About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Melt Processing, Casting and Recycling
|
| Presentation Title |
Decarbonization of Aluminum Cast House Furnaces Using Plasma Torches |
| Author(s) |
Stephane Menard, Ramzi Ishak, Simon Vecten, Vincent Goutiere, François Rivard, Juan E. Salazar, Jayson Tessier, Agathe Tshipama, Jacob Whitsitt |
| On-Site Speaker (Planned) |
Stephane Menard |
| Abstract Scope |
An experimental campaign was conducted by Rio Tinto, Alcoa, and PyroGenesis to further investigate plasma as heating source for aluminium furnaces with the goal of reducing their carbon footprint. For this purpose, a 300 kg pilot furnace was used, primarily as a casting furnace; but also as a melting furnace; to prepare various commercial alloys, replicating processes in industrial cast houses. The impact of replacing the furnace’s natural gas burner with a plasma torch was investigated in both operating modes. Results show that plasma improves the furnace’s thermal performance, leading to significant energy savings, shorter melting times, and reduces dross generation, all without compromising metal quality. However, dross generation proved to be highly sensitive to air infiltration, and improvements were necessary at the beginning of the campaign to achieve the observed positive results. Proper furnace sealing also emerged as a key factor in minimizing NOx emissions and reducing noise levels. |
| Proceedings Inclusion? |
Planned: Light Metals |
| Keywords |
Other, Aluminum, Other |