Over the past 25 years, Insertec has developed a range of specific solutions for the aluminum recycling sector, among which tilting rotary furnaces stand out for their versatility, productivity, and efficiency in demanding processes.
The FARB rotary furnace is a highly versatile unit capable of processing a wide variety of materials, such as engine blocks with inserts, cans, chips, and slags. It represents one of the most effective alternatives for melting processes without decoating, an option that combines productivity and operational efficiency, although the metal quality obtained may be lower than that achieved with prior decoating.
This equipment is fitted with an Oxy-gas combustion system, a cutting-edge technology in the aluminum recycling industry that enables shorter melting cycles and improved energy efficiency. As a result, the furnace contributes to increased plant productivity while meeting current environmental requirements, with controlled emissions and reduced final waste.
Advantages of the FARB Rotary Furnace
- Multi-product equipment capable of processing different types of materials
- Lower operating costs
- Increased energy efficiency through oxygen utilization
- Reduced amount of flux salts and waste compared to central well furnaces
- Increased productivity thanks to shorter operating cycles
However, in this type of equipment, the refractory lining is one of the most critical elements to ensure furnace robustness, reliability, and long service life. This is where Insertec’s refractory division provides innovative engineering solutions that allow the overall performance of the equipment to be further enhanced.
The key to successful refractory lining performance lies in the combination of three fundamental factors:
- The design and selection of the most suitable materials according to the specific working conditions in each furnace zone.
- The lining design, including anchoring methods, insulation, thicknesses, and geometry.
- The correct installation of the refractory lining.
The purpose of refractory engineering is to successfully combine these three factors, and Insertec achieves this objective through the development of precast refractory shapes, specifically designed for each application.
The use of precast refractory shapes eliminates most of the drawbacks associated with traditional brick and castable linings, while combining the advantages of both systems. These shapes are manufactured through a strictly controlled quality process, including mold design and fabrication, mixing, vibration, demolding, and final heat treatment. This ensures uniform technical properties throughout the entire geometry of the piece, as well as optimal performance according to the specific requirements of each furnace zone.
In addition, the precast shapes are delivered to the customer ready for installation and commissioning. They can be installed by mechanical personnel following detailed drawings and installation instructions, allowing significant reductions in installation time and scheduled shutdown duration.
Another important advantage is the possibility of keeping spare parts available either on-site or in the manufacturer’s warehouse, minimizing replacement time in the event of unplanned shutdowns.
The uniform characteristics of the shapes, together with optimized materials and designs, result in a significant increase in refractory service life, leading to lower repair costs — both for the refractory itself and for the metallic components it protects — as well as a reduction in the number of maintenance interventions required inside the installation.
This reduction in maintenance activities also leads to substantial improvements in safety and hygiene conditions, as it reduces worker exposure to high-risk tasks such as demolition work, handling heavy components, or working in confined spaces and difficult-to-access areas. Consequently, the likelihood of incidents or accidents is significantly reduced.
Finally, the longer service life of refractory components has a clear environmental and economic benefit, due to the reduction in waste generation and the associated waste management requirements.
Discover our solutions to enhance the robustness and efficiency of your rotary furnaces:
https://www.insertec.biz/refractory-solutions/aluminium-foundry/rotary-furnace/