Details of Grant 

EPSRC Reference:	GR/R15399/01
Title:	Physical and Computation Modelling of Non-Chlorine Cleaning of Aluminium In Furnaces as a Tool For Cleaning Process Design
Principal Investigator:	Jolly, Professor M
Other Investigators:	Nienow, Professor A Campbell, Professor J
Researcher Co-Investigators:
Project Partners:	British Aluminium Ltd N-Tec Pyrotek Engineering Materials Ltd
Department:	IRC in Materials Processing
Organisation:	University of Birmingham
Scheme:	Standard Research (Pre-FEC)
Starts:	17 February 2001	Ends:	16 February 2004	Value (£):	526,248
EPSRC Research Topic Classifications:	Materials Processing
EPSRC Industrial Sector Classifications:	Manufacturing
Related Grants:
Panel History:
Summary on Grant Application Form
Aluminium slab is made by the semi-continuous process of DC casting. Gaseous chlorine is bubbled through a lance into the melt to eliminate certain elements from the aluminium which are detrimental to its quality. The process is generally inefficient in the use of chlorine and it also gives rise to a potentially severe environmental issue as it leaves the reactor. An alternative approach is to undertake an equivalent chemical reaction using granulated fluxes made primarily of solid halides. Dissolution and mixing of these granules is required which depends on the local temperature and motion of the melt relative to the granule. The approach has been found to work satisfactorily when a reaction chamber (or a crucible) is used which has a shape close to the optimum which enables mixing to be readily undertaken. However, in many cases the geometry is far from satisfactory. Many furnaces are rectangular shallow baths with poor access that is restricted to small doors in the side wall above the liquid aluminium surface. Mixing difficulties are then enormously increased. The research intends to determine the relationship between melt agitation, effect of carrier gas, effect of furnace geometry and impeller design. The rules for the optimum configuration of impeller position and design for a variety of furnace designs will be determined.The project will give a fundamental understanding to an alternative process aimed at reducing the environmental impact of aluminium slab casting. The modelling and simulation will relate process parameters to process design.
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Organisation Website:	http://www.bham.ac.uk