Abstract: An integrated aluminum melting and holding system is provided. The system includes, in combination, a hearth for receiving and melting a charge of aluminum pieces, a holding chamber for maintaining the elevated temperature for casting, and a well to allow removal of the molten aluminum for delivery to a casting station. The hearth includes a combustion chamber having a fuel burner section communicating with the hearth for burning hydrocarbon fuel with air to produce effluent hot gases in the burner section for circulation through the hearth for melting the aluminum pieces. The holding chamber receives molten aluminum from the hearth. The holding chamber has at least a substantial portion positioned below a substantial portion of the hearth. The holding chamber includes at least one immersion heater in contact with the molten aluminum. The holding chamber further includes a lid configured to contact the molten aluminum disposed within the holding chamber.

Abstract: Disclosed is a molten metal holding furnace system and a baffle and/or heater for use therein. The baffle/heater includes, among other things, a heat conductive body, at least one heater apertures and at least one passageways from a first side of the baffle body to the second side of the baffle body. Heaters within the heater apertures are isolated within the baffle body from the molten metal.