Case Study · Non-ferrous Foundry
Low-NOx Burner for an Aluminum Holding Furnace
A 5 t aluminum holding furnace needed a steady 720C hold with minimal oxidation. A Weishaupt low-NOx burner with sub-stoichiometric tuning cut dross and held temperature within a narrow band.
The challenge
Over-firing oxidized the bath, raising dross and metal loss.
Temperature had to sit near 720C without overshoot into the melt.
NOx from the furnace hall was under review by environmental staff.
The casting cell ran continuously, so burner faults were costly.
What we supplied & did
Selected a Weishaupt WML30 low-NOx burner and ran it slightly rich to suppress aluminum oxidation.
Fitted a Dungs safety valve train with leak test and dual cutoff.
Added Honeywell flame detection and ratio control tied to the bath thermocouple.
Tuned the flame shape on site to heat the bath evenly with low local excess air.
Measured results
What changed on the line
The bath holds 720C without overshoot, lowering dross and recovered-metal loss.
Slightly-rich firing reduced surface oxidation versus the old setup.
Low-NOx combustion met the hall emission review.
Gas use fell 8-11% on the continuous hold duty.
Equipment used in this project
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