THE STATE OF THE ART "In-Line Aluminum Purification System"

Almex LARS®™ Liquid Aluminum Refining System cleans metal by removing physical (hydrogen gas inclusions,) chemicals (alkali metals) & metallurgical (alkali salts & Sludge inter-metallic) impurities. LARS operation is based on the proven principle of high-energy diffusion and chemically driven mass transfer. System utilizing rotating gas sparging device have been available in the industry for over 20 years but, only LARS offers gas preheating and other advanced features. LARS™ has over 75% degassing efficiency and over 99% inclusion removal efficiency.

	Liquid Aluminum Refining System - LARS®™ U.S. Patent No. 5,846,481.

 

With over 500 million lbs. of hard alloy processed over the past 7 years, LARS®™ is effective in making the following contributions to the bottom line of cast-house:

	Furnace pre-treatment eliminated
	Holding furnace eliminated
	No-need to have ball filter
	Pass Mil-2154 Class-AA inspections
	Pay back period of under 1 year

 

Summery of Advance Features:

Metallurgical sophistication:   In-Situ process gas preheating: gives superior degassing and inclusion capture Attrition [intense] Mixing of Melt & Bubbles: Controls vortexing and reduces "carry-over" Reactor Shape & Slope: Preventive Bubbles agglomeration and improve efficiency for same "residency time"   Thermal Stabilization:   Heater Surface Area: Large number (48) of small heaters 19mm [0.75" dia.] provide rapid temperature equalization  Intelligent PLC assisted thermal control with 6 thermocouples

Mechanical Easing:

 

	Rotor change over: in less than 12 minutes
	Dross Ports: Just the metal line [No access through roof is required]

Longevity and Life:

 

	Nitrogen Shrouding over Tiles and Heater Junction Boxes
	Silicon Carbide covered graphite components

Total Quality Assurance in Metal Treatment:

 

Mass flow alarms, Differential Temperature Alarms, Rotor RPM alarms

Environmental Safety:

 

	Noiseless & cool atmosphere around LARS reactor
	PLC & Mass flow meter assisted halogen control

Capacity Range and Foot Print:

 

	Hexagonal Reaction Chambers
	Numerous inlet-outlet orientations

LARS®™ Reactors are made in 5 different sizes ranging from flow rate of 10,000 pounds per hour to 150,000 pounds per hour. Depending on each application's unique requirement, the footprint and the port locations (i.e. inlet, outlet, skimming and draining) are custom designed. As designers, we believe this is the best way to provide value and convenience around your casting pit and furnace.

 

Metallurgical Sophistication:

How Gas is preheated? Gas Preheating is achieved by making the gas flow through the passageway formed by the helical groove [machined on the O.D. of the graphite shaft] and the inner wall of the graphite cylinder. Gas captures heat from graphite cylinder, which is immersed in the molten aluminum. The gas flow path is extended 30 times its length. Preheating of gas help retain fine bubble size. [i.e. prevent the undesirable growth in the bubble] after gas contacts molten aluminum.

 

How Vortexing is controlled? Vortexing is controlled by generating cross and reverse velocity vectors in the melt. Rotational metal velocity in made to increase [at point P1] and decrease [at point P2] generating intimate mixing of liquid at points Q1, Q2, Q3 etc. The resultant velocity vector has no vortexing tendency. Absence of vortexing prevents reentry of dross in upper layer of melt and reduces bubble carryover at the lower [exit] end of the reactor.

 

How bubble coalescence is minimized?  Reactor Volume is increase from bottom to top in a controlled manner to accommodate increase in gas bubble volume [resulting from reduced metallostatic pressure.] This prevents bubble coalescence and keeps gas surface area higher for longer duration of gas' total residence time in the reactor.

 

Advantage over compatible in-line systems:

Guaranteed Technological Superiority:

 

	Degassing efficiency above 68%
	Inclusion removal to pass 60 ppi CFF
	Alkali removal- Na, Ca, Li<1 ppm output
	Alkali salt removal- to pass sonic Mil 2154 AA testing

Rapid return on investment:

 

Pay back period of under 1 year

Elimination of furnace fluxing requirement:

Many of our customers (including hard-alloy manufactures) do not use a holding furnace at all. Pretreatment in the melter is not required either (except for canstock).

The table given below illustrates model number, flow rate capacity and size for each unit.

	LARS model	lbs/hour	tons/hour	inches	cms
	RL-3	10,000 lbs/hr	5	48 x 54	122 x 138	1 rotor, no halogen
	RL-12	30,000 lbs/hr	15	50 x 80	127 x 204	2 rotors
	RL-16	60,000 lbs/hr	30	60 x 90	152 x 229	2 rotors
	RL-36	90,000 lbs/hr	45	72 x 102	183 x 259	2 rotors
	RL-42	150,000 lbs/hr	75	66 x 144	168 x 366	3 rotors, "L" Shape available

The table given below lists reaction chamber volume, gas and power requirements for each model.

	LARS model	Approximate Reactor Capacity [Aluminum weight]		Heater Connection Requirement [kw]	Argon Process Gas Consumption  [during casting]  (39 scfh=1NM3)	N2 Shroud Gas Consumption [continuous requirement]
		lbs	kgs.
	RL-3	1,000	450	30 kw	75 cfh @ 40 psig	45 cfh @ 30 psig
	RL-12	2,400	1,100	45 kw	150	90 cfh
	RL-16	4,200	1,900	60 kw	180	90 chf
	RL-36	6,000	2,700	60 kw	210	90 chf
	RL-42	8,100	3,700	90 kw	270	135 chf

 

Click here for LARS Flash Presentation

 

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