Abstract: A material scrap submergence device comprises a body (10) of heat resistant and/or a refractory material that includes a side wall (12) and a base (14) that define a submergence chamber (10). The refractory body (10) can include passages (24) that receive rods (22). The rods (22) can place the refractory body (10) under compression. In another embodiment, the body is confined by a frame (72) attached to the body. The submergence chamber (10) can also be used as a gas injection chamber.

Abstract: A metal scrap submergence device comprising an open top chamber including walls of a heat resistant material, an inlet positioned in a side wall of the chamber, an outlet positioned in the base of said chamber, and a ramp adjacent said side wall of the chamber.

Abstract: A method of melting metal scrap in a molten melting media, the method comprising (a) providing a source of molten melting media in a furnace, the melting media in the furnace having a first surface level; (b) providing a first melting bay in fluid communication with the furnace to receive molten melting media from the furnace to provide a body of molten melting media in the first melting bay for purposes of melting floatable metal scrap, the first melting bay having: (i) a bottom; and (ii) an outer wall connected to the bottom defining the first melting bay, the outer wall having a generally spiral shaped cross section terminating in a mouth of a channel for removing melting media and molten scrap to an adjacent bay, the spiral shaped cross section receding away from a generally central axis of the first melting bay.

Abstract: A process for the recovery of metallic aluminum, mixtures of salts, and an aluminum oxide-metallic aluminum product from secondary aluminum dross. The process includes treating the dross with leach water to dissolve the salt content. Magnesium chloride is preferably added to the leach water to maintain the pH in the range of about 7-8.5, thereby reducing ammonia production in the treating step and enhancing recovery of metallic aluminum.

Abstract: A continuous salt-based process is provided for melting and reclaiming aluminum from aluminum scrap containing impurities including heating a molten salt in a heat bay, mixing the heated salt with aluminum scrap or skim in a charge bay to form a molten charge mixture, separating aluminum from impurities in the charge bay by coalescing aluminum to form a molten aluminum metal pad, chlorinating a portion of the charge mixture from the charge bay to form a chlorinated salt mixture and metal chlorides, removing metal chlorides from the salt mixture, and feeding the salt mixture back to the heat bay. In one aspect, the chlorinating step of the present invention includes introducing carbon monoxide or, preferably, solid carbon to control oxide concentration. The process further comprises adding fluorides and removing metal chlorides from the salt to maintain a preferred salt composition.

Abstract: An improved electrolytic cell and process are provided wherein metals and metal alloys are formed from oxides or nitrides in a molten salt, without the evolution of halogen or halogen compounds, with less corrosion and reduced power consumption by the use of an electrode having an extended or substantially increased surface area effective for the evolution of oxygen and carbon oxide, and a molten salt electrolyte effective at low temperature.

Abstract: Disclosed is a method of melting aluminum scrap and removing skim therefrom having reduced amounts of aluminum contained therein. Melted scrap and salt is added to a body of molten aluminum in a skim removal bay and a layer containing salt and skim is collected on the surface of the body, the layer containing high levels of molten aluminum in lower regions of said layer. The layer is treated so that upper regions thereof contain reduced amounts of aluminum, the treating aiding molten aluminum in the layer to return to the body. A portion of the treated layer is removed from upper regions thereof, the portion comprised of salt, skim and aluminum.

Abstract: A container for a material, said container having a liner comprised of an equilibrated reaction product of the material. Preferably, the material is a molten aluminum-lithium alloy and the reaction product consists essentially of lithium aluminate. A method of making the container comprises shaping a substance into a vessel, said substance having sufficient porosity to react with the material and form a non-wetting reaction product without spalling; and introducing the material to the vessel. A method of making a container liner by applying a substance to the container inner surface and introducing the alloy to the inner surface is also disclosed.

Abstract: In a system for treating and managing hot aluminum dross, the dross is compacted and delivered by a pair of "squeeze" rolls in a continuous semi-solid sheet, readily broken up for further treatment or disposal. The rolls may be cooled or heated as required to condition the dross appropriately, for storage or immediate further treatment. Ribs on the rolls and/or a stepped "break" chute downstream of the rolls may be used to break the compacted dross into "patties" for convenient handling.

Abstract: A method for the recovery of free aluminum metal from its dross is disclosed. The dross is charged into a receptacle having at least one inclined sidewall and at least one passageway extending through the receptacle's bottom. The passageway is sized and configured to permit the passage of free aluminum metal but inhibit the passage of the dross' network of solid particles. Dross having been charged into the receptacle is then mechanically compacted by applying compressive forces on the dross towards the inclined sidewall. Such compression causes the free aluminum in the dross to coalesce and pass through the passageway in the receptacle's bottom. Steps are also taken during the aforesaid charging and compaction steps to prevent or inhibit the dross from cooling. Free aluminum passing through the receptacle's bottom passageway is then collected. Compacted dross remaining in the receptacle can be subjected to conventional reprocessing techniques for recovering remaining aluminum contained therein.

Abstract: A power driven press for recovering aluminum from aluminum dross is disclosed. The press has a receptacle for containing dross. The receptacle has at least one inclined sidewall and at least one passageway extending through its bottom. The passageway is sized and configured to permit the passage of free aluminum but inhibit the passage of a network of solid particles contained within the dross. Ram means for mechanically compacting the dross is also provided. The ram means applies a compressive force on the dross towards the inclined sidewall of the receptacle to force coalescence and separate a substantial portion of the free aluminum from the dross and pass it through the passageway provided in the receptacle's bottom. The ram means is provided with a ramming surface which faces the inclined sidewall surface of the receptacle. The ramming surface is inclined at an angle which is slightly less than that of the sidewall surface.

Abstract: Apparatus for melting relatively large floating units of metal scrap in a molten melting media or medium, the units having oxide films and solid, liquid and gaseous inclusions. After the units are charged into a melting medium, layers of freshly melted metal are presented to the molten media. The apparatus includes a bay for heating the molten media and means for pumping the media from the heating bay to a circular bay for receiving the large units of metal scrap. Located in the circular bay is a rotor means for moving the media therein at a velocity sufficient to sweep away the surface and insulating layers of the floating units in a rapid manner such that new metal is rapidly and continuously exposed to the melting media without the floating units being submerged in the media. A third bay is included for collecting skim material from the molten media leaving the circular bay.

Abstract: An improved method and apparatus for ingesting and melting metal scrap that otherwise tends to float on the surface of a molten melting media. The method includes the steps of providing a supply of the melting media and directing the media from the supply to an upper portion of a receptacle having an outlet opening in the lower portion thereof. The flow of the melting media entering the receptacle produces a free vortex of the media in the receptacle, as the media flows out the lower opening. The amount of the flow of the melting media to the receptacle and the size of the lower opening are such that a predetermined level of the media is maintained in the receptacle. The symmetry and continuity of the flow pattern of the vortex are disturbed in such a manner that floating metal solids (and any associated skim material) entering the vortex from the upper portion of the receptacle are rapidly ingested into the melting media.

Abstract: A method of removing skim from molten metal comprises providing a body of molten metal and passing a fluxing gas therethrough to carry skim to the surface of the metal. The skim on the surface is treated to substantially reduce the amount of molten metal contained therein and to provide the skim in a substantially powdery form. A portion of the treated skim in finely divided form is removed to a collector.

Abstract: An improved system for melting metal scrap in a molten melting media includes a housing generally cylindrical in cross section and having upper and lower portions. Metal scrap is introduced to a body of molten melting media contained in the upper portion of the housing. A supply of molten melting media is added to the upper portion of the housing through a volute located in the lower portion. The molten melting media is supplied or added by action of an impeller located in the lower portion and mounted on a drive shaft extending through the upper portion. Vanes are mounted on the drive shaft to control the flow motion of the body of molten melting media and metal scrap in the upper portion of the housing by creating a vortex in this body for purposes of mixing the melting media and metal scrap. An opening is provided in the upper portion to remove melted scrap and melting media at a rate substantially commensurate with their rate of introduction.

Abstract: A system for melting metal scrap in a molten melting media comprises a housing having an upper portion wherein the melting media and scrap are brought together to initiate melting. The housing also has a lower portion in which a volute is located. An impeller, having a central hub, a circumferential band surrounding the hub, and canted vanes projecting radially from the hub to the band, is positioned in the lower portion of the housing to cooperate with the volute so that upon rotation of the impeller, metal scrap and melting media are moved downwardly and out of the housing.