Fire risk problem of aluminum foundry

During various modes of operation of the melting furnace, a large amount of aerosol particles consisting mainly of amorphous carbon is generated irregularly depending on the current state (especially during the loading of the return material), accompanied by the development of significant amounts of volatile organic compounds and methane. The resulting mixture of organic substances is not quantitatively eliminated in the afterburner chamber of the melting furnace. The VOC mass flow remains almost unchanged and only the methane mass flow decreases. The mass flux of aerosol particles, on the other hand, increases after passing through the afterburner chamber, with particles of aluminium metal contributing significantly to this increase. The aerosol particles trapped on the textile filter of the melting furnace are thus composed of particles of amorphous carbon and particles of inorganic origin (metallic aluminium and limestone). The structure and surface properties of the carbon particles pose a significant risk of textile filter ignition. From the measurement results obtained, the following solution to the hazardous condition of the plant can be found: (a) a change in the existing technology, for example: changing the design of the part of the melting furnace into which the return material is fed; changing the heat input and the mode of the gas burner and fan in this part of the furnace; a significant reduction of the flue gas flow in the A-gauge and afterburner chamber or change of machining emulsion; (b) the installation of an additional gas burner in the newly installed afterburner chamber, to which the flue gases from the part of the melting furnace into which the return material is fed would be discharged in the existing return material inlet mode.