By John A Taylor; John F Grandfield; A Prasad
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Extra info for Aluminium cast house technology XI : selected, peer reviewed papers from the international conference, organised by the CAST CRC, on behalf of the aluminium industry : it was held from 13-16 September, 2009, on the Gold Coast, Queensland, Australia
This paper will look at how dross is generated within the furnace in the first place, followed by ways to minimize the dross generation within the furnace using continuous and sub-surface circulation which can also provide significant energy and CO2 reductions. A separate paper will discuss dross processing options and possibilities. In summary, by careful attention to the equipment and process techniques around the furnace and the follow-on dross management significant cost savings and environmental benefits can be realized by cast house operations.
Figure 7. Metatarsal ‘smelter’ boot. Figure 8. Standard slip on foundry boot. Figure 9. Dip test sock 24 Aluminium Cast House Technology XI Safety Glasses and Face Shields The 1986 Foundry Code of Practice refers to the need for safety glasses to have ‘side shields’ (figure 10). Polycarbonate safety glasses available in 2009 are nearly universally of the ‘wrap around’ variety (figure 11) and are far more ‘snug’ fitting than 1986 variants. The need for specialised side shields is still a necessity for prescription glasses.
On the most part, endothermic fluxing is now generally used in the industry although exothermic fluxes are still predominantly used in Asia. Operator training and understanding of the use of flux is critical to making any material achieve the intended result. Furnace Temperature The temperature of the metal is the single most important controllable factor that determines the level of dross generation in a furnace. Once the temperature of the metal exceeds 782°C, dross generation increases exponentially  as shown in Figure 4.