The ingot casting line applies to recycled aluminum recovery. 
Working Principle and Technology of the Production Line
Based on the composite technology of "bottom-pour continuous casting + electromagnetic stirring directional solidification", waste aluminum (containing over 95% can materials) is heated to 720±15ºC in a dual-frequency induction melting furnace. The molten aluminum is injected into the crystallizer through a PID intelligent flow control system (accuracy ±0.5L/min). The crystallizer adopts a beryllium bronze inner wall with spiral water channel design, ensuring the molten aluminum crystallizes into a shell at a speed of 0.8-1.2m/min. The billet drawing system is equipped with servo motor synchronous control technology, achieving speed stability of ±0.05mm/s to effectively reduce crack defects. The secondary cooling zone uses zoned water mist cooling technology, with 8 independent temperature control modules regulating the cooling rate at 5-15ºC/s to ensure columnar crystal structure accounts for ≥85%. The whole line has an automation rate of 92%, processing 120-180 tons of waste aluminum daily with a yield exceeding 98.5%.
Parameter Table
| Length of ingot casting line |
Number of molds |
Number of molds |
Number of molds6.5KG10KG15KG |
Melting time is 40 - 90 minutes per batch |
Casting speed is 4 - 6 meters per minute (adjustable) |
Motor power of ingot casting line |
| 4M |
48PCs |
300Kg |
2.2KW |
| 5M |
60Pcs |
500kg |
3KW |
| 6M |
72PCs |
3W |
| 8M |
96Pcs |
1Ton |
4KW |
| 9M |
108PCs |
|
4KW |
| 11M |
132Pcs |
2Ton |
4KW |
| 13M |
156Pcs |
5KW |
| 17M |
206Pcs |
3Ton |
5KW |
| 21M-26M |
245-314PCs |
6KW |
Core Equipment and Systems
- Melting Unit: Adopts dual-frequency induction melting furnace (500Hz+3000Hz composite frequency), combined with supersonic gas spray gun (thermal efficiency ≥88%), which increases melting speed of light materials like cans by 30%. The intelligent feeding system achieves ±0.3kg feeding accuracy via laser ranging and weight sensors, and real-time monitoring of molten aluminum composition by a spectrometer ensures high-quality ingots with Si≤0.2% and Fe≤0.35%.
- Cooling System: Innovatively applies a plate heat exchanger + cooling tower closed-loop system, with 96% cooling water recycling rate. The crystallizer cooling water inlet temperature is controlled at 25±3ºC, outlet temperature rise ≤12ºC, and infrared thermal imaging monitors the crystallizer surface temperature to ensure temperature difference ≤15ºC, reducing defects like cold shuts and shrinkage pores.
- Customized Solutions: Provides modular design, with production line length customizable between 12-28m, ingot mold quantity supporting 30-120 configurations, and producing 6kg-25kg ingots of different specifications to meet demands of die-casting, profiles, forging and other industries.
Production Advantages and Effects
- Energy Consumption Data: Power consumption per ton of aluminum ≤480kWh (industry average 550-620kWh), gas consumption ≤85m³ (industry average 100-120m³), with comprehensive energy saving rate over 18%.
- Quality Stability: Chemical composition fluctuation of ingots ≤±0.03%, physical properties meeting GB/T 1196-2017 standards, and internal flaw detection qualification rate ≥99.2%.
- Typical Customer Cases:
- A regenerative aluminum enterprise in Zhejiang: After adopting the line, labor cost decreased by 40%, defect rate dropped from 3.2% to 0.8%, saving over 3 million yuan annually.
- A die-casting factory in Guangdong: Using customized small-specification ingots (6kg/block), melting efficiency increased by 22%, and mold life extended by 15%.
Audited Supplier 
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