19 COMMUNICATION ISSUE transfer in melting aluminum is accomplished through radiation, we have made this aspect central to our design. Using a series of highly radiant burners evenly distributed in the roof we bring this radiant heat source closer to the bath than other furnace manufacturers. Having the heat source close to the bath greatly increases the efficiency of the Schaefer design. We overcome the obstacle of a lower roof by then having cleaning access to the main chamber at both ends of the furnace. On many furnaces we then add component aspects that some of the other furnaces’ types have depending on our customers' particular needs. Many of our units have a pre-heat hearth at one end. This feature allows for sow and ingot loading at one end in a manner without the metal losses that occur in a dry hearth as we draft the waste gasses across the sows minimizing the metal losses. Once they sweat Contact: JEFF ZURFACE [email protected] then they are pushed into the hot metal bath where the stored Btus in the aluminum help finish the melting process. External side wells on units that allow easy charging of returns, gates and risers back into the furnace, combined with a properly sized circulation pump for the greatest available efficiency in well melting. These extra features along with a properly insulated lining can enhance the efficiency from 1230 to 1500 Btu per hour fuel usage when melting and a furnace that provides for minimal metal losses (3-4%). Fuel Fired Dry Hearth furnaces This type of furnace is well suited to knock down and melt heavy solids as cold solids absorb heat readily. Solids are loaded onto a dry tapered ramp and many manufactures directly fire at solids like sows or ingot bundles loaded on the sloped ramp. The metal loss from direct impingement of the flame and burner velocities is quite high especially on lighter weight scrap. The efficiency of these type of furnaces ranges from 1800 to 2000 Btu per pound. Because there are two separate chambers (melt and hold) and two separate combustion systems, these tend to cost more than a low headroom reverb melter. There is significant amount communication that needs to take place to determine which furnace is right for your production. Spending the time to clarify your goals with objectives will help to ensure your furnace will fit the space, and provide years of service meeting your defined production needs.
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