Tenova LOI Thermprocess has successfully completed the agreed production optimization for a new two-chamber TCF® melting furnace at E-Max Billets in Kerkrade, the Netherlands. After the optimization, the furnace is the only required melting unit for higher contaminated scrap and has achieved the performance parameters discussed in advance.
Following this success, Tenova LOI Thermprocess has been awarded the contract for the design, supply, installation, and commissioning of another two-chamber TCF® melting furnace and a melting and casting furnace (MCF) for the production expansion for E-Max billets. In addition, the company was entrusted with the modernization of the customer's plant.
Higher efficiency of modern TCF® technology
The two-chamber melting furnaces previously used by E-Max Billets, which were also acquired by Tenova LOI Thermprocess in 1990, are now being successively removed from current production and demolished after 32 years of operation and 1,500,000 t of molten aluminum.
The new TCF® melting furnace reduces metal loss and specific natural gas consumption per ton of molten aluminum by more than 20% and achieves a daily output of 150 t of liquid aluminum. The plant is also capable of treating more highly contaminated scrap, which significantly increases efficiency.
The Tenova LOI Thermprocess order also includes a tiltable MCF, this will be commissioned in spring 2023. This is capable of melting scrap with light organic impurities in a single furnace chamber. The new technology enables a reduction in overall emissions through a special process that ensures lower metal losses and safe integrated post-combustion. This can ensure sustainable and economical production of liquid aluminum.
