Chamber furnace

meltingcleaningpreheating

Overview
Melting and holding furnaces engineered for aluminum primary and secondary operations in North and South America. SECO/WARWICK systems are built to integrate with upstream and downstream casting processes and are configurable for melting, holding, cleaning and alloying tasks.

Advantages / Design features

• Furnace design — Complete solutions with engineered construction, advanced PLC control, combustion options and high‑performance refractory linings for reliable melt quality.
• Steel construction — Reinforced steel structures at critical stress points including door openings, tap/drain plugs and external well penetrations.
• Controls — PLC-based controls, SCADA and Ethernet communications, optimized fuel/air control and remote monitoring of set points, alarms and fuel usage.
• Combustion systems — Burner selection and placement tailored to application (low‑NOx, regenerative options); flame management to protect refractory and metal quality.
• Refractory lining — Linings specified by alloy, freeze plane and abrasion/attack resistance; options for energy-saving insulating materials.
• Cost vs. performance — Configurable options such as preheated combustion air, charge preheat chambers, recirculation pumps and stirrers to balance budget and throughput.

Some of our recent installations (examples)

• 142,000 lb single-well melter with low‑NOx burners for extrusion scrap melting at ~12,000 lb/h; includes stainless window for future electromagnetic sidewall stirrer and pump well for molten metal transfer.
• 260,000 lb single-well melter with Bloom Twin regenerative burners melting shredded scrap at up to 24,000 lb/h plus an extended sill melting 6,000 lb/h of sows — combined melt rate ~30,000 lb/h; features under‑hearth cooling, air‑cooled hot wall and divided well with Metaullics J50 circulation pump.
• 45,000 lb batch melter with regenerative burners for in-house return scrap melting at ~10,000 lb/h; suited for expansion projects and medium‑scale recycling operations.

Features / Processes

• Nonferrous melting
• Extrusion scrap melting
• Shredded scrap melting
• Return scrap melting
• Holding and temperature control

Industries

• Aluminum producers
• Primary and secondary aluminum operations

Technical characteristics / specifications

• Furnace types: single‑well melters, batch melters, holding furnaces in multiple sizes and shapes to meet melt rate and capacity requirements.
• Melt capacities: examples at 45,000 lb, 142,000 lb and 260,000 lb.
• Melt rates: examples at 10,000 lb/h, 12,000 lb/h, 24,000 lb/h and combined rates to ~30,000 lb/h.
• Efficiency examples: ~1,100–1,150 Btu/lb (application dependent).
• Combustion: compatible with low‑NOx and regenerative burner systems; options for preheated combustion air.
• Controls: PLC-based control, SCADA and Ethernet communications; remote alarm and set‑point monitoring.
• Refractory: tailored linings for alloy, freeze plane and wear resistance; energy‑saving insulating materials available.
• Structural: reinforced steel construction at critical points; localized reinforcement for heavy‑duty areas.
• Optional equipment: charge preheat chambers, metal recirculation pumps (e.g., Metaullics J50), stirrers, under‑hearth cooling, air‑cooled hot walls and pump wells for automated metal transfer.
• Engineering support: systems engineered to customer specifications with integration support for plant engineering, production and maintenance.