Rotary Flux Injector and Degassing Unit with Micron-Level Bubbles Pump Effect and Hydrogen Content Below 0.10 ml/100g Al

The "Rotary Flux Injector" is hailed as the "ultimate weapon" – an apt description in the industry, as it represents one of the highest levels of aluminum melt purification technology today.

Below is a comprehensive breakdown of this "ultimate weapon" – from why it is so powerful, to its core working principles, technical advantages, and future trends.

I. Why is it the "Ultimate Weapon"? – Core Advantages Unveiled

Traditional refining methods (such as powder injection refining and static inert gas flotation) suffer from low efficiency, inconsistent results, high labor intensity, and environmental unfriendliness. The emergence of the rotary refiner has completely transformed this landscape.

• Extremely High Purification Efficiency

  • Micron-Level Bubbles: Its core rotor shears and crushes the injected inert gas (nitrogen or argon) into extremely fine (micron-sized), uniformly distributed bubbles. According to Stokes' law, smaller bubbles rise more slowly, remain in the aluminum melt longer, and have a larger contact area with inclusions and hydrogen, leading to an exponential improvement in removal efficiency.

  • "Pump" Effect: The high-speed rotating rotor acts like a centrifugal pump, generating strong shear forces and vortices. This forcibly disperses refining agents (e.g., fluxes) into every corner of the melt and breaks up nascent alumina films, exposing inclusions for adsorption and removal by the micro-bubbles.

• Excellent and Stable Results

  • Hydrogen Content: It can consistently reduce hydrogen content in the aluminum melt to below 0.10 ml/100g Al, with exceptional cases achieving 0.08 ml/100g Al or lower.

  • Inclusion Removal: Effectively removes oxide slag and non-metallic inclusions, significantly improving melt cleanliness.

  • Uniform Composition and Temperature: The intense stirring action rapidly homogenizes temperature and alloy composition in the bath, preventing segregation.

• Significant Economic Benefits

  • High Gas Utilization: Traditional methods produce large bubbles that escape quickly, resulting in low gas utilization. The rotary generator produces micro-bubbles, maximizing gas utilization and saving on gas and refining agent consumption.

  • Shortened Production Cycle: Refining time is significantly reduced (typically 10-20 minutes to achieve ideal results), increasing furnace turnover.

  • Improved Product Quality: Reduces gas porosity and slag inclusions in castings, greatly improving yield rates – crucial for high-demand sectors like aerospace and automotive.

• Automation and Environmental Friendliness

  • Enables fully automated operation with one-button start/stop, making the refining process traceable and repeatable, reducing reliance on operator experience.

  • The process occurs in a sealed or semi-sealed environment, minimizing smoke and exhaust emissions, and significantly improving the working environment.

II. How Does the "Weapon" Work? – Core Technology Analysis

A rotary refiner mainly consists of a drive system, lifting system, graphite rotor (core), gas supply system, and automatic control system.

Its workflow can be summarized as follows:

1. Positioning: The refiner moves above the furnace, and the lifting system slowly inserts the graphite rotor into the aluminum melt to the appropriate depth.

2. Rotation and Gas Supply: The rotor starts and rotates at high speed (typically hundreds to thousands of RPM), while high-purity inert gas is introduced.

3. Bubble Fragmentation and Dispersion: Gas is ejected through specially designed nozzles (e.g., umbrella-shaped, impeller-shaped) at the bottom of the rotor, instantly sheared and broken into countless micron-sized bubbles by the high-speed rotation.

4. Purification Reaction:

   • Degassing: Dissolved hydrogen (H₂) in the aluminum melt diffuses into these inert bubbles (since the hydrogen partial pressure inside the bubbles is zero) and is carried to the surface as the bubbles rise.

   • Slag Removal: Fine oxide slag collides with these micro-bubbles, adheres to their surfaces, and is "carried" to the dross on the melt surface.

5. Skimming and Completion: After refining, the rotor is raised, the melt is allowed to settle briefly, and the resulting surface dross is skimmed off, yielding clean aluminum.

III. The "Soul" of the Weapon – The Graphite Rotor

The graphite rotor is the core consumable component, directly contacting the high-temperature aluminum melt. Its design and material are crucial.

• Material: Must use high-purity, high-strength, oxidation-resistant, and aluminum-erosion-resistant high-purity isostatic graphite.

• Design: The structure of the rotor head (e.g., straight cylinder, umbrella-shaped, impeller-shaped) determines bubble fragmentation efficiency and distribution range, representing proprietary technical know-how of equipment manufacturers.

IV. The Future of the "Ultimate Weapon" – Development Trends

• Intelligence and Digitalization: Integration of advanced sensors and AI algorithms for real-time monitoring and automatic adjustment of rotation speed and gas flow, achieving adaptive refining and ensuring optimal results every time.

• Online Processing: Beyond in-furnace treatment, rotary technology is widely used in trough online degassing systems, enabling continuous purification as aluminum moves from the holding furnace to the caster – key for high-quality continuous casting.

• Material Innovation: Development of longer-lasting, higher-performance graphite rotors and protective sleeves to reduce operating costs.

• Multi-Functional Integration: Incorporation of temperature measurement, hydrogen measurement, and rapid composition analysis functions, transforming it into an "integrated quality control center" for the melting shop.

Conclusion

The Rotary Furnace Refiner, leveraging its superior physical principles (generating micro-bubbles + intense stirring), has revolutionized aluminum melt purification efficiency and effectiveness. It is not only the "ultimate weapon" for enhancing aluminum product quality but also an essential core asset for modern aluminum processing enterprises striving for high efficiency, energy savings, environmental friendliness, and automated production. Its adoption and application level directly reflect the core competitiveness of a nation or enterprise in the aluminum processing industry.

For industry professionals, when selecting and using this "weapon," close attention must be paid to rotor design, control system stability, and the professionalism of after-sales service.

Product Tags:

Micron-Level Bubbles Rotary Flux Injector

      

Pump Effect Rotary Degassing Unit

      

Hydrogen Content Below 0.10 ml/100g Al Aluminum Refining Machine

      

Rotary Flux Injector and Degassing Unit with Micron-Level Bubbles Pump Effect and Hydrogen Content Below 0.10 ml/100g Al Images