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The principle of filtration of molten aluminum and the choice of ceramic foam filters

2022-08-12

The principle of filtration of molten aluminum and the choice of ceramic foam filters


The principle of filtration for molten aluminum


The characteristics of ceramic foam filter plate are similar to activated carbon, it has the characteristics of a multi-layer network multi-dimensional through-hole, and the connection between holes and holes. When filtering, the molten aluminum carries inclusions along the zigzag filter plate channel and the porous pore flow and the filter plate foam skeleton contact with the direct interception adsorption deposition and other effects, when the melt flows in the hole when the filter plate channel is curved, the melt flowing through the channel changes the flow direction, the inclusions collide with the hole wall and firmly adhere to the hole wall.

Use and selection of filter plates


A ceramic foam filter plate is installed in the filter box between the furnace mouth and the shunt plate, the filter box is made of "Chinese refractory No. 5" refractory material, it can pass through thousands of times of quenching and heat without cracking, has the advantages of high strength and high thermal insulation performance, and is currently the best material for making filter boxes, flow slots and so on. The closer the filter box is to the shunted disc, the better because it shortens the flow distance of the aluminum filtration and reduces or avoids the re-generation of oxides. The molten aluminum flows out of the furnace mouth through the filter box and then through the flow through to the human diversion disc. When the filter device starts, the drop before and after the melt filtration is about 50mm, and with the extension of the filtration time, the inclusions on the surface of the filter plate and the hole wall increase, the filter flow decreases, the gap between front and back increases, and by the end of casting, the drop increases to 60~120mm. The selection of the filter plate must be based on the flow of the molten aluminum, and secondly, the cleanliness of the melt, the maximum content of inclusions, and the total throughput of the melt should be considered (see Tables 1 and 2).


Table 1 Physical properties of foam ceramic filter plates

Thickness

20-50mm

holes number

15-45 holes/inches(500-1770 holes/m)

Hole inches

80%-85%

Bulk density

0.359~0.45g/cm3

Air permeability

(1000~2000)×10-7

Compressive strength

1300℃  55 N/cm2

Fire resistance

>1800℃

   

Table 2 Typical flow characteristics of 25 mesh foam ceramic filter plates

Ceramic foam filter specification/mm

Volume

/m3

Maximum metal 

flow  /kg*min-1

Optimum flow range

 /kg*min-1

Typical filtering volume /t

178*178*50

0.0213

57.00

25-45

4.2

229*229*50

0.0378

118.00

35-102

6.9

305*305*50

0.0745

198.00

90-165

13.8

381*381*50

0.1220

325.80

130-265

23.2

432*432*50

0.1600

427.20

210-350

34.5

508*508*50

0.2270

606.60

280-465

43.7

585*585*50

0.3440

772.20

370-640

57.3

 

The filtration effect of the ceramic foam filter plate is mainly guaranteed by its size and porosity, the larger the pores of the filter plate, the better the passability, the greater the flow, but the worse the slag removal effect, for aluminum castings with strict requirements, a filter plate with small pores should be selected. If using a filter plate of 40-45 wells/inch (1770 wells/m).