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Aluminum Melting Table A2.13 - Assumptions Used for Calculating Aluminum Melting Energy Consumption and Exhaust Gas Waste Heat Loss Energy Primary Aluminum Melting Secondary Al Refining Furnaces 2,734,062 48.2 49.2 134.6 °F °C 1292 700 No Heat Recovery 2,471,235 823,745 6,029,042 3.6 3.8 9.3 2100 1150 1000 538 With Recovery Total 2.6 54.4 2.7 55.7 2.2 146.1 Production (tons/year)a Energy Consumption (10^6 Btu/ton)b Consumption adjusted for yield, (10^6 Btu/ton)c Energy Consumption (TBtu/Year) Assumed Average Exhaust Temperatured 3,294,980 a. Total primary and secondary aluminum production from Patricia A Plunkert, 2007. USGS Mineral Commodity Summaries 2007. Year 2006 estimate. Percent of secondary furnaces using waste heat recovery based on personal communication with Rooy, E., indicating 1/3 of furnaces with capacities over 40,000 lbs use waste heat recovery. In order to account for less waste heat recovery in smaller furnaces, assumed only 25% of all secondary furnaces use waste heat recovery. b. Energy consumption in primary aluminum refining from BCS, 2003, US Requirements for Aluminum Production: Historical Perspective, Theoretical Limit sand New Opportunities. Tables F-1 and F-2.. Value does not include electricity-related losses. Secondary aluminum specific energy for systems with and without heat recovery from Li, T. "Performance of secondary aluminum melting: Thermodynamic analysis and plant-site experiments." Energy 31. p. 1770. 2006. c. BCS 2003, Table F2. Yield for primary ingot casting is about 98%, secondary casting is about 96%. (Note, yield for shape casting is significantly lower, but accounted for in metal casting calculations (Table A 16). d. Primary aluminum melting temperature from BCS 2003, p.27. Secondary aluminum temperature from Wechsler, T. and Gitman, G. "Use of the Pyretron Variable Ratio Air/Oxygen Fuel/Burner System for Aluminum Melting," Aluminum Industry Energy Conservation Workshop XI Papers. The Aluminum Association. p. 273. 1990. A-16PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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