Method for producing aluminum oxygen absorber, aluminum powder, and zinc oxide in a single batch process.

Abstract

Provided is a method for producing an aluminum deoxidizer, aluminum powder, and zinc oxide in a single batch process. The present invention relates to a method for producing an aluminum deoxidizer, aluminum powder, and zinc oxide in a single batch process. The method includes a step of supplying gallium dross to an induction furnace and melting the gallium dross. The method includes a step of extracting zinc oxide powder, deoxidized aluminum, and aluminum powder from the molten gallium dross.

Description

【Technical Field】 【0001】 The present disclosure relates to the field of treating gallium dross formed during the zinc plating process of steel. In particular, the present invention relates to, but is not limited to, a method for producing aluminum deoxidizer, aluminum powder, and zinc oxide from gallium dross in a single batch process. 【Background Art】 【0002】 Gallium dross is a byproduct generated in the step of zinc plating steel. Steel products are zinc plated to improve the corrosion resistance of steel. Zinc plating is widely used to coat steel, and the zinc plating process is performed by immersing steel products in a bath of molten zinc and aluminum. In the zinc plating process, a large amount of zinc and aluminum are lost in the form of gallium dross, so new zinc and aluminum are regularly added. Gallium dross is a combination of free zinc and Zn-Fe-Al intermetallic compounds and is formed by multiple reactions between zinc, aluminum, and dissolved iron from the immersed steel products. Since gallium dross contains zinc and aluminum at high concentrations, it is a valuable byproduct. However, due to the lack of technology and efforts to extract zinc and aluminum from gallium dross, zinc and aluminum resources are often wasted. In addition, the long-term storage of gallium dross causes long-term environmental problems. 【0003】 Conventionally, multiple techniques have been studied for recovering zinc and aluminum from galvalume dross using different extraction processes, including, but not limited to, distillation, electrolytic refining, leaching, and supergravity techniques. However, these conventional techniques use separate, independent processes for each type of extraction to extract zinc, aluminum, silicon, iron, etc., from raw materials such as galvalume dross. Thus, manufacturers produce aluminum deoxidizer / powder and zinc oxide, but in two different batches from two different raw materials using two independent processes. These produce aluminum-finished products from aluminum-containing raw materials and similarly produce zinc-finished products from zinc-containing raw materials, and are not related to each other. Such conventional techniques require enormous time and cost for the infrastructure to extract aluminum powder, zinc oxide, etc. Therefore, a process is needed to produce aluminum deoxidizer / powder and zinc oxide from a single raw material, namely galvalume dross, in a single batch process. 【0004】 This disclosure aims to overcome one or more of the limitations described above, as well as other limitations related to the prior art. [Overview of the Initiative] 【0005】 The present invention provides a method for producing aluminum deoxidizing agent, aluminum powder, and zinc oxide from galvalume dross in a single-batch process. The method includes the step of supplying galvalume dross to an induction furnace to melt the galvalume dross, the galvalume dross being received as a byproduct. The received galvalume dross is classified into either top-grade galvalume dross, bottom-grade galvalume dross, and specified-size galvalume dross, with the top-grade and bottom-grade galvalume dross being classified based on the iron content of the received galvalume dross. The method further includes the step of transferring the molten galvalume dross to a silicon carbide crucible furnace and heating the molten galvalume dross to a predetermined temperature, the heating of which causes zinc vapor to evaporate from the top of the molten galvalume dross. This method includes the steps of collecting zinc vapor in an oxidation chamber to produce zinc oxide powder, and adding pure aluminum to the residual molten metal based on a determination of the quality of the molten metal, wherein the residual molten metal is the residual contents after the zinc vapor has evaporated from the molten galvalume dross. This method further includes the step of casting the molten metal in a casting machine to produce an aluminum deoxidizer or aluminum powder. 【0006】 The above summary is illustrative only and does not limit the scope in any way. Further embodiments, features, and characteristics will become apparent by reference to the drawings and the detailed description below, in addition to the exemplary aspects, embodiments, and features described above. [Brief explanation of the drawing] 【0007】 Novel features and characteristics of this disclosure are described in the appended claims. However, the disclosure itself, as well as its preferred modes of use, further purposes and advantages, are best understood by referring to the following detailed description of exemplary embodiments, when read in conjunction with the drawings. Herein, one or more embodiments are described only as examples with reference to the drawings, where the same reference numerals represent the same elements, as follows: [Figure 1] This flowchart shows a method for producing aluminum oxygen scavenger, aluminum powder, and zinc oxide from galvalume dross in a single batch process according to an embodiment of the present disclosure. [Figure 2A] This is a flowchart showing the steps for processing received galvalume dross according to an embodiment of the present disclosure. [Figure 2B] This flowchart shows the steps for producing zinc oxide powder from received galvalume dross according to an embodiment of the present disclosure. [Figure 3A] This flowchart shows the steps for treating residual molten metal after zinc vapor extraction, according to an embodiment of the present disclosure. [Figure 3B] This flowchart shows the steps for producing aluminum powder from residual molten metal according to an embodiment of the present disclosure. [Modes for carrying out the invention] 【0008】 In this document, the term “exemplary” is used to mean “serving as an example, case, or illustration.” No embodiment or implementation of the subject matter of the present invention described “exemplary” herein shall necessarily be construed as being preferable or advantageous to any other embodiment. 【0009】 While various modifications and alternative forms are possible for the present invention, specific embodiments are shown as examples in the drawings and described in detail below. However, it should be understood that the disclosure is not intended to be limited to the disclosed form, but rather is intended to cover all modifications, equivalents, and alternatives that fall within the spirit and scope of the disclosure. 【0010】 The terms “comprise,” “comprising,” and variations thereof are intended to cover non-exclusive inclusion, meaning that a setup, device, or process containing a list of components or steps does not necessarily contain only those components or steps, but may also contain other components or steps not explicitly listed or specific to such setup, device, or process. In other words, the inclusion of one or more elements in a system or apparatus following “comprise” does not, unless further constraints, exclude the presence of other or additional elements in the system or apparatus. 【0011】 Embodiments of the present disclosure provide a method for producing aluminum deoxidizer, aluminum powder, and zinc oxide from galvalume dross in a single-batch process. The method includes the step of feeding galvalume dross into an induction furnace to melt the galvalume dross, the galvalume dross being received as a byproduct. The received galvalume dross is sorted into either top-grade galvalume dross, bottom-grade galvalume dross, and specified-size galvalume dross before being fed into the induction furnace, with the top-grade and bottom-grade galvalume dross being sorted based on the iron content of the received galvalume dross. The method further includes the step of transferring the molten galvalume dross to a silicon carbide crucible furnace and heating the molten galvalume dross to a predetermined temperature, wherein, upon heating the molten galvalume dross, zinc vapor evaporates from the top of the molten galvalume dross. This method includes the steps of collecting zinc vapor in an oxidation chamber to produce zinc oxide powder, and adding pure aluminum to the residual molten metal based on a determination of the quality of the molten metal, wherein the residual molten metal is the residual contents after the zinc vapor has evaporated from the molten galvalume dross. This method further includes the step of casting the molten metal in a casting machine to produce an aluminum deoxidizer or aluminum powder. 【0012】 The following paragraphs will describe the present disclosure with reference to Figures 1 and 3B. In the figures, Figure 1 illustrates an exemplary method of the present disclosure, showing the various steps of Method (100) for producing aluminum deoxidizer, aluminum powder, and zinc oxide in a single-batch process. Method (100) allows manufacturers to produce aluminum deoxidizer, aluminum powder, and zinc oxide in a single-batch process from galvalume dross, a waste by-product of the galvanizing step of metal products. Thus, Method (100) eliminates the need to use two independent processes, two different batches, and two different raw materials to produce aluminum deoxidizer / powder and zinc oxide from galvalume dross. In one embodiment, Method (100) according to the present disclosure helps to independently branch galvalume dross into secondary aluminum and zinc in a single-batch process. Thus, Method (100) allows manufacturers to recycle galvalume dross using the most efficient technology. Furthermore, Method (100) requires only one set of machinery to produce both secondary aluminum and zinc oxide. Therefore, the present invention saves cost, time, fuel, energy, site area, and manual labor compared to conventional methods for producing secondary aluminum and zinc. 【0013】 However, those skilled in the art will understand that the size and configuration of the machine set required to carry out this method (100) can be modified according to the requirements of different types of installation environments. Any such modification shall be construed as being within the scope of this disclosure. 【0014】 As shown in Figure 1, Method (100) comprises one or more blocks performed to produce an aluminum deoxidizer, aluminum powder, and zinc oxide in a single-batch process. The order in which Method (100) is described is not intended to be construed as a restriction, and the Method can be implemented by combining any number of the described Method blocks in any order. Furthermore, individual blocks can be removed from the Method without departing from the spirit and scope of the subject matter described herein. 【0015】 In block (102), galvalume dross is supplied to an induction furnace and melted. In one embodiment, galvalume dross is received as a by-product and is available in the form of large blocks, the weight of which ranges from 50 kg to 1,500 kg, depending on the source of the dross, i.e., how the dross is handled at the plant that produces such dross. Upon receiving the galvalume dross, it is classified into either top-grade galvalume dross, bottom-grade galvalume dross, and specified-size galvalume dross. Top-grade and bottom-grade galvalume dross are classified based on the iron content of the received galvalume dross. In one example, top-grade galvalume dross may contain the chemical composition of aluminum, zinc, iron, silicon, and copper in the proportions listed in Table 1. 【0016】 [Table 1] 【0017】 In another example, bottom-grade galvalume dross may contain the chemical composition of aluminum, zinc, iron, silicon, and copper in the proportions listed in Table 2. 【0018】 [Table 2] 【0019】 Furthermore, gallium dross is supplied to an induction furnace and melted. In one embodiment, in the case of top-grade gallium dross, the gallium dross is directly supplied to the induction furnace for melting. In the case of bottom-grade gallium dross, the gallium dross is cut into small pieces with each piece having a dimension of 21 inches or less, and such small pieces of bottom-grade gallium dross are directly transferred to a silicon carbide crucible furnace for processing. The top-grade gallium dross is supplied to the induction furnace using an overhead crane, and at this time, a crane with an appropriate capacity is used to safely transfer the top-grade gallium to the induction furnace. A set of iron hooks attached to the block of top-grade gallium dross is removed as soon as possible to prevent iron from accumulating in the metal tank. 【0020】 An induction furnace is an electric furnace that induction-heats gallium dross to apply heat. The capacity of the induction furnace ranges from less than 1 kilogram to 100 tons and is used for melting steel, copper, aluminum, and precious metals. Compared with most other metal melting methods, the induction furnace provides a clean, energy-efficient, and properly controlled melting process. The induction furnace operates on the principle of induction heating and heats conductive materials non-contact. Therefore, in an induction furnace, there is no need to burn fuel or other external heat sources. 【0021】 Therefore, the received gallium dross is melted in the induction furnace. Furthermore, the process of melting the received gallium dross is carried out in steps as shown in Figure 2A. 【0022】 In block (202), a flux additive is added to the molten gallium dross. In one embodiment, a flux additive in the form of a mixture of cover flux (1.5% of the induction furnace batch weight) and sodium cryolite (0.5% of the induction batch weight) is added to the bath, i.e., the molten gallium dross. As a result, the upper surface of the molten gallium dross is covered with the flux, minimizing the oxidation of the metal. 【0023】 Block ((204)) removes slag from the molten galvalume dross. In one embodiment, the slag is a composite solution of silicates and oxides that is generated when the galvalume dross melts and solidifies when cooled. Removing the slag from the molten galvalume dross helps to remove impurities and protects the refractory lining of the induction furnace from excessive wear. 【0024】 After removing the slag from the top of the molten galvalume dross, the slag-free molten galvalume dross is further processed as shown in Figure 1. 【0025】 In block (104), molten galvalume dross without slag is transferred to a silicon carbide crucible furnace. In one embodiment, molten galvalume dross without slag is transferred to a silicon carbide crucible furnace for high-temperature processing of the molten galvalume dross. The silicon carbide crucible furnace is designed to achieve high-precision high-temperature uniformity and to efficiently indirectly heat non-ferrous metals. Silicon carbide is a ceramic material with relatively high electrical conductivity compared to other ceramics. 【0026】 In the process of transferring slag-free molten galvalume dross to a silicon carbide crucible furnace, the induction furnace is tilted 90 degrees, and the molten galvalume dross flows through a trough and fills a ladle. Furthermore, the molten galvalume dross is transferred from the ladle to the silicon carbide crucible furnace. In the case of bottom galvalume dross, the solid bottom galvalume dross is supplied directly to the silicon carbide crucible furnace and melted. 【0027】 Therefore, the upper galvalume dross is first added to the induction furnace for melting, and then the molten metal of the galvalume dross is transferred to the silicon carbide crucible furnace. The induction furnace is a larger furnace than the silicon carbide crucible furnace. Therefore, the induction furnace can accommodate larger galvalume dross pieces and can melt larger galvalume dross pieces without cutting them into smaller pieces. Also, using an induction furnace results in lower fuel costs and saves time compared to the silicon carbide crucible furnace, thus increasing the production of zinc and secondary aluminum. However, if necessary, the upper galvalume dross can also be melted directly in the silicon carbide crucible furnace, for example, when the induction furnace is occupied with other materials in operation or is undergoing maintenance, or when more galvalume dross is needed in multiple silicon carbide crucible furnaces than the induction furnace can handle. 【0028】 In block (106), the molten galvalume dross is heated to a predetermined temperature, causing zinc vapor to evaporate. In one embodiment, the molten galvalume dross is further heated in a silicon carbide crucible furnace. The molten galvalume dross is heated to a predetermined temperature range of 1300°C to 1400°C to boil the metals in the molten galvalume dross. When the molten galvalume dross is heated, zinc vapor evaporates from above the molten galvalume dross. Since zinc has a boiling point of 907°C, it is converted into a gas, while the boiling points of the other metals in the galvalume dross, namely aluminum (Al), silicon (Si), iron (Fe), and copper (Cu), are 2470°C, 2355°C, 2862°C, and 2560°C, respectively. Because the boiling point of zinc is lower than that of the other metallic elements (Al, Si, Fe, Cu) in the galvalume dross, only zinc evaporates to form zinc vapor, while the other metals remain molten in the crucible. 【0029】 In block (108), zinc vapor is collected in an oxidation chamber to produce zinc oxide powder. In one embodiment, zinc vapor is collected in an oxidation chamber, where it reacts with oxygen in the air to produce zinc oxide vapor. Furthermore, the process of collecting zinc oxide vapor is carried out in the steps shown in Figure 2B. 【0030】 In block (212), zinc oxide vapor is transported through a long pipe and cooled. In one embodiment, zinc oxide vapor is transported through a 400-foot-long pipe and cooled to form a fine white solid powder, i.e., zinc oxide powder. 【0031】 In block (214), zinc oxide powder is collected in a pulse-jet airbag housing. In one embodiment, solid powdered zinc oxide is discharged from the pulse-jet airbag housing. The pulse-jet airbag housing or pulse-jet dust collector is a self-cleaning dry filtration system. The pulse-jet dust collector cleaning system removes particulate matter and dust from the surface of the internal filter media by jetting compressed air. Pulse-jet dust collectors are used because they are easy to operate, have low energy consumption, and require minimal maintenance. 【0032】 In block (216), the zinc oxide powder is passed through a blender. In one embodiment, once the pulse jet filtration of the zinc oxide powder is complete, the zinc oxide powder is passed through a blender, and the bulk density of the zinc oxide powder increases. 【0033】 Block (218) determines the quality of the zinc oxide powder. In one embodiment, the quality of the zinc oxide is checked multiple times periodically by each quality assurance team in the laboratory under the same heating conditions, following standard quality steps. After determining the quality, the zinc oxide is weighed and packed into 25 kg HDPE bags. 【0034】 As an example, zinc oxide produced from galvalume dross is evaluated to have a purity within the range shown in Table 3. 【0035】 [Table 3] 【0036】 Therefore, zinc oxide white seal grade is produced as a finished product that is applied in the manufacture of ceramics, rubber, and paints. 【0037】 Once the evaporation of zinc from the top of the molten galvalume dross is complete, the remaining molten metal is further processed as shown in Figure 1. 【0038】 In block (110), pure aluminum is added to the residual molten metal based on the quality of the molten metal. In one embodiment, the process of adding pure aluminum to the residual molten metal is carried out in the steps shown in Figure 3A. 【0039】 In block (302), a flux additive is added to the residual molten metal. In one embodiment, once the evaporation of zinc is complete, a pink cover flux, which is a flux additive, is added to the residual molten metal and the mixture is stirred. The residual molten metal is the residue after the zinc vapor has evaporated from the molten galvalume dross, and the residue contains secondary aluminum with small amounts of other elements such as Si, Fe, and Cu. 【0040】 Typically, secondary aluminum is made from recycled aluminum scrap obtained from all kinds of aluminum products and profiles, such as aluminum turned parts, aluminum sheets, aluminum strips, aluminum radiators, cast aluminum, extruded parts, painted siding, and aluminum dross. Generally, secondary aluminum has a high tolerance for alloying elements such as iron, magnesium, and silicon. 【0041】 In block (304), slag is removed from the residual molten metal. In one embodiment, the slag is removed from the residual molten metal by hand or using power tools. 【0042】 Block (306) evaluates the chemical composition of residual molten metal without slag. In one embodiment, a sample of residual molten metal is evaluated for its chemical composition by a quality assurance team using laboratory quality equipment such as an optical emission spectrophotometer (OES). 【0043】 OES is used to instantly determine the chemical composition of finished products and raw materials. OES is a reliable and widely used analytical instrument used to determine the elemental composition of a wide range of metals. Types of samples tested using OES include molten samples in primary and secondary metal production, and tubes, bolts, rods, wires, and plates in the metalworking industry. OES can analyze a wide range of elements from hydrogen to uranium in solid metal samples, covering a broad concentration range, achieving extremely high precision, accuracy, and low detection limits. 【0044】 Quality testing helps determine whether the chemical composition of the residual molten metal matches customer requirements. 【0045】 In block (308), pure aluminum is added to the residual molten metal based on evaluation. In one embodiment, if a discrepancy with customer requirements is found, pure aluminum is added to the silicon carbide crucible furnace to achieve the desired composition of the residual molten metal. A sample of the residual molten metal is taken again and evaluated with OES to confirm that the chemical composition of the molten metal conforms to customer requirements. If the received quality is not as expected, a 99.5% pure aluminum ingot or aluminum scrap is added to the remaining molten metal and the mixture is stirred to homogenize it. After the addition of pure aluminum, a sample of the residual molten metal is taken again and the chemical composition is checked using OES. 【0046】 Therefore, adding pure aluminum to the residual molten metal improves the quality of the secondary aluminum. 【0047】 Once quality testing is complete and the desired quality of the secondary aluminum is determined, the remaining molten metal is further processed as shown in Figure 1. 【0048】 In block (112), an aluminum deoxidizer / aluminum powder is produced by casting or atomizing the residual molten metal. 【0049】 In one embodiment, once the quality of the secondary aluminum is finalized, the residual molten metal is cast into a mold of the desired shape to obtain aluminum deoxidizer in the desired form. When creating shot-like shapes, the molten metal is transferred to a shot casting machine such as a homemade chakari, where it passes through holes in a tray and solidifies upon cooling to form droplets called shots or granules. For aluminum ingots, cubes, or hemispheres, the molten metal is poured into customized molds of the respective shapes and sizes according to customer requirements. Furthermore, the aluminum deoxidizer is packaged in 50kg HDPE woven bags or 1MT jumbo HDPE bags, as required by the customer. 【0050】 As an example, an aluminum oxygen scavenger produced from galvalume dross (which has a low iron content) is estimated to have the chemical composition shown in Table 4. 【0051】 [Table 4] 【0052】 As an example, an aluminum oxygen absorber produced from bottom galvalume dross (high iron content) is estimated to have the chemical composition shown in Table 5. 【0053】 [Table 5] 【0054】 Aluminum deoxidizers, manufactured from galvalume dross, are used to deoxidize molten steel and improve its quality. Molten steel contains dissolved oxygen, which must be removed during the melting process. Failure to do so will result in porosity in the solid steel, reducing its tensile strength. 【0055】 In another embodiment, residual molten metal is processed to produce aluminum powder. The process for producing aluminum powder from residual molten metal is carried out in the steps shown in Figure 3B. 【0056】 In block (312), the residual molten metal is transferred to a holding furnace. In one embodiment, the holding furnace is used for further processing of the molten metal. The holding furnace is a heated reservoir for holding the molten metal in preparation for casting. 【0057】 In block (314), molten aluminum is atomized to form fine aluminum shots. In one embodiment, a jet of high-pressure air is used in a holding furnace to atomize the molten metal into fine molten particles or shots, which are then cooled to form a solid powder, i.e., aluminum powder. 【0058】 In block (316), fine aluminum shots are collected in a collection chamber. In one embodiment, the fine aluminum shots are collected in a collection chamber attached to a holding furnace. In one embodiment, the fine aluminum shots are collected in a collection chamber attached to a holding furnace. Hot air from the chamber is drawn in by a 3HP fan. 【0059】 In block (318), the fine aluminum shots are sieved to various sizes. In one embodiment, aluminum powder in the form of fine aluminum shots is sieved to various sizes and packed into 25 kg HDPE bags. The finer aluminum powder is collected in a cyclone located between the fan and the collection chamber. The fine aluminum shots are used in a variety of applications. 【0060】 For example, aluminum powder produced from galvalume dross is estimated to have the chemical composition shown in Table 6. 【0061】 [Table 6] 【0062】 Aluminum powder produced by the spraying method is used in a variety of applications, including the manufacture of ferroalloys such as ferromanganese and ferrochrome. During the production of ferroalloys, aluminum powder is added to induce a thermite reaction, an exothermic reaction that generates the extreme heat necessary for the formation of ferroalloys. Aluminum powder can also be used for the same purpose in the firecracker industry. In the aforementioned applications, the size of the aluminum powder varies from -10 mesh to +100 mesh. 【0063】 Furthermore, finer aluminum powder with a mesh size of -200 mesh is used in the production of aluminum phosphide (ALPHOS), a fumigant. Aluminum powder with a mesh size of -300 mesh is used in the production of AAC blocks (aeration autoconclave blocks). 【0064】 In the experiment, information related to each process cycle is recorded. In the illustrative diagram, each process cycle, or batch, of the silicon carbide crucible furnace is called a heat and assigned a heat number. The weight of each heat is 800 kg as input, either in the molten state (for upper galvalume dross) or in the solid state (for lower galvalume dross). The manufacturing steps of each heat consist of four stages: filling, oxidation, sampling, and casting. In the filling stage, the feed is heated to a boil at 1400°C, and the filling process takes 1 hour if molten metal is supplied from an induction furnace to the silicon carbide crucible furnace, or 4 hours if solid dross is melted directly. Furthermore, the oxidation process takes about 6 hours, during which zinc vapor reacts with oxygen to form zinc oxide. Furthermore, the sampling process takes about 0.5 hours, and the casting process takes about 1.5 hours. Thus, the total time per heating is about 12 hours, but this time can be reduced to about 9 hours if the molten metal is transferred directly to the silicon carbide crucible furnace. Furthermore, when aluminum is powdered, the molten metal is immediately transferred to the holding furnace, saving one hour of casting time in the process cycle and reducing the total heating time to approximately eight hours. 【0065】 In another example, it is observed that with an input of 100 kg of top galvalume dross, the output received is 98 kg of finished product, i.e., aluminum and zinc. When bottom galvalume dross is used as input, 95 kg of finished product is obtained. Therefore, the yield for top galvalume dross is 98%, and the yield for bottom galvalume dross is 95%. 【0066】 In yet another example, the slag formed on molten galvalume dross contains both metallic and nonmetallic components. The slag is placed in steel containers and transported to a shed using a combination of cranes and rails. The slag is further processed in a vibrating machine, which disperses the internal heat of the slag, causing the metallic components to coagulate and convert them into a liquid, which is then poured from the vibrating machine into a mold to form an ingot. The remaining material is cooled for several hours, then passed through a ball mill, and then a crusher to further separate the remaining metallic and nonmetallic components. The metallic components recovered from the slag are remelted in an induction furnace and transferred to a silicon carbide crucible furnace, where the zinc is removed by oxidation and the remaining aluminum is cast. Benefits of this disclosure: 【0067】 The present invention provides a method (100) that enables manufacturers to produce aluminum oxygen scavenger, aluminum powder, and zinc oxide from galvalume dross, a waste by-product of the zinc plating process of metal products, in a single-batch process. Thus, this method (100) eliminates the need to use two independent processes, two different batches, and two different raw materials to produce aluminum oxygen scavenger / powder and zinc oxide. 【0068】 Furthermore, this method (100) helps to independently separate galvalume dross into secondary aluminum and zinc in a single batch process. Thus, this method (100) creates new applications for galvalume dross. This method (100) also enables manufacturers to recycle galvalume dross in the most efficient and environmentally friendly way. In addition, using galvalume dross results in significantly lower costs compared to the cost of raw materials used in separate manufacturing processes for producing aluminum deoxidizers, aluminum powder, and zinc oxide. 【0069】 This method (100) allows for a significant reduction in raw material costs compared to competing manufacturers, thus providing manufacturers with a substantial cost advantage. Consequently, manufacturers can sell secondary aluminum and zinc at lower prices than other producers. 【0070】 Furthermore, this method (100) requires only one set of machinery to produce both secondary aluminum and zinc oxide. Therefore, the present invention saves cost, time, fuel, energy, site area, and manual labor compared to conventional methods for producing secondary aluminum and zinc. 【0071】 The detailed description of embodiments of this disclosure refers to accompanying drawings illustrating specific embodiments that form part of this specification and enable the implementation of this disclosure. These embodiments are described in sufficient detail so that those skilled in the art can implement this disclosure, and it should be understood that other embodiments may be used and modifications may be made without departing from the scope of this disclosure. Therefore, this description should not be construed as restrictive. Equivalent: 【0072】 With regard to substantially any use of plural and / or singular terms herein, those skilled in the art can translate from plural to singular and / or singular to plural as appropriate to the context and / or use. For clarity, various singular / plural permutations may be explicitly listed herein. Generally, it will be understood by those skilled in the art that the terms used herein, and in particular in the appended claims (e.g., in the body of the appended claims), are generally intended to be “open” terms (for example, the term “includes” should be interpreted as “includes, but not limited to,” the term “has” should be interpreted as “has at least,” and the term “includes” should be interpreted as “includes, but not limited to,” etc.). Furthermore, it will be understood by those skilled in the art that if a particular number of descriptions in an introduced claim are intended, such intent is explicitly stated in the claim, and if such statement is absent, such intent does not exist. For example, to aid understanding, the following appended claims may use the introductory phrases “at least one” and “one or more” to introduce the description of the claim. However, the use of such phrases should not be interpreted as meaning that the introduction of a claim description with the indefinite article “a” or “an” limits a particular claim containing the introduced claim description to an invention containing only one such description. Even if the same claim contains the introductory phrase "one or more" or "at least one" and the indefinite article "a" or "an" (for example, "a" and / or "an" should generally be interpreted as meaning "at least one" or "one or more"), the same applies to the use of the definite article used to introduce the statement of a claim. 【0073】 Furthermore, even when a specific number of claims introduced is explicitly stated, a person skilled in the art will recognize that such a statement should generally be interpreted to mean at least the number stated (for example, the mere statement “two claims” without other modifiers usually means at least two claims, or two or more claims). Moreover, when a rule similar to “at least one of A, B, C, etc.” is used, such interpretation is generally intended to mean that a person skilled in the art will understand the rule (for example, “a system comprising at least one of A, B, C” includes, but is not limited to, systems comprising only A, only B, only C, both A and B, both A and C, both B and C, and / or both A, B, and C, etc.). Where a rule similar to “at least one of A, B, C, etc.” is used, such interpretation is generally intended to mean that a person skilled in the art will understand the rule (for example, “a system including at least one of A, B, C, etc.” includes, but is not limited to, a system including only A, only B, only C, both A and B, both A and C, both B and C, and / or all of A, B and C, etc.). Furthermore, a person skilled in the art will understand that substantially any separator and / or phrase presenting two or more alternative terms in a description, claim, or drawing should be understood to consider the possibility of including one of the terms, either of the terms, or both of the terms. For example, the phrase “A or B” is understood to include the possibilities of “A” or “B” or “A and B”. 【0074】 While various aspects and embodiments are disclosed herein, other aspects and embodiments will also be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are illustrative and not limiting, and the true scope and spirit are shown by the following claims.

Claims

[Claim 1] A method for recovering aluminum and zinc from galvalume dross in a single batch process, A step of supplying galvalume dross to an induction furnace and melting the galvalume dross, wherein the galvalume dross is received as a by-product, and the above step, The process involves transferring molten galvalume dross to a silicon carbide crucible furnace and heating the molten galvalume dross to a predetermined temperature, wherein when the molten galvalume dross is heated, zinc vapor evaporates from above the molten galvalume dross. The steps include collecting the zinc vapor in an oxidation chamber to produce zinc oxide powder, Based on the results of a quality test of the molten metal residue remaining after heating molten galvalume dross to evaporate zinc vapor, the step of adding pure aluminum to the molten metal residue, A method comprising the step of casting the molten metal residue in a casting machine to produce an aluminum deoxidizer or aluminum powder. [Claim 2] The step of melting the received galvalume dross is, The process involves adding a flux additive, a mixture of cover flux and sodium cryolite, to the molten galvalume dross, and covering the top of the molten galvalume dross with flux to minimize the oxidation level. The method according to claim 1, comprising the step of removing slag from the top of the molten galvalume dross. [Claim 3] The step of transferring the molten galvalume dross to a silicon carbide crucible furnace is, The step of tilting the induction furnace 90 degrees, wherein the molten galvalume dross flows through a trough and fills a ladle, and the step of, The method according to claim 1, comprising the step of transferring molten galvalume dross from the ladle to the silicon carbide crucible furnace. [Claim 4] The method according to claim 1, wherein the molten galvalume dross is heated to a predetermined temperature range of 1300°C to 1400°C to boil the metal of the molten galvalume dross. [Claim 5] The step of collecting zinc vapor in the oxidation chamber is, The zinc oxide produced by the oxidation of the zinc vapor is transported through a pipe 121.92 meters (400 feet) long and cooled to form a fine white solid zinc oxide powder. The steps include collecting the zinc oxide powder with a pulse jet dust collector, A step of determining the quality of the zinc oxide powder based on predefined criteria, The method according to claim 1, comprising the step of increasing the bulk density of the zinc oxide powder by passing it through a blender having a function of stirring the powder to increase its density. [Claim 6] The step of adding pure aluminum to the molten metal residue is, The steps include adding a flux additive to the molten metal residue, The steps include removing slag from the top of the molten metal residue, The steps include evaluating the chemical composition of the molten metal residue sample from which the slag has been removed by conducting a quality test on the molten metal residue sample from which the slag has been removed, and The method according to claim 1, comprising the step of adding pure aluminum to the molten metal residue based on an evaluation of the chemical composition of the molten metal residue to achieve a desired composition of the molten metal residue. [Claim 7] The method according to claim 1, wherein the molten metal residue is cast into a mold of a desired shape to obtain an aluminum oxygen scavenger of a desired shape. [Claim 8] The step of generating aluminum powder from the molten metal residue is, The steps include transferring the molten metal residue to a holding furnace, The process involves atomizing the molten metal residue by the injection of high-pressure air to form fine aluminum shots, The steps include collecting fine aluminum shots in a collection chamber attached to a holding furnace, The method according to claim 1, comprising the step of sieving fine aluminum shots into various sizes.

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