The design of an aluminium melting furnace has faced two challenges: mathematical modelling and simulative optimization. This paper first uses fluid dynamics to model the aluminium process mathematically. Then, the model is utilized to simulate a round shaped reverberatory furnace for melting aluminium alloys. In order to achieve the highest thermal efficiency of the furnace, modelling and simulation are performed to predict complex flow patterns, geometries, temperature profiles of the mixture-gas air through the main chamber, as well as the melting tower attached to the furnace. The results led to the establishment of optimal position and angle of the burner, which are validated through physical experiments, ensuring recirculation of the combustion gases through the melting chamber and the melting tower. Furthermore, a proper arrangement of refractory materials is derived to avoid heat losses through the outer surface of the furnace. Temperature profiles are also determined for the optimization to arrive at the final design of the furnace. Compared with manual designs previously practiced, the simulation-based optimal design of furnaces offers excellent guidance, an increase in the aluminium processing and magnesium removal for more refined alloys, and an increased processing rate of aluminium chip accession.

In this work, the experimental results obtained during the preparation of Al-Ni and Al-Ni-Mg alloys using the aluminothermic reduction of NiO by submerged powder injection, assisted with mechanical agitation are presented and discussed. The analyzed variables were melt temperature, agitation speed, and initial magnesium concentration in the molten alloy. For some of the experiments performed, it was found that the Ni concentration increased from 0 to about 3 wt-% after 90 min of treatment at constant temperature and constant agitation speed. In order to determine the values of the kinetic parameters of interest, such as the activation energy and the rate constants, the values of the results obtained were fitted to the kinetic formulae available. Moreover, the kinetics of the reaction were found to be governed by the diffusion of Al and Mg to the NiO boundary layer, where MgAl₂O₄ or Al₂O₃ were formed as the main reaction products. Finally, from a thermodynamic study of the system, the main reactions that took place are explained.

Al-Sr master alloys were prepared by aluminothermic reduction of SrO in molten aluminum processed from scrap. The trials were performed at 500 kg pilot plant scale, using a gas operated furnace with a silicon carbide crucible. The effect of temperature, initial magnesium concentration and agitation speed on the aluminothermic reduction rate of SrO powders was studied. Moreover, the microstructure of Al-Sr master alloys prepared has been analyzed by means of optical microscopy, X-ray diffraction (XRD), and scanning electron microscopy (MEB). In this sense, the morphology of secondary constituents and the structure of Al4Sr phase were evaluated. The results showed that the aluminothermic reduction technique is useful for producing Al-Sr master alloys, observing the presence of the Al4Sr intermetallic phase as the main secondary constituent.

Magnesium is considered as impurity element in aluminum recycled for obtaining some cast alloys, with low concentration Mg, because at 0.1 wt% results in fragility, fractures, and defects. This research applies the aluminothermic reduction process to decrease magnesium content in aluminum cans by adding ZnO, to produce reaction products solid-state (Al2O3, MgO and MgAl2O4), and there is a possibility to obtain Al-Zn alloy. The conditions of the process were, melting temperature (750, 800, 850°C) and stirring velocity (200, 250, 300 rpm). The Mg and Zn contents were measured for chemical analysis and scrap generated from every process was analyzed by X-ray diffraction. The results show how the aluminothermic reduction decreased Mg from 0.93 to 0.06 wt% and increased zinc up to 5.52wt % in the molten metal. Therefore, this process can be used to remove Mg and can also prevent the generation of polluting gases into the environment.