Melt Loss Minimization and Dross Management

摘要

Melt loss is often not given the attention it deserves in casthouse operations, considering its large economic impact. In primary aluminum casthouses, melt loss is usually the biggest variable cost, and in remelt casthouses, it is the single largest expense, greater than labor and utilities. This is often the case when remelting lighter gauge scraps such as post-consumer scrap or cold mill side trim. Because melt loss can be difficult to track or quantify, it sometimes goes un-monitored. Without good measurement, melt loss is difficult to control and improve. In this paper, dross generation, melt loss, and dross processing are reviewed. In addition, a deep dive into melt loss calculations and sources of errors is presented.