Aluminum Slag Recycling Plant: A Green Factory Construction Solution Turning Waste into Treasure
Aluminum slag, a solid waste generated during aluminum smelting and processing, produces approximately 100-150 kg of slag per ton of aluminum processed. Improper dumping not only occupies land but also pollutes soil and water sources due to harmful substances such as fluorides and nitrogen oxides. Constructing an aluminum slag recycling plant can achieve the secondary utilization of aluminum resources and solve solid waste pollution problems, making it a crucial link in the circular economy of the aluminum industry.
I. Plant Planning and Layout
The aluminum slag recycling plant needs to be located in an industrial park, far from residential areas and water sources, covering an area of approximately 15-20 acres. It should be functionally divided into four main areas: The raw material area is equipped with enclosed silos for storing aluminum slag to be processed, preventing dust dispersion; the production area houses the core equipment production line, adopting a modular design and reserving space for future expansion; the finished product area includes an aluminum ingot storage warehouse and a by-product stacking area, with clear zoning; the auxiliary area includes office buildings, laboratories, and environmental protection facilities to ensure efficient integration of production and management. Meanwhile, the plant area must be equipped with dedicated transportation channels, using enclosed trucks to transport aluminum slag, reducing secondary pollution during transportation.
II. Core Processes and Equipment Configuration
Aluminum slag recycling adopts a four-stage process: pretreatment, extraction, refining, and environmental treatment. In the pretreatment stage, large impurities in the aluminum slag are separated by a vibrating screen, and then the slag is crushed to below 50 mm by a jaw crusher, improving the aluminum metal recovery rate. The extraction stage is the core link, employing a combined process of hot pressing and cold separation. The hot press compresses the aluminum slag at a temperature of 600-650℃, separating coarse aluminum liquid. Cold separation uses magnetic separation and airflow separation equipment to extract fine aluminum particles from the slag, achieving an overall aluminum recovery rate of over 85%. The refining process utilizes a medium-frequency induction furnace to heat the crude aluminum liquid to 720-750℃. Refining agents are added to remove hydrogen and non-metallic impurities, ultimately casting recycled aluminum ingots with a purity of over 99.5%. Environmental protection is indispensable. Dust generated during crushing and screening is collected by bag filters, and exhaust gas is purified by desulfurization and denitrification devices before being discharged in compliance with standards. The treated waste residue can be used as building aggregate or cement additive, achieving zero solid waste emissions throughout the entire process. Major equipment must be energy-efficient, such as variable frequency crushers and waste heat recovery furnaces, to reduce production energy consumption.
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III. Environmental Protection and Safety Assurance
For environmental protection, the plant area must construct rainwater collection ponds and wastewater treatment plants. Production wastewater is treated and recycled, with no external discharge. Solid waste is stored separately, with recyclable portions transferred regularly, and hazardous waste disposed of by professional organizations. For safety management, explosion-proof lighting and fire-fighting facilities are installed in the production area. Operators must undergo professional training and be equipped with anti-scalding and dust-proof protective equipment. A regular equipment maintenance system is established to ensure production safety.
IV. Economic Benefits and Market Prospects Based on a daily processing capacity of 100 tons of aluminum slag, an aluminum slag recycling plant can produce 8-10 tons of recycled aluminum and 15-20 tons of building aggregate as byproducts daily, with annual sales revenue reaching 20-30 million yuan. With the increasing demand from the recycled aluminum industry and tightening environmental policies, the aluminum slag recycling market has broad prospects. Simultaneously, the plant can apply for special environmental subsidies and tax incentives, further reducing operating costs and achieving a win-win situation for both environmental and economic benefits.
