This Is How Factories Recycle Billions Of Tons Of Aluminum. Copper Extrusion Press Machine

aluminum recycling is a crucial component in the pursuit of a perfect circular flow economy it enables the transformation of used beverage cans into new beverage cans old cars into new cars and discarded window frames into fresh window frames each year a significant amount of aluminum waste is generated with approximately 36 000 tons of old aluminum window frames contributing to this growing mountain of discarded material this waste arises not only from building Renovations but also from The increased use of lightweight aluminum in the automotive and electronics Industries consequently there is a pressing need to address this Challenge and find effective methods to recycle aluminum efficiently the recycling process begins with the use of shears and a conventional Shredder to cut up the frames magnetic separators and an eddy current separator are then employed to extract metal screws hinges as well as any rubber wood and plastic components the resulting Shredder waste consists predominantly of aluminum but also contains remnants of aluminum that are unsuitable for window frame Alloys such as old aluminum window handles and rivets to address this issue a special x-ray machine is utilized to sort out these unsuitable materials unlike the first Shredder the second Shredder phase involves re-shredding and sieving the material optimizing it for the subsequent x-ray transmission machine the coarse aluminum parts are meticulously cut into chips measuring between four to six centimeters using specially hardened steel blades due to aluminum's abrasive nature these blades are necessary to withstand the wear caused by this material Gall Megan's two Shear shredders have a combined capacity of producing over 100 tons of aluminum chips per day subsequently a screening unit is employed to filter out smaller particles resulting in a material flow that possesses nearly homogeneous geometry facilitating the detection of individual fragments in the subsequent x-ray machine the individual parts are examined by powerful x-ray sources with an energy of 160 kiloelectron volts to ensure worker safety from radiation exposure the unit is covered with a robust lead Shield the aluminum chips are spread evenly on a wide conveyor belt with x-ray lamps inspecting them from above simultaneously an x-ray detector beneath the belt measures the incoming radiation based on this data a computer is able to differentiate between various Alloys and operates a strip fitted with nearly 400 pressurized air Jets these air Jets blow off the unsuitable material at a rate of 1000 parts per second this groundbreaking technology enables the separation of unsuitable heavy metal alloys which typically constitute about two to four percent of the material redirecting them to other material Cycles the majority of the recycled material consists of Highly valuable aluminum Alloys such as 6060 and 6063 which have been extensively used for window frame production for several decades Gall Megan's Innovative Shredder and sorting technology allow for the recycling of thirty thousand tons of this high quality material annually which is then easily transported to customers like the Hydro Aluminum Company Hydro Aluminum located in the nearby town of boxit produces approximately 90 000 tons of aluminum billets per year these billets serve as a vital primary material for pressing plants where they are used to manufacture aluminum profiles including those for window frames the recycled material in the form of aluminum billets is melted down at hydro's plant in cockpits through a specialized process Extrusion billets are produced measuring approximately 25 centimeters in length these Extrusion billets already composed of recycled aluminum and with minimal primary aluminum content are crucial for minimizing the environmental impact of the entire production process when considering the entire production cycle even on this relatively small scale the recycling project at Gall Megan results in a remarkable reduction of over 200 000 tons of CO2 emissions annually the German environment Ministry recognizes this sorting technology as a key Innovation for the metal industry as it strives for enhanced Environmental Protection and resource conservation the altiser aluminum company based in Saudi Arabia is a prominent manufacturer of aluminum Extrusion profiles in the Mena region as part of their efforts to increase their supply capacity altisier recently placed an order with SMS group a leading provider of machinery and equipment for two new eight-inch aluminum Extrusion presses with a maximum press force of 27 Mega Newtons all six of the Extrusion presses currently operated by altiser are supplied by SMS group the company has been relying on SMS group for their machines and services for the past 22 years emphasizing the importance of quality and reliable equipment the production process at altisier's plant begins with the separation and cleaning of aluminum billets on the delivery table the billets then pass through a gas-fired continuous furnace equipped with an energy efficient heat recovery system after preheating the billets are cut to the required length based on calculations considering the finished length degree of deformation and scrap rate to achieve precise temperature control the billets undergo induction taper Heating the leading end of the Billet is warmer than the tail end enabling isothermal or isobaric Extrusion using KDX technology software this advanced technology increases production efficiency by up to 10 percent to prevent the dummy block from sticking the tail end of the Billet is coated with soot the centerpiece of the plant is the Extrusion press manufactured in Germany and equipped with patented Technologies the Press features a front loading design allowing for compactness short dead cycle times an optimized Billet clamping and air evacuation the plant's efficiency is further enhanced by a Precision linear guide ensuring high quality product output once the Extrusion process is completed the profiles are cooled using either air or water Mist depending on the profile type or alloy a double polar system synchronizes the extraction of profiles to ensure uninterrupted Manufacturing profiles are then cut using a flying saw and undergo further cooling stretching and cropping of the leading and tail ends the profiles are delivered to a manual discharging station through a conveyor system subsequently the profiles enter an aging furnace for metallurgical microstructure adjustment surface treatment and final finishing are carried out before the profiles are ready for shipping throughout the entire production process quality control is insured through the use of the pcast.net system from SMS group the system provides comprehensive process control and monitoring supported by intuitive and user-friendly human machine interface masks the Extrusion press is equipped with an automatic die cursor change system enabling quick profile modifications in under 30 seconds altiser's decision to choose Extrusion presses from SMS group the world's market leader has proven to be beneficial with their expansion adding presses 5 and 6 to their production line altiser continues to rely on SMS group for their high quality machines and excellent service including maintenance and support SMS group a leading engineering and plant construction company provides innovative solutions for aluminum plants they offer state-of-the-art Technologies and equipment to optimize the efficiency productivity and sustainability of aluminum production SMS group Solutions Encompass the entire process chain of aluminum production including smelting casting rolling and finishing they provide Advanced smelting Technologies like pre-baked anode cells or energy efficient direct current DC technology ensuring cost-effective and environmentally friendly operations additionally SMS groups casting Technologies enable the production of various aluminum products such as sheets plates extrusions and profiles the rolling Mills facilitate the shaping and processing of aluminum into desired forms while their finishing Technologies ensure the highest quality surface treatment in coding the cswa aluminum tandem Cold Mill developed by SMS group is a cutting-edge technology used in aluminum plants for efficient and high quality Cold Rolling of aluminum coils with its Advanced features and capabilities it has revolutionized the aluminum industry enabling manufacturers to produce Superior Aluminum Products with precision and consistency the cswa aluminum tandem Cold Mill is designed specifically for processing aluminum coils in a continuous and automated manner it consists of a series of rolling stands arranged in a tandem configuration where the aluminum coils undergo multiple rolling passes to achieve the desired thickness and surface quality the mill operates at high speeds ensuring rapid production and improved productivity foreign one of the key advantages of the cswa aluminum tandem Cold Mill is its ability to handle a wide range of aluminum alloys whether it's standard Alloys such as 1000 series or 3000 Series or more specialized Alloys like Aerospace grade or Automotive grade aluminum this Mill can effectively process them all this versatility allows aluminum plants to cater to various industry requirements and produce tailored products for different applications the mill incorporates Advanced Automation and control systems which ensure precise and consistent rolling parameters throughout the production process the automated controls regulate the tension speed and force applied to the aluminum coils resulting in uniform thickness and surface finish this level of control minimizes variations and defects in the rolled coils ensuring high quality output another noteworthy feature of the cswa aluminum tandem Cold Mill is its efficient energy utilization the mill is equipped with state-of-the-art Drive systems and optimized rolling processes that reduce energy consumption while maintaining High productivity this not only lowers operational costs for aluminum plants but also contributes to a more sustainable and environmentally friendly manufacturing process in terms of Maintenance and upkeep the cswa aluminum tandem Cold Mill is designed for ease of operation and maintenance it incorporates Advanced Diagnostic systems that monitor the performance of critical components and provide real-time feedback to operators this proactive approach enables timely maintenance interventions minimizing downtime and maximizing Mill availability furthermore SMS group offers comprehensive support and services for the cswa aluminum tandem Cold Mill their team of experts provides installation commissioning and training to ensure seamless integration and optimal utilization of the mill additionally they offer ongoing technical assistance spare parts supply and performance optimization to maximize the Mill's longevity and efficiency the Extrusion press sarback manufactured by the SMS group is a cutting-edge machine designed for forging and pressing applications with its advanced technology and robust construction the sarback Extrusion press offers high performance capabilities delivering exceptional results in various Industries the Extrusion process is widely used in manufacturing to create complex shapes and components with Superior strength and precision the sarbach Press is specifically engineered to excel in this process providing efficient and reliable performance its versatility allows it to handle a wide range of materials including aluminum copper steel and titanium alloys one of the key features of the sarback Extrusion press is its state-of-the-art control system equipped with Advanced Automation and monitoring capabilities the Press ensures precise control over the Extrusion process parameters such as temperature pressure and speed this level of control guarantees consistent product quality and minimizes material waste enhancing overall operational efficiency the SMS group a renowned leader in the field of plant and Machinery engineering has incorporated Innovative design elements into the sarback Extrusion press its robust frame and hydraulic system Ensure High rigidity and stability during operation enabling the press to withstand the intense forces involved in the Extrusion process this durability translates into prolonged machine life and reduced maintenance requirements resulting in increased productivity and cost effectiveness furthermore the sarback Press offers flexibility in terms of production capacity it is available in different tonnage options allowing manufacturers to choose the press size that best suits their specific production needs the modular design of the press also facilitates easy customization and adaptation to evolving requirements ensuring long-term usability and versatility in addition to its technical prowess the sarback Extrusion press prioritizes operator safety and user-friendly operation the Press is equipped with Comprehensive safety features including Advanced control systems safety interlocks and emergency stop mechanisms these features guarantee a secure working environment and minimize the risk of accidents or injuries the sarback Press is backed by the expertise and support of the SMS group renowned for its commitment to customer satisfaction their comprehensive service network ensures timely assistance and maintenance minimizing downtime and maximizing productivity

Channel: iMachines TV

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Length: 19min 17sec (1157 seconds)

Published: Thu May 18 2023