Aleris International was part of a four-year DOE program on "Improving Energy Efficiency in Aluminum Melting". Key findings from this work were interpreted and implemented on a corporate-wide basis. 1) Natural gas savings were realized by adjusting burner input based on the bath area for melting and holding furnaces. 2) Modifying burner loading for an asymmetrical and symmetrical reverberatory furnace was investigated. 3) The PHAST program was utilized to understand and quantify the potential of preheated combustion air. Additional modeling was done for this paper to analyze response from a different furnace design. Methods and results will be discussed in this paper.
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