Assan Aluminium Dilovasi, Teknik Aluminyum Kocaeli and Tekyar Gebze deliver Turkey's 900,000 t/y primary + secondary aluminum. Molten Al is 680-750 C; molten aluminum + water = steam explosion. NFPA 484 requires dry casting floor, pit protection, scrap-charge moisture limits and Class D fire protection.
Molten Al Hazard
- Temperature: 680-750 C
- Density: 2.37 g/cm3
- With water: Steam explosion
- Mg addition: Al-Mg raises risk
- Ignition: Scrap can ignite
Casting Pit Protection
- Dry floor: Moisture <0.1 percent
- Refractory: SiC furnace lining
- Pit base: Refractory concrete
- Drainage: Fully dry
- Chamfer: Emergency runoff
Scrap Charging
- Preheat: 200 C drying
- Moisture test: <0.1 percent mandatory
- Charge rate: Slow, bundles
- Sealed UBC: Al can processing
- Dross skim: Two-hand plasma stone
Degas and Dust
- Rotary degasser: Ar N2
- Cl2 fluxing: Regulated
- Dust collector: Wet
- Al Kst: 415 bar m/s St3
- Ventilation: 12 ACH
Turkey Casting
- Assan Dilovasi: 470,000 t
- Teknik Aluminyum: 200,000 t
- Tekyar Gebze: 50,000 t
- 2021 Assan: Scrap-charge fire
- Aselsan Al housings: Defense
Aluminum with SprinkCalc
SprinkCalc sizes aluminum casting pit dry, degas Ar N2, Kst 415 bar m/s, scrap preheat 200 C and NFPA 484 layout.
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Sources & Further Reading
NFPA 484, AFS 20-91, TAI Aluminum, OSHA 1910.269, TS EN 573. NFPA 484 Combustible Metals.