exhaust gas treatment
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A hood is attached above the fore hearth of the melting furnace. Black smoke produced when scrap is put into the molten metal is absorbed into the hood, and is treated with a bag filter type dust collector. Since the countermeasure against the combustion system emission have been conventionally made in terms of height (K value regulation) of the exhaust port (chimney stack) mainly from the viewpoint of sulfur oxides, factories which started operations earlier, have no dust collectors, but an increasing number of factories are recently provided with them and also at the combustion system. Many factories collect the emission from the fore hearth systems and combustion systems collectively. [2] Situation of the Class I Designated Chemical Substances released a. Dioxin Melting of aluminum scrap containing organic chlorine compounds, etc. causes dioxin, which is released to air from the rear exhaust port after passing through the bag filter type dust collector. Measures for reducing releases include tightening the selection of aluminum scrap, high efficiency of the existing facilities, etc. complete education and training, etc. b. Others (Cr, Ni, Be, Mn) The above substances are used as alloying elements depending on the types of the manufacturing, and most of them are shipped out contained in products. A portion is released as aluminum dross (recycle), and collected dust (waste). I-3 Refining process Melted alloy undergoes refining through de-magnesium treatment, degassing, inclusion removal, etc. The removal of magnesium is a process essential and peculiar to secondary alloy manufacturing. De-magnesium treatment is a means of magnesium removal using the chemical reaction of magnesium and chlorine by blowing or spraying, or stirring chlorine gas, or flux mainly composed of chloride into the molten metal. From a global point of view, industrial technology of de-magnesium in place of chlorine gas and chloride has not yet been established. However, by increasing the contact area and time with chlorine gas and flux and increasing the temperature, etc. to enhance reaction efficiency, it is possible to theoretically reduce the usage of chlorine gas and flux. [1] Exhaust gas treatment [2] Situation of the Class I Designated Chemical Substances released Basically the same as in (2) Melting process.
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3. Aluminum alloy manufacturing process drawing

*What is flux?
Exhaust gas (released to air)
The main components of flux used for aluminium alloy production are chlorides and fluorides, such as NaCl, KCl, AlF3, etc., however, flux containing the ClassDesignated Chemical Substances is not used. Its purpose is dross separation from the aluminum melt, molten metal refining, and removal of impurities such as magnesium.
Exhaust gas treatment
Collected dust (waste) Products (products shipped out)
Raw material/material Pretreatment process
Melting process
Refining process (Use of flux)
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Aluminum dross (recycle) Exhaust gas treatment Dust collected (waste) Chlorine ash (waste, partly recycled)
(Use of chlorine gas) Refining process Products (products shipped out)
Exhaust gas treatment
Exhaust gas (released to air) Waste alkaline solution (waste) Exhaust gas (released to air)
. Class I Designated Chemical Substances (Class I Substances)

related to the Industry
Cabinet Order No. Name of substance Chrome and trivalent chrome compounds Dioxin Nickel Beryllium and its compounds Manganese and its compounds
68 179 231 294 311
. Examples of Methods for Estimating Releases and Transfers

III-1 Manganese (Mn)
B
Amount released to air
Amount of Class I Substances handled
G
Melting Refining Product
E
Consumption amount
Aluminum dross
Collected dust
Amount of product
stock
Amount recycled
Industrial waste collector
Transfers D
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1. Amount handled A (amount used for current year)

Name of material (Content of Class I Substance) Al-10% Mn Mn 10% Metallic Mn Mn 100% 3000S BM Scrap Mn 0.8% Mn less than 1.0% n (Calculation not required) Annual amount used 65.0 T/year 0.50 T/year Amount of Class I Substances used Mn 6,500kg/year Mn 500kg/year *1 *1. Mn should be calculated because the total amount used is more than 1T/year, though it is less than 1T/year for a single material. 7,000 kg/year (+ from materials other than covered materials)
Amount handled A
2. Releases, transfers and the amount recycled ( B, C, and D) Estimate using emission factor (*2, refer to the separate table).
Raw material used AlMn
Metallic Mn
Type Release to air Dust transferred Dross recycled Total (B+C+D)
Emission factor*2 (g/Mn1kg) 0.00 0.00 0.03 0.03 15 15
AlMn
Metallic Mn
AlMn
Metallic Mn
B Amount of Class I Substances used (kg/year) Mn 6,500 500 Mn 6,500 500 Mn 6,500 500
axb Releases/Transfers (kg/year) (Total) 0.00 (0.00 kg/year = B) 0.00 0.20 (0.22 kg/year = D) 0.02 97.5 (105kg/year = C) 7.5 105.22 = 105 kg/year
3. Product g (the amount of Class I Substances contained in the products manufactured this year) Only the products made of the raw materials of Al-10% Mn and metal Mn which contain the Class I Substances, are targeted.
(Content of Class I Substances) Amount of production for this year Content of Class I Substances (total content)
Kind of product
AC4A.1 AC4B.1 AD3.1 3004
*3
(Mn 0.50%) (Mn 0.40%) (Mn 0.45%) (Mn 1.1%)
600 T/year 1,000 400 100 2,100 T/ year
Mn Mn Mn Mn
3,000 kg/year 4,000 1,800 1,100
Total (including Mn in the used raw materials other than the target materials )
9,900 kg/year ( = g)
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(*3 Indicated using the JIS code rather than customers code) A < g, the result cannot be used as it is. (g includes Mn from other than the target raw materials) 4. Consumption E and amount of product stock F (1) Product amount G = E + F Mass balance limited to the amount of target raw material handled is A = B + C + D + G. G = A (B + C + D) = 7,000 105 = 6,895 kg/year = E + F (2) Calculation of amounts of E and F [1] Content of the Class I Substances of the products included in the stock (f)*4
Kind of product AC4A.1 AC4B.1 AD3.1 3004 (Mn0.50%) (Mn0.40%) (Mn0.45%) (Mn1.1%) Total Product stock ( shows decreased stock) 10T 20T 30T 5T 15T Content of Class I Substance Mn 50kg 80 135 55 Mn 50kg(=f)
(*4 Increase and decrease in the amounts at the beginning and end of the fiscal year) [2] With use of the results up to now and E and F are obtained proportionally
Total content of Mn Amount of Mn in the target raw materials handled e f g 9,900 50 = 9,850 kg/year 50 (4 (2) item [1]) 9,900 kg/year (from item 3) G E F 6,895 kg/year (4 item (1))
E = 9,850/9,900 x 6,895 = 6,860.2 6,860 kg/year F = 50/9,900 x 6,895 = 34.8 35 kg/year 5. Summary
A: Amount handled 7,000 kg/year B: Amount released to the air 0.0 C: Amount of dross recycled 105 D: Amount of dust transferred 0.2 E: Consumption 6,860 kg/year F: Amount of product stock 35 kg/year G: Product amount 6,895 kg/year
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Note 1: Amounts to be reported are B and D. Note 2: B and D are in kg/year, and significant figure is two digits (up to the first decimal place)
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11.

Aluminum Alloy Ingot Manufacturing Industry

3. Aluminum alloy manufacturing process drawing

Exhaust gas (released to air)

Exhaust gas treatment

Collected dust (waste) Products (products shipped out)

Raw material/material Pretreatment process

Refining process (Use of flux)

(Use of chlorine gas) Refining process Products (products shipped out)

Exhaust gas treatment

. Class I Designated Chemical Substances (Class I Substances)

68 179 231 294 311

. Examples of Methods for Estimating Releases and Transfers

Amount of Class I Substances handled

Industrial waste collector

1. Amount handled A (amount used for current year)

Type Release to air Dust transferred Dross recycled Total (B+C+D)

Emission factor*2 (g/Mn1kg) 0.00 0.00 0.03 0.03 15 15

AC4A.1 AC4B.1 AD3.1 3004

(Mn 0.50%) (Mn 0.40%) (Mn 0.45%) (Mn 1.1%)

600 T/year 1,000 400 100 2,100 T/ year

3,000 kg/year 4,000 1,800 1,100

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