A system and method for filling a mold with molten aluminum includes a molten metal pump, a vessel configured to contain molten metal, a mold for receiving molten metal, and a conduit between the vessel and the mold. Molten metal is pumped in the vessel until it reaches a level at which it flows through the conduit and into the mold. The flow of molten metal into the mold is stabilized to maintain a level of molten metal in the mold. A skin of solid metal forms between the mold and the conduit, at which time the pumping of molten metal can cease. The mold with solid metal in it can be moved.

A smart molten metal pump system and method automatically controls the operating speed of the pump rather than requiring an operator to control the speed. The system includes a pump, a controller for controlling the speed of the pump and one or more vibration sensors (such as an accelerometer) to measure vibration. The controller receives input about the vibration of the pump or one or more pump components, and possibly other data, such as the temperature of the molten metal, and/or the depth of the molten metal, ad/or parameters related to the operation of the pump. The controller analyzes the one or more inputs to vary the speed of the pump, turn the pump off, and/or send a communication to an operator.

A launder for use in moving molten metal includes at least one relatively narrow channel through which molten metal flows. Using a narrow, rather than broad, channel permits better control of the flow and helps prevent overflowing the launder or a structure adjacent the launder. A molten metal pumping or transfer system may utilize a launder as disclosed herein.

A method of providing an inerting atmosphere to the surface of molten aluminum in a vortex charge well of a reverberatory melting furnace is provided. The purpose is to improve aluminum recovery (reduce aluminum oxidation melt loss) by displacing the ambient atmosphere above the molten vortex with an inert gas. The method includes introducing a flow of an inerting gas into an inerting region immediately above the surface of the vortex charge well. The inerting gas may be selected from the group consisting of nitrogen, argon, or a mixture thereof. The inerting gas may be introduced into the charge inlet chute, through a diffuser, or a ring manifold. The vortex charge well may include a lid.

A method of providing an inerting atmosphere to the surface of molten aluminum in a vortex charge well of a reverberatory melting furnace is provided. The purpose is to improve aluminum recovery (reduce aluminum oxidation melt loss) by displacing the ambient atmosphere above the molten vortex with an inert gas. The method includes introducing a flow of an inerting gas into an inerting region immediately above the surface of the vortex charge well. The inerting gas may be selected from the group consisting of nitrogen, argon, or a mixture thereof. The inerting gas may be introduced into the charge inlet chute, through a diffuser, or a ring manifold. The vortex charge well may include a lid.

A smart molten metal pump system and method automatically controls the operating speed of the pump rather than requiring an operator to control the speed. The system includes a pump, a controller for controlling the speed of the pump and one or more vibration sensors (such as an accelerometer) to measure vibration. The controller receives input about the vibration of the pump or one or more pump components, and possibly other data, such as the temperature of the molten metal, and/or the depth of the molten metal, ad/or parameters related to the operation of the pump. The controller analyzes the one or more inputs to vary the speed of the pump, turn the pump off, and/or send a communication to an operator.

The present invention discloses a cylindrical heating apparatus for aluminum foil annealing furnaces. During use, a fan sends air through an air inlet into the cylindrical shell, where the air flows circumferentially along the inner wall of the cylindrical shell, a guide plate directs a portion of the air to middle areas of the cylindrical shell to enhance the heat convection exchange between heating cores located in the middle areas of the cylindrical shell and the air, thereby improving the heating efficiency of the heating cores.