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In the aluminum and aluminum alloy casting production line, aluminum liquid filtration, purification, and degassing (usually referred to as rotary jet degassing) are key links that ensure the performance of the final product and improve the yield rate. The core issues that aluminum plants pay great attention to in this process are directly related to their production costs, efficiency, and market competitiveness.

1. Purification efficiency and stability:
Inclusion removal: Can all kinds of non-metallic inclusions (oxides, flux, furnace lining materials, etc.) be efficiently removed to prevent them from becoming the source of product cracks or reducing performance

Hydrogen removal effect: Can the dissolved hydrogen content be quickly and stably reduced to the target level (usually less than 0.15ml/100g Al or even lower) to prevent the casting from producing pores and looseness

Alkali metal control: Can harmful alkali metal elements such as sodium, lithium, and calcium be effectively removed to prevent hot cracking and processing brittleness

Process stability: Is the equipment performance stable and reliable, and is the treatment effect small between batches to ensure consistent product quality

2. Operating cost and economic benefits:
Equipment and consumables life: Is the ceramic foam filter durable, and how often is it replaced? How long is the life of key components such as degassing rotors and degassing box linings? Frequent replacement leads to huge downtime losses.

Energy consumption: Is the nitrogen/argon consumption and power consumption of degassing equipment (especially large equipment) optimized?

Metal loss: Does the processing process cause excessive aluminum liquid to oxidize or remain in the equipment (such as filter plate tanks, degassing boxes), causing waste?

Maintenance cost: Is the equipment easy to maintain, and is the downtime associated with maintenance too long?

3. Production efficiency and ease of operation:
Processing flux: Can the equipment meet the increasing production line speed and large tonnage processing needs?

Online time: Is the alumina ceramic foam filter replacement and degassing equipment maintenance quick and convenient, minimizing production line downtime?

Automation and integration: Is the equipment easy to integrate with the existing production line automation system? Do you know if the operation interface is friendly?

Safety: How to ensure the safety of the equipment in the high-temperature aluminum liquid operation environment?

4. Product quality assurance:
Secondary pollution risk: Will the filter medium or degassing equipment components themselves shed particles and contaminate the aluminum liquid?

Temperature control: Is the temperature drop of the aluminum liquid controllable during the treatment process? Avoid affecting the subsequent casting process.

Process traceability: Can the equipment provide records and monitoring of key process parameters (such as gas flow, rotor speed, pressure difference, processing time, etc)

As a professional manufacturer of alumina ceramic filter plates and aluminum liquid degassing equipment, we deeply understand these pain points and are committed to providing efficient and reliable solutions that meet the core needs of aluminum plants:

1. Improve purification efficiency and stability:
*Advanced ceramic filter plate technology:

Gradient pore structure design: Our alumina ceramic filter plates adopt a unique gradient pore size design (such as 30/50/50ppi) to achieve efficient deep filtration, maximize the capture of inclusions of different sizes, and significantly improve the purity of the melt.

High purity and excellent corrosion resistance: Selected high-purity raw materials (Al2O3 > 90%) and optimized sintering process ensure that the filter plate has excellent chemical stability and corrosion resistance in high-temperature aluminum liquid, avoids self-contamination of the melt, and ensures long-term stability of the filtering effect.

Excellent thermal shock resistance: The special formula and structural design give the filter plate excellent thermal shock resistance, and it is not easy to crack when the temperature rises rapidly, which improves the service life and operational safety.

* Efficient degassing equipment technology:

Optimized rotor design: The use of fluid-dynamically optimized graphite or ceramic rotors (with impeller shape and opening design) produces small, uniform, and dispersed bubbles, thereby significantly increasing the gas-liquid contact area and bubble rising distance, and improving the dehydrogenation efficiency and alkali metal removal rate.

Accurate gas control system: Equipped with high-precision flowmeters, pressure regulating valves, and automatic control systems to ensure correct and stable inert gas (N2/Ar) flow, avoid gas waste, and achieve the best degassing effect.

Optimized degassing box design: The internal flow field is reasonably designed to ensure that the aluminum liquid is fully mixed and has sufficient residence time in the box, thereby improving the purification efficiency; the high-performance refractory material lining is used to resist the erosion of aluminum liquid and extend the service life.

2. Reduce operating costs and improve economic benefits:
* Extend the life of key components:

High-durability filter plate: By improving material strength and optimizing microstructure (such as introducing reinforcement phase), our alumina ceramic filter plate has a longer service life, significantly reducing the consumable cost and replacement frequency per unit output, and reducing downtime.

Long-life rotor and lining: The rotor is made of high-quality graphite or special ceramic materials, and the optimized degassing box lining material and structural design are used to greatly extend the life of key wearing parts, reduce spare parts consumption, and maintenance costs.

Optimize energy and metal loss: Efficient gas utilization: The precise gas control system and optimized rotor design ensure that the consumption of inert gas is effectively reduced while achieving the same or even better degassing effect.

Low stagnation design: The degassing box and filtration system design focuses on reducing the aluminum liquid retention, reducing metal loss, and minimizing cleaning difficulty.

Insulation performance: Good equipment insulation design reduces the temperature drop of aluminum liquid during the treatment process and reduces the energy consumption of remelting.

3. Ensure efficient production and convenient operation:
* High throughput design:

Provide filter plates and degassing units of various specifications and sizes to meet different processing throughput requirements from laboratory to large-scale industrial production.

* Quick replacement and maintenance:

Modular design: The degassing equipment adopts a modular design, and key components (such as rotor lifting mechanism, heater) are easy to disassemble and replace, shortening maintenance time.

Convenient filter plate replacement system: Design an easy-to-operate filter box structure, with special tools, to achieve fast and safe replacement of filter plates.

* Automation and intelligence:

Integrated control system: The equipment is equipped with an advanced PLC/HMI control system to achieve accurate setting of process parameters, real-time monitoring, data recording and traceability, and facilitate quality management and process optimization.

Remote monitoring and diagnosis (optional): Provide remote support options for fast fault diagnosis and maintenance guidance.

Strengthen safety design: The equipment is equipped with complete safety protection measures (such as emergency stop, liquid level alarm, aluminum leakage detection, protective cover, etc.) to ensure the safety of operators.

4. Ensure the quality of the final product:
"Zero" pollution commitment: High-purity, high-stability alumina ceramic filter plate and carefully designed internal structures of degassing equipment minimize the risk of secondary pollution introduced by the equipment itself.

Process stability guarantee: The high reliability of the equipment and the precise controllability of process parameters are the basis for ensuring high consistency of product quality between batches.

Temperature stability: Effective insulation measures and (optional) heating systems help maintain the stability of aluminum liquid processing temperature.

We are well aware that technological development is endless. To continue to meet and exceed customer expectations, we are committed to:

Material R&D innovation: Continuously explore higher-performance ceramic composite materials and more durable graphite/ceramic rotor materials to pursue longer service life and better purification effects.

Design optimization: Using CFD simulation and other means, continuously optimize the degassing box flow field, rotor structure, and filter plate pore distribution to pursue efficiency limits.

Intelligent upgrade: Deepen the intelligence level of equipment, develop process optimization and predictive maintenance functions based on big data and artificial intelligence, and help customers achieve "smart smelting".

The wide application of aluminum alloy products has put forward strict requirements on their quality. As the key to improving product quality, aluminum alloy liquid degassing unit is leading the aluminum alloy production industry to achieve a leap from basic manufacturing to high-end quality.

From a technical point of view, the rotary injection method builds the core technical framework of the degassing unit. With the help of the high-speed rotation of the graphite rotor, the inert gas is broken into tiny bubbles, starting the "purification journey" in the aluminum liquid. The gas partial pressure difference drives the hydrogen to diffuse continuously into the bubbles, and the surface adsorption effect makes impurities nowhere to hide. This ingenious physical process allows the harmful gases and impurities in the aluminum liquid to be gradually removed.

At the practical application level, a degassing-equipment is present in many fields. In the field of aerospace, it helps to produce high-strength and high-stability aluminum alloy parts; in the wave of lightweight development of automobiles, it provides high-quality guarantees for various aluminum alloy castings and improves vehicle performance and safety; in the recycling process of recycled aluminum, it makes resource recycling more efficient and reduces the pressure of primary aluminum mining.

The diversity of equipment types provides precise adaptation solutions for different production scenarios. Fixed equipment is like a "steel guard", providing stable and efficient degassing services for large production lines; mobile equipment is like a flexible "guerrilla", rushing to different furnaces at any time to complete purification tasks; hoisting equipment plays an important role under special working conditions with its space utilization advantage. The division of labor and cooperation between single-rotor and multi-rotor equipment also makes the degassing treatment more refined to meet the differentiated needs of different companies.

In actual production, the effect of degassing equipment is remarkable. The high degassing rate effectively eliminates the hidden dangers of porosity in castings, and the reduction of inclusions greatly improves the purity of the aluminum liquid. The improvement of product quality not only enhances the market competitiveness of enterprises but also promotes the aluminum alloy industry to develop in a higher quality and more sustainable direction, becoming an important driving force for technological innovation and quality upgrading in the industry.

In the precise world of aluminum alloy manufacturing, every slight change may affect the final product's performance. The gas hidden inside the casting is like a lurking "enemy", which may cause problems such as pores and loose tissue at any time, seriously threatening the quality of aluminum alloy products. The aluminum alloy liquid degassing equipment is the behind-the-scenes hero in this quality defense war. With its unique technical means, it guards every checkpoint in aluminum alloy production.

The core "weapon" of the degassing equipment is the rotary injection method. The high-speed rotating graphite rotor is like a skilled magician, turning nitrogen or argon with a purity of over 99.99% into countless tiny diffuse bubbles. These bubbles rely on the gas partial pressure difference principle to continuously "absorb" hydrogen in the aluminum liquid like a sponge absorbing water. When the bubbles slowly float up, they not only take away hydrogen but also use the surface adsorption principle to firmly "stick" impurities such as oxide inclusions to the surface, achieving double purification. Its spiral floating path allows the bubbles to fully contact with the aluminum liquid, greatly improving the purification efficiency.

In the application field, degassing equipment shows strong adaptability. In automobile manufacturing, it "escorts" the engine cylinder and wheel hub to ensure that the parts have a dense internal structure and excellent mechanical properties; in the processing of aluminum plates and aluminum foils, it ensures that the aluminum liquid has a uniform structure and avoids cracks in subsequent processing; the recycled aluminum industry is even more inseparable from it. Through efficient purification, the recycled aluminum liquid is reborn and reaches the quality standard of primary aluminum.

degassing equipment also has a rich "family". According to the mobile mode, fixed equipment is rooted in the production line and continuously processes a large amount of aluminum liquid; mobile equipment flexibly shuttles between different furnaces to meet the needs of small and medium-sized enterprises; hoisting equipment cleverly uses space and can also show its prowess in a small aluminum melting room. According to the number of rotors, single-rotor equipment is suitable for basic degassing tasks, and multi-rotor equipment can cope with complex working conditions and purify aluminum liquid with high gas content and many inclusion layer by layers.

With excellent degassing ability, this type of equipment can significantly reduce the hydrogen content of aluminum alloy liquid, and the degassing rate of some advanced equipment exceeds 90%. At the same time, a large number of inclusions are removed, significantly improving the purity of the aluminum liquid. The stable degassing effect makes the casting quality more reliable, reduces the scrap rate, and significantly improves the production efficiency of the enterprise, laying a solid foundation for aluminum alloy products to move towards the high-end market.

In the precise world of aluminum alloy manufacturing, every slight change may affect the final product's performance. The gas hidden inside the casting is like a lurking "enemy", which may cause problems such as pores and loose tissue at any time, seriously threatening the quality of aluminum alloy products. The aluminum alloy liquid degassing equipment is the behind-the-scenes hero in this quality defense war. With its unique technical means, it guards every checkpoint in aluminum alloy production.

The core "weapon" of the degassing equipment is the rotary injection method. The high-speed rotating graphite rotor is like a skilled magician, turning nitrogen or argon with a purity of over 99.99% into countless tiny diffuse bubbles. These bubbles rely on the gas partial pressure difference principle to continuously "absorb" hydrogen in the aluminum liquid like a sponge absorbing water. When the bubbles slowly float up, they not only take away hydrogen but also use the surface adsorption principle to firmly "stick" impurities such as oxide inclusions to the surface, achieving double purification. Its spiral floating path allows the bubbles to fully contact with the aluminum liquid, greatly improving the purification efficiency.

In the application field, degassing equipment shows strong adaptability. In automobile manufacturing, it "escorts" the engine cylinder and wheel hub to ensure that the parts have a dense internal structure and excellent mechanical properties; in the processing of aluminum plates and aluminum foils, it ensures that the aluminum liquid has a uniform structure and avoids cracks in subsequent processing; the recycled aluminum industry is even more inseparable from it. Through efficient purification, the recycled aluminum liquid is reborn and reaches the quality standard of primary aluminum.

degassing equipment also has a rich "family". According to the mobile mode, fixed equipment is rooted in the production line and continuously processes a large amount of aluminum liquid; mobile equipment flexibly shuttles between different furnaces to meet the needs of small and medium-sized enterprises; hoisting equipment cleverly uses space and can also show its prowess in a small aluminum melting room. According to the number of rotors, single-rotor equipment is suitable for basic degassing tasks, and multi-rotor equipment can cope with complex working conditions and purify aluminum liquid with high gas content and many inclusion layer by layers.

With excellent degassing ability, this type of equipment can significantly reduce the hydrogen content of aluminum alloy liquid, and the degassing rate of some advanced equipment exceeds 90%. At the same time, a large number of inclusions are removed, significantly improving the purity of the aluminum liquid. The stable degassing effect makes the casting quality more reliable, reduces the scrap rate, and significantly improves the production efficiency of the enterprise, laying a solid foundation for aluminum alloy products to move towards the high-end market.

In the huge system of industrial production, every link is like a precision gear, meshing with each other and jointly promoting the efficient operation of production. The filtration link is undoubtedly key to ensuring product quality and smooth production. Among many filter materials, aluminum ceramic foam filter plates can be called "invisible guards". With their unique advantages, they silently guard the quality and efficiency of industrial production.

From a microscopic perspective, the internal structure of the alumina ceramic filter plate is like an exquisite maze. The criss-crossing and interconnected capillary pores have a pore size precisely controlled between 1 and 10 microns. This special structure gives it a strong filtering ability. When a fluid containing impurities flows through the filter plate, particles larger than the micropore size are directly intercepted on the surface of the filter plate, just like pedestrians who stray into a dead end, completing the initial filtration of mechanical screening.

For those particles that are smaller in size and smaller than the micropore size, alumina-ceramic filter plates have another set of coping strategies. Its hydrophilic properties make water and the ceramic surface produce strong surface tension, forming a magical capillary phenomenon. With the help of vacuum suction, the filtrate can pass through the micropores smoothly, while the air is kept out, so that the micropores are always filled with liquid. In this way, when tiny particles pass through the micropores, they will be firmly adsorbed on the pore wall, achieving deep filtration and purification.

In actual industrial applications, taking the ceramic vacuum filter as an example, its work process is divided into the slurry suction area, drying area, unloading area, and backwashing area. In the slurry suction area, the filter plate is like a hard-working "gold digger", immersed in the slurry tank, with the help of the strong suction of the vacuum, the suspended materials in the slurry are adsorbed on its surface, the solid materials are left, and the filtrate is smoothly discharged or recycled. Then, the filter plate enters the drying area, and under the continuous action of the vacuum, the filter cake is further dehydrated. After the drying is completed, the scraper in the unloading area gently scrapes, and the filter cake is unloaded. Finally, the filter plate enters the backwash area, and the filtered water enters the filter plate through the distribution head, washing away the particles blocked in the micropores and completing a complete filtration cycle.

In terms of production and manufacturing, the birth of alumina ceramic foam Filter plates is also full of wisdom and ingenuity. The main raw material, α-alumina, is combined with kaolin, potassium feldspar, and other additives. Some processes also cleverly use alumina foam ceramic waste, which not only reduces costs but also optimizes particle grading. From batching ball milling, impregnation molding, to drying treatment, surface spraying, and finally high-temperature sintering, every step is strictly controlled to ensure product quality.

With these excellent properties, alumina ceramic filter plates have shown their prowess in many fields. In the metal smelting and casting industry, it is a "master" in purifying aluminum water, helping to produce high-quality aluminum alloy products; in the mine concentrate filtration and dehydration operation, it can efficiently process various concentrates; in the field of environmental protection, it is a powerful assistant in the treatment of "three wastes", realizing the efficient separation of pollutants and the recycling of resources. In addition, it can be seen in many industries such as the coal and chemical industries.

Alumina ceramic filter plates, with their unique filtering principles, rigorous production processes, and wide applications, play an indispensable and important role in industrial production, safeguarding industrial development.