CA1121118A - Method and apparatus for treating aluminous metal skim material and by-products of said method - Google Patents

Abstract

ABSTRACT
A method for treating hot skim material to separate, recover, and prepare for use bath aluminum and non-aluminous constituents contained in the hot skim materials involves a centrifuge having a rotatable bowl to receive a charge of skim material. The centrifuge then both consolidates the non-aluminous constituent thereof into a semi-porous cake and separates and discharges molten aluminum as the bowl is rotated. The semi-porous cake is cooled and found to be friabls. Thereafter the friable cake is crushed and screened to be used as a foaming and extending agent.

Description

Thls lnvention reLa-t~s ko the ar-t of recovering aluminum rom skim mate ial, and it particularly concerr,~
the treatment of hot skim material in a manner ~hich allows recovery and use of non-aluminous constituents of skim material as a new by-product.
As used herein, al~ninum (or aluminous metal) in cludes the metal itself and alloys containing aluminwn as the principal element by weight. The aluminum product ob-tained in accordance wi~h the invention mav contain incidental amounts of skim residue, usually amounting to less than 5~
by welght. The term skim material refers to a kind of dross or skim commonly formed on a body of molten aluminum. It is a viscous, mushy or powdery substance of variable composition which floats on molten alumi~um, and may include oxides/ nitrides and other non-metallic compounds. Removal of such dross by skimming carries with it a considerable quantity of aluminum, and the skim material often is subjected to some t~pe of treat-ment to recover ~t least part of its aluminum value~.
Meltiny furnace ~kim materia:l can amount to as much a5 1.5 to 4% of the furnace charge, and its ~luminum content generally ranges from about 55 to 80~ of the ~eight of the ,_ skim material. Thus, the efficient recovery of aluminum alone from skim material can have economic implications o~ appreciable significance. In the past, the residual non-al~.;inous portion of the skim material has normally been discarded and has served as a source of pollution.
BACKGROUND OF TE~E INVENTION
.. .. .
Conventional methods of skim processing involve 29 p~ysical removal of the skim from the melt surface by mechanicaL

-2-a~

means, followed by secondary treatment to reclaim as much of the aluminous metal content as possible.
The handling of the skim in the metal melting or holding furnace has a direct influence on the extent of subsequent recovery of aluminous metal frcm the skim. When a suf~icient layer of skim has accumulated on the melt, it should be removed promptly, not only so that heating may continue efficiently, but more importantly, to minimize or prevent oxidation of the ~ntrained metal.

Skim formation on a melt surface apparently commences as a result of oxide in th~ original charge floating to the surface with adhering metal. In this original state relatively little oxidation has taken place, and the layer on the melt may contain as much as 95 percent metal. If heat is supplied through this layer, the layer acts as a barrier to heat trans~er and its temperature increases. Oxidation begins to increase and changes in physical form can be noted. Oxidation i~
promo~ed by the presence o air or products of combustion in an open heaxth ~urnace. Hot molten aluminum skim will com~ine pref~rentially with oxygen to form o~ides, but reactions can proceed with nitrogen to form nitrides and with carbon dioxide to form oxides a~d carbides.
As heating pro^eeds, the original wet mushy skim can change to a powdery form, in which the aluminum appears to form droplets with po~7dered non-metalllc materials on the surface. This latter physical form has a higher oxidation rate than the wet mushy for~. As these reactions ~re highly exothermic and increase with temperature and mass of the layer, 29 they can quickly get out of control and a reaction known as thermiting takes place. TherMitiny results in a rapid loss of metal through oxidation and it ls difficult to control.
Skim can also be gen~rated as the result of metal transfer operations. Such skim is generally of the wet mushy type but it behaves similarly to skim originating from melting.
Skim can also be generated from fluxing with gases such as chlorine, chlorine-nitrogen or other gases used for metal cleanliness purposes. These operations themselves may ignite the skim giving ~urther oxidation.
In prior-art aluminum melting it has been an object to generate the least amount of non-metallic material and separate as much metal as possible in the unoxidized state from the skim itself without regard for recovering the non-aluminous constituents of the skim.
In the past, for example, thermiting has been em-ployed intentionally to separate aluminum metal from sklm.
While thermiting occurs as the result of igniting molten alu-millum and using it as a fuel, such burning can be used to separate molten aluminwn from a mass of skim, particularl~
when combined with some form of agitation. Thermiting may be induced by the use of a solid ignition salt flux. Mixtures such as 75 percent sodium chloride-25 percent cryolite, anhydrous aluminum chloride, or proprietary compositions containing an active fluourlde are generally employed~ Gaseous chlorine may be introduced illtO the melt below the skim layer in con-junction with such treatment. ~owever, the introduction of such chemicals contaminates the non-aluminous constituents o~
the skim thereby inhibitlng their recovery and use as well as making it difficult to dispose of them because they serve as a source of pollution.
31 It has been proposed, in one prior-art approach, to Lrl ~L 8 handle the skim so as to induce and maintain thermiting or burning under controlled conditions by working the skim in an inclined rotary barrel open to the atmospheré, under oxidizing conditions, thus permitting a certain proportion of the metal content to be consumed, in order to recover the rest. This method has the drawbacks of being technically complicated to operate, and of causing voluminous fumes during tumbling of the thermi.ting skim.
In a subsequent development, the method was modi-fied by covering the rotary barrel and introducing gaseous ; chlorine to provide an inert aluminum chloride vapor atmos-phere. However, with this method, when the cover is removed, ~; a thermiting residue is exposed to the air, creating fume : control and safety problems even more acute than those en-countered using an open barrel.
A more recent development has been the rotary salt flux furnace process, which is believed to be presently in use, and which in~olves placing the alum:inous skim or dross inside a rotary barrel ~urnace, and then adding a predeter-mined amount of a salt flux in solid ~orm. The furnace isthen rotated at a suitable rate of speed to obtain a tumbling ~ or cascading action of the mixture of dross and solid flux to break up large lumps of dross. H at is then applied to the mixture by means of an oil or gas burner effective to liquefy the flux. After the flux is liquefied, the mixture is subjected to a gentle rolling action at a lower speed of rotation, during which the recoverable molten metal is separated from the dross. The flux is preferably a eutectic mixture of about 55 percent potassium chloride and 45 percent sodium chloride, to which from 2.5 percent to 5 percent of 31 cryolite.or other fiuoride may be added to promote oxide removal ~rom ~he metal particles. This method ha~ th~
disadvantag~s of appl~ing the burner flame directly to the flux, thus presentiny a po.ssible sourse of air pollution, and also requiring a rather high proportion of flux, amounting to about 50 percent or more by weight of the skim. Also, importantly, the tesidue is contaminated with flux which can be a major detriment to further recovery, processing or disposal thereof. The installation of the rotary furnace also xepresants a considerable capital i~vestment.
More recently still, the method of molten flux salt stirring in reclaiming aluminous metal from skim or dross has been provide~ ~hich helps ,o avoid many of the disadvantages of flux treatment. Skim removed from a body of molten aluminum is placed in a preheated pot, covered with a molten salt flux and subjected to stirring action.
This technique permits the u~e of much le~s salt flux, minimi~es the emission of fumes from the pot, and impro~e~
the recovery o al~ninum. However, it has certain disadvan~
tages in commorl with any flux treatment, as rela-t~d to contamination o. the non aluminous residue, and usually invol~-es the hot dumping of residue at temperatures high enough to be hazardous and to cause objectionable fuming.
A_cordingly, wh.at the art has sought, arid by various means has attempted to find, is an effici~nt method of recovering aluminous metal from s~im material -~ith the ieast possible coct and diificulty o operation~ It is an object of this invention to p~ovide a proces~ for treating .olten aluminum hot skim material ~co not only recover an accepLable aMount of aluminum therefrom hut to als~ recover relativel~ uncontaminated non-al~uminous constitu~Ant.C therefrom.

~ .

It i5 a furt.her object of -this invention to provid~
a method for treating non-alurninous constituents of hot skim for subsequent use thereof.
It is also an object o~ thi5 invention to provide new by-products from a process of treating skim material.

GE:NERAL DESCRIPTION OF THE INV:E:NTION
As noted above, various ~echniques have been used for treating aluminous metal skim material, many of which in-volve a molten salt fluxo An object of the present invention is to accomplish the separation and recovery of aluminum from skim material without the use of flux, and, as far as possible, without resort to a thermiting reaction by which much of its al~minum content is combusted to provide heat.
It has been found, in accordance with the invention t that hot skim material as removed from a melting furnace, ~ for example, is susceptible to treatment me~hanica1ly in a ; suitable centrifuge device to extract a large, and acceptable, propor~ion of its metallic aluminum conkent, lea~ing an un cont~ninated ash-ll]ce residue containing carbides, nitrides, ZO and some aluminum. This residue is relatively ary and friable, and can be crushed, milled and screened to ~orm useful by-products.
: The centrifuging is conveniently accomplished using a container-like centrifuge bowl of special design, particu-larly with regard to its having a peripheral outiet orifice for discharging the molten aluminum which is separated from residual portions of the skim material that remain in the bowl after centrifugi:lg. 1'his type of centrifuge construction has been found superior or treating skim material, because the 29 skim residue will consoliaate, or bridge across the gap created ~y a relatively narrow per:ipheral ou~le~t wlthout lnterfering appreciably with -the outlet flow of molten aluminumc In this respect, the skim residue consolidates into a semi-poruos cake which, to some extent, filters aluminum passing through the narrow peripheral outlet. In contrast, using a Large number of small outlet holes peripherally of the centrifuge tends to result in plugging the holes, making the removal of skim residue more difficult.
The outlet orifice may be continuous peripherally, or divided into a few segrnents as desired for purposes of pro-viding adequate support between separate wall and closure com-ponents of the centrifuge bowl. The peripheral gap should be at least 1/8 inch and up to about 1 inch, but usually a gap on the order of 3/16 to 1/2 inch will suffice. Suitable speeds of rotation are relatively slow, being typically, at least a'.oout 150 rpm, and preferably about 200 to 300 rpm, for equipment about 3 feet in diameter, when processing skim material at 1400 F., and correspondingly faster or slower for other bowl diameters to achieve sirnilar centrifugal effects.
It has been found convenient to place a charge of skim material in the bowl and then operate the centrifuge to rotate the bowl and its charge gradually to operating speed~
rrhis rnay take as much as a minute or two after whlch spinning at the selected operating speed continues for about 5 to 10 minutes. Starting slowly helps to distribute the charge more uniformly, and the subsequent higher speed assures continued separation of molten aluminum after the easier-to-remove por-tions have been discharged at lower speed. If desired, part of the molten aluminum contents of the charge can even be poured from the bowl before the balance is centrifuged to achieve further separationO

~9 It is 50metime9 desirable to preheat the bowl, if it is not hot enough already frorn recent previous use, to avoid premature solidi~ication of aluminum and achieve satis-factory recovery. A recovery of 40 to 75~ ~pref. at least 65--) of the available aluminum content of the skim material is usuaily ~ufficient, because getting out all or even greater a}nounts cannot be accomplished easily enough to warrant the effort, and leaving a certain minimum amount of aluminum in the residue increases its commercial value as a saleable by-product.
In the centrifuge method of the present invention, skim material is pulled from a melting furnace as in other methods of treatment, but preferably as soon as the furnace charge has completely melted. This conserves energy in the furnace, since the skim or dross acts as an insulatlng blanket which interferes wi~h heat transfer from burners of the furnace to the melt, and the condition then pertaining usually corres-ponds to the highest overall temperature the skim will reach ~1ith a minimum of oxidation.
The hot skim material is charged into the con-tainer bowl o~ a suitable centrifuge unit tor into a separate re-movable bowI in the case of remote operation of the centrifuge), and covered. If desired an inert gas may be inje~ted into the ~_ - bowl. The centrlfuge unit with such bowl and its charge in place is operated at a speed sufficient to separate molten aluminum from residual portions of the charge. The separated aluminum is conveniently expelled from the centrifuge bowl during spinning and collected in a reservoir trough or drained into suitable molds. The residue is retained in the bowl and preferably cooled at least below 1000~ to reduce the chances of thermiting. During the cooling process -the g_ bowl preEerably is or xernains covered, and may be flooded with an inert gas if desired. Of course, the used bowl containing hot residue material may be removable from the centrifuge so that the unit can be operated again with another bowl.
The skim material is preferably centrifuged at a temperature between 1350~. and 1500F. Below 1350F., and above the liquidus of the alloy involved, the conservation of heat needed to keep the metallic phase iiquid and easily extractable is more difficult to achieve. Below the liquidus (but above the solidus) yield is markedly reduced. The procéss is operable above 1500F., but usually with considera~le metal loss due to spontaneous thermiting unless the skim material is kept under inert gas.
The ~entrifuged xesidue, after cooling below about 1,000F., is airly cohere~t, or caked, howevex, the residue is preferably cooled to below about 350~F. for sa~ety and ease of unloading from the bowl ~ith the generation of a minimum of dust. By way o~ example, a skim material originally containiny 70~ aluminum by weight, was treated to recover about 70~ of its available aluminum content (or 49 pounds per 100 lbs. of skim material). The residue has a metallic alumin~m content of approximately 40%, the balance being metallic oxides, carbides, nitrides and the lik-.
The residue frorn rhe centrifuge is suitable for conventional reclama'~ion treatment. I~ can be readily crushed and screened into fractions of different metallic content. For example, a +4 mesh (Tyler Seive Series~ fxaction may have a metallic content of about 50%, and can be puddle melfed or remelted wifh a rninimum amount o flux to form a recovered melt. A -4 ~2~ mesh fraction may be processed as 32 in tne prior-art to separate alwninum therefrom. A -Z3 +lO0 --iO~

mesh fraction may be recrushed an~ screened. And a -100 mesh fraction may be used as a foamingJe~tending agent in cements, or plastic materials/ thus utilizing its carbide and nitride content, as well as the metallic fraction, ~or yas generation.
With regard to various features of construction of the centrifuge apparatus, as provided in accordance with the invention, it has been found desirable to use a centrifuge having bowl-like container means adapted to receive a charge of the skim material, with a narrow peripheral outlet orifice for discharging molten aluminum as it is separated from resi-dual portions of the charge. This can be accomplished in various ways. Thus, the bowl m`ay have a separate base or bottom closure and a cooperating removable sleeve forming an outer wall of the bowl. An outlet gap is provided peripherally of the bowl, for example, either by mounting such a sleeve in spaced relation to the base, or ~y allowing freedom of movement of the sleeve away from the base when they are rotated, with adjustable stop ~ans to limit the exten~ o~ such movement~ In the latter arrangement, the sleeve may he frusto-conically shaped to taper outwardly toward the base (i.e. inwardly toward the top) to cause a lifting action of the charge against the sleeve during rotation at operating speed. Or the bowl may have an integral side wall and bottom, with an upper partial closure member at the top, leaving a peripheral outlet gap adjacent the wall~
In that case the bowl wall may be ~apered outwardly toward the top.
The bowl components are preferably lined with an insulating refractory and may be further heat insulate~, if desired, as by mounting the bowl for rotation within a ~tationary enclosure or outer casing. The bowl is rotated by suitable drive means, such as an air motor or an electric motor, which may inclu~e a vari.able speed control, and the bowl is. preEerabl~ removable from the centrifuge unit such as by being supported 'or rotation on a motor-driven turntable.
Positive drive is achieved by temporarily interconnecting the bowl and turntable mechani.cally as by means of centeriny studs or ~eleasable pin connection~.
Where the centrifuge bowl includes separate sleeve and base members arranged to be spaced apart during rotation to ~orm a peripheral outlet gap therebetween, it has been found convenient to provide for controlling the size of this gap, such as by providing radial extensions of the base member and corresponding lateral tabs on the sleeve, with upwardly ex-tending studs afflxed to such extensions and associated stop means adjustably placed along the studs to contact the corres-ponding tabs and either set or li~it the rélative spacing be-tween such sleeve and base members of the bowl.
The crushing and screening apparatus are described . in detail below.
These and oth~r details of constxuction are illus-trated i.n, and will be described further in connection with,the accompanying drawings of presently preferred embodiments, in which:
_ FIG. 1 shows a skim centrifuge unit, largely in -~ vertical cross-section, including a centrifuge container of the type comprising a refractory lined base component mounted on a motor driven turntable ~nd a separate refractory li.ned sleeve member forming an outer wall of the container, with a stationary collector trough arranged to receive material ais-charged from the container through a peripheral outlet gap be~
tween the base and s].eeve portions thereof;
31 FIG. 2 is a fragmentary plan view showing an arrange-~LZ~1~8 ment for transrnitting rotary motion of the turntable to the base component of the centrifuge container of FIG. 1, FIG. 3 is an enlarged view of a portion of FIG. 1 to show details of an arrangement for controlling or adjusting the peripheral outlet gap between the centrifuge container's sleeve and base portions' FIG. 4 is a plan view of the collector trough from the orientation of plane IV-IV in FIG. 1, FIG. 5 iS a partial transverse section through an interior baffle of the collector trough, taken along the plane V-V of FIG. 4;
FIG. 6 shows an alternate embodiment of the centrifuge container, having an integral side wall and bottom, FIG. 7 iS a schematic representation of a hammer mill used to crush residual skim material, FIG. 8 iS a cross-sectional, partially schematic, view of a ball mill that is used to further crush resi.dual skim material in practicing this invention, FIG. 9 is an isomekr.ic view, part:ially schematic, partially magnified as to screen openings, of a screening assembly as is used for sorting crushed residual skim material in practicing this invention, and, FIG. 10 iS a magnified cross-sectional view of a piece Qf cement fabricated with a foaming/extending agent of this invention.
With reference to FIG. 1, it may be seen that the centrifuge unit 10 includes a motor driven turntable 12, having a drive shaft 14 with upper and lower support bearings 16 and 18, and having a motor 20, motor pulley 22, shaft pulley 24 and interconnecting V-belt 26. Mounted for rotation with the turntable 12 is a centrifuge container ~aviny ~n outer perip~eral sleeve or wall 30 with an interior refractory lining 32, and a cooperatirlg base plate 34 havirlg an interior refractory - 13a -~s,j ~

lining 3G. The base plate includes a hollo~l tapered central enlargement o.r socket 33 cooperating with a correspondiny frusto-conical hub 40 on the turntable 12 to center the base plate on the turntable. Rotation of the turntable 12 is transmitted to the base plate 34 by means of a dog 42 on the former engaging a similar dog 44 on the latter, as shown in FIG. 2.
The peripheral wall 30 has three lateral tabs 46 ~at 120 spacings~. to a~ford mechanical constraint relative to the base plate 34, as shown in greater detail in FIG. 3, and particularly to provide connec~ions for adjusting the outlet gap 35 between them. These connactions include corres-ponding extensions 48 on the base plate, a collar-like support 50 affixed to each such extension~ a threaded stud 52 secured to each collar and passing upwardly through the associated tab 46, and an upper lock nut 54 to limit the outward mave--ment of the wall 30 from the base plate 34. A lower lock nut 56 is also used when it is desired to set a fixed outlet gap; otherwise, the wall can simply be allowed to move away from the base plate as khe unit is rotated unti.l the tabs ~6 engage the upper lock nuts 54. Openings at the ~ase of collars 50 ~re useful for connecting hooks to lift the whole unit off the turntable a~ter a spinning cycle.
- The centrifuge container also has a refractory lined, removable top cover 60 (~IG. 1~ to provide for introducing . ~ .
skim materia.l after the sidewall sleeve 30 has been placed on the base plate 34. Lift rings 62 are provided for removing the cover, and similar rings or lugs 64 are provided for re-moving the centrifuge container (i.e. the base plate 34 and sleeve 30 as a unit~ from the turntable 12.

3~ . Rs the centrifuye is rotated wi-th a charge of skim ,~ ~

material in place, a non-aluminous portion of the skim is consolidated int3 a porous cake at the inside of the outlet gap 35. Molten aluminum separates from residual portions o~
the charge, some of it being filtered through the porous _ . . ..
cake, and passes through the peripheral outlet gap 35 between sleeve 30 and the base plate 34. The molten aluminum is collected in a trough 66. The trough (which is formed to serve also as a deflector shield) is divided by interior partitions or baffles 68 (see FIGS. 4 and 5) to afford easier removal o~ the aluminum 67 when it has solidified in the trough.
The residual skim material is usually allowed to cool below about 350F. before it is removed from the centrifuge ; bowl. After removal, friable residue is crushed, preferabl~
perfoxmed dry. In the illustrated embodiment, the crushing of residual skim material 100 is firstly accomplished in a hammer mill 102 which is schemakially illustrated in FIG. 7 and secor.dly, in a ball or rod, mill 10~ as is illustrated in FIG~ 8.
Preferably, the hammer mill reduces the resi~ual skim material 1~0 until no piece is more than ahout 1 inch in any dimension.
The residual skim material 100 is treated by a rotating drum 106 and mill balls 108 of the ball mill 104 until it appears to be segregated into rounded, generally larger, bits and angular-surfaced, generally smaller, bits. ~rhis separation typically takes ~etween 4 and 16 hours of ball milling~ The larger, roun~ed ~its include a high percentage of metal whereas the angular-surfaced, generally smaller, bit5 include a higher percentage of non-al~minous materials.

The crushed residual skim material is then screened, or si~ted ln a screening assembly 110 including a Fough sieve or screen 112, a medium .~creen 114, a fine screen 116, and a final surface 118. Using the Tyler Sieve Series, the rough screen 112 has a No. 4 mesh (0.185 inches or 4.699 mm openi~gs), the medium screen 114 has a ~o. 28 mesh (0.0232 inch, .589 mm), and the fine screen 116 has a No. 100 mesh (0.0058 inch or 0.147 mm). Thus, once residual skim ma~erial has been sifted through the screening assembly 110 by shaking the screens 112 through 116 with an eccentric wneeI 120, for example, the mater.ial which is : on top of the rough screen 112 is identified as a ~4 mesh rac-tion, the material on the medium screen 114 is identified as a

-4 ~28 mesh-fraction, the material on the fine screen 116 is identified as a -28 ~100 mesh fraction while the material on the final surface 118 is identified as a -100 mesh fraction.
The -100 mesh fraction gathered from the final surface 118 is a rathe~ unusual Eoaming and extending agent for use in cement and other hardening type plastics, for example. ~he ~100 mesh fraction contains inert ingredients (mai.nly the oxides o~
vArious metals), potential gas formers in the ~rm o~ metallic (mainly alumlnum and magnesium) nitrides and/o:r carbides (mainly aluminum and magnesium) as well as an aluminous metallic portion.
The metallic portion of the -100 mesh fraction is not lower than 15~ by weight and preferably in the range of 20-40~ by weight.
The presence of the nitrides and carbides has been determined qualitatively, however, they have not yet been measured. It is thought that they constitute between 0.1 and 10~ of the -100 mesh fraction. The remaining portion of the fraction is made up of ~he inert ingredients. The foaming/extending agent (the -100 mesh fraction~ is added to fluid cement 122, plastic or the like. The metallic.portion of the foaming/extending agent will react with an acid or a base in, or added to, the fluid cement, or other plastic construction material, to produce a gas such as hydrogen. ~.

It is not thought necessary to describe thls aspect of the pro--cessin greater detail inasmuch as aluminum powder has lony been used in the past as a foaming or extending agent in this manner.
However, in addition, the carbides and nitrides in the foaming/
extending agent also combine in aqueous fluid cement mix-tures, for example, -to also yield useful gaseous p~oducts. For example, aluminum carbide or oxy-carbides may react with water or acidic solutions to produce methane.
The gases that are produced in the fluid cement 122, or other plastic, to create bubbles 124 (shown to be greatly magnified in Fig. 10) therein which cause the cement 122 or other plast:ic construction material, to "foam up". This unique plastic construction material then hardens in this foamed or extended state to provide a construction material of lesser density (weight per unit volume) than it would normally have had, the construction material hardened without the foaminy/
extending agent being added thereto.
Finally, inert ingredients 126, such a,s metallic oxides, in the foaming/extending agent (the -100 mesh fraction), act simply as extenders or f.ill.ers.
It shouLd be noted that the use of the -100 mesh fraction as a foaming/extending agent is possible because in removing the alumnium from the skim material slats and flux have not been added to contaminate the skim material.
The ~4 mesh fraction that is removed from the rough screen 112 has a sufficiently-high aluminum content that it can be "puddle melted" directly into a heel (molten metal) in a furnace.
The -4 ~2~ mesh fraction taken from the medium screen 114 can be processed as was done with skim in the prior-art to get the aluminum from it. Although such processing produces the pollution and other problems ~et forth in khe "~ackyround of the Invention", above, it is noted that suc~h problems are on a very ~mall scale si.nce only a small fraction _17a-~jV ~/

~9 ~

of skim material is being processed and thi5 fraction has a higher percent~ge of aluminum in it than raw skim processed in the prior art. Alternately, this -4 ~28 mesh fraction may, preferably, be water washed to remove most of the carbides and nitrides, then dried, and fed direc-tly to an aluminum Feduction cell as a source of metal.
The -28 ~100 mesh fraction taken from the fine screer.
116 is put through the ball mill 104 once again and then re-screened with the screening assembly 110. This step can be consolidated with the processing of a subsequent charge of skim material.
~ n alternate embodiment of the centriuge container is shown in FIG. 6. In this case the refractory lined sleeve 70 and its integral bottom together ~orm a rotatable bowl 72;
and the sleeve is tapered oppositely to that of FIG. 1 ~i.e.
upward and outwardly). A peripheral outlet gap is provided at the top of the bowl~ adjacent a refractor~ lined upper closure element 74 wh.ich i5 mounted on a support stud 76 affixed .
~o the upp~r flattened portion of a central conical enlargement 78.

The followin~ illustrative examples of the practice of the invention are based on oparation of a centrifuge unit as shown generally in FI~S. 1-5 of the drawings, for treatment o~ skim material from an oil-~ired melting furnace. Furnace temperatures ran 1~25_1490F. The skim was removed when the burners were off.
Skim was raked to the furnace door with a ramj then drained and brought to the top of a steel chute~ A hoe was used to manually transfer skim down the chute into the ce~trlluge bowl. Small pockets of thermiting skim were obser~ed during this transfer. The chute was removed, the load rou~hly dis-tribu-terl in the bowl, and the bowl cover lowered and locked ~18-in pl~ce. ~n each test run the bowl was graduall~y accelerated to about 200 rpm in about 30 seconcl.s.
The following Table I surNmarizes the operatlon and results of three test runs.
TABLE I

; Base-wall Maximum Duration Gross Metal Remarks openinq speed _ of Spin recover~ _ _ inch _ _ rpm minutes lbs~ /0 1/32 250 7 62 31 Bowl Wall rested on the base, 3003*

1/16 225 5 60 35 Most of run at 17S
to 200 rpm, 6063*
1/8 200 7 136 46 6063*

.
*The numerals 3003 and 6063 refer to the particular aluminum alloy being processed; the alloys are registered with the Aluminum Association.

__ _ . _ ~ . . e . .._ It may be noted that the separated aluminum was more readily dicharged from the rota-ting centrifuge bowl when the outlet gap was increased. The metal product obtained at about 1/8 inch outlet gap contained no noticeable ashy residue.
~ xtracted metal striking the deflector shield out wardly of the bowl either flowed into the collector trough, or first solidified on the shield and subsquently cooled quickly enough to shrink and drop off into the collector trough.
Residual portions of the charge were collected and retained in the bowl. After cooling, the entire bowl (base, wall and cover) was removed from the centrifuge. ~he bowl wall an and cover were lifted free from the base~ The residue did not stick to either the bowl wall or the bowl base and was readily firable (easily broken with the hands). For the third run listed in Table I, the gross metal recovery of 46% is based on 156 lbs. of residue (about 30~O aluminum content) and 136 lbs.
of recovery product metal discharged (4~2 lbs. residue content, ~i,~
"~, -1.9--or about 97~ alumin~). A gr~b samplc of the original skiln charge analyzed about 61.2~ aluminum content. Thus, a free-metal recovery of 74% was obtained, based on 132 lbs. of aluminum recovered in the centrifuge discharge and 41 lbs.
in the skim residue.
Additional test runs were made usin~ an outlet gap of abvut 3/16 inch and a maximum speed of rotation of about ~00 rpm. Similar results were obtained.
The oaming/extending agent tthe -100 fraction taken from the final surface 118 of the screening assembly 110) has been employed in tests in the manner described above to construct foamed concrete. The foamed concrete weighed only about 60 lbs. per cubic foot which is clearly much less dense than normal concrete.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing ~rom the spirit and scope of the invention. For example, di~ferent mesh size~ of screens could be used for the screeniny assembly 110 of FIG. 9. Further, the fractions taken from screens 112, 114, and 11~ could be processed and utilized in other manners than ~ those described herein. Also, a jaw crusher, or other type of crusher, could be used instead of the ha~mer mill of FIG. 7.
The embodiments of the invention in which an exclusive property or privilege are claimed are ds~ined as follows:

Claims (14)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:-

1. A method of treating molten aluminum skim material to separate and recover aluminum and/or non-aluminous constituents contained therein, without adding a salt flux to the skim material, which comprises centrifuging said skim material in a centrifuge device to separate an aluminum portion of said skim from a residual portion of said skim, discharging the separated aluminum from said centrifuge device and option-ally recovering the residual portion remaining in said centrifu-ge device after centrifuging, said residual portion containing said non-aluminous constituents.

2. A method of treating hot skim material after its removal from a body of molten aluminum to separate and recover aluminum contained therein, without adding a salt flux to the skim material, which comprises the steps of.
rotating a charge of said skim material in a rotatable container having at least one peripheral gap therein, said gap having a width in the range of from 1/8 to 1 inch, at a temperature of at least above the liquidus under conditions effective substantially to avoid thermitting, and at a speed of rotation sufficient to separate molten aluminum from residual portions of the charge, consolidating residual portions of said charge to from a porous filter cake at said gap as the charge is being rotated, said container having a wall against which said residual portions are driven by centrifugal force and consolidated to form said porous filter cake at said gap, with said porous filter cake substantially blocking the escape of residual portions of the charge from said container' discharging separated aluminum radially outwardly around and through said porous filter cake and through said gap.

3. A method as claimed in claim 2, wherein said peripheral gap has a width within the range of from 3/16 to 1/2 inch.

4. A method as claimed in claim 3, including stopping rotation of said rotatable container, cooling residual portions of the charge in said container to a temperature below 1000°F, and removing the caked, cooled material comprising said porous filter cake.

5. A method as claimed in claim 2, wherein said peripheral gap has a width of around 3/16 inch and some of the aluminum discharged radially outwardly is first filtered through said porous filter cake.

6. A method of treating molten aluminum skim material to separate and recover therefrom non-aluminous constituents suitable for use as foaming and extending agents, without adding a salt flux to the skim material, which comprises the steps of:
gathering skim from molten aluminum;
centrifuging said skim in a centrifuge device to se-parate an aluminum portion of said skim from a residual portion of said skim, the separated aluminum being discharged from said centrifuge device, and removing the residual portion remaining in said centrifuge device after centrifuging,said residual por-tion containing said non-aluminous constituents;

crushing said residual portion of said skim and sorting particles therefrom to be used as a foaming and extending agent in plastic construction materials, said sorted particles being smaller than around 0.0058 inch (0.147 mm).

7. A method as claimed in claim 6, wherein said centrifuging step is carried out in a centrifuge bowl having a peripheral gap therein, with a width in the range of from 1/8 to 1 inch, said centrifuge bowl having a wall which consolidates said residual portion of said skim into a porous cake at said gap to filter some aluminum passing through said gap, said aluminum portion of said skim being driven through said porous cake and said gap.

8. A method as claimed in claim 6, wherein the sorting of said particles is accomplished with a screening assembly having at least two screens in series each successive screen having a smaller mesh size than the previous screen, the residual portion remaining on the larger mesh screen being further processed to obtain an aluminum fraction therefrom and the residual material passing through the finer mesh screen constituting said foaming/extending agent.

9. A method as claimed in claim 8, wherein there are at least three screens and wherein the largest-mesh screen has a hole size of approximately 0.185 inches (4.699 mm), the second largest-mesh screen has an opening size of approximately 000232 inch (0.589 mm), and the finest mesh screen has an opening size of approximately 0.0058 inch (0.147 mm), and wherein the residual material caught by said finest mesh screen is again crushed and screened.

10. A method of reclaiming aluminous metal, metallic oxides and metallic nitrides and carbides from mol-ten aluminum skim material, without adding a salt flux to the skim material, comprising the steps of:
gathering skim from molten aluminum, centrifuging said skim to separate an aluminum por-tion of said skim from a residual portion of said skim, said centrifuge being accomplished in a centrifuge bowl having a-t least one peripheral gap with a width in the range of from 1/8 inch to 1 inch and a wall for consolidating said residual portion of said skim into a porous cake at said gap, said aluminum portion of said skim being driven through said porous cake and said gap;
crushing said residual portion of said skim to form crushed particles;
sorting said crushed particles according to size into a small-particle fraction containing metallic nitrides and carbides and into at least one large-particle fraction;
further treating said large particle fraction to extract aluminous metal therefrom.

11. A method as claimed in claim 10, wherein said small-particle fraction has a particle size of less than approximately 0.0058 inch (0.147 mm).

12. A method as claimed in claim 11, wherein said large particle fraction is separated into at least two other subfractions, a first having a particle size less than approximately 0.0232 inch (0.589 mm) and a second having a particle size greater than approximately 0.0232 inch (0.589 mm), and wherein the further step is included of further crushing and sorting said first subfraction to obtain additional particles having a size less than approximately 0.0058 inch (0.147 mm) to add to said small-particles fraction containing metallic nitrides and carbides.

13. A method as claimed in claim 10, wherein the width of said gap is in the range of from 3/16 to 1/2 inch.

14. A method as claimed in claim 10, wherein said gap is around 3/16 inch in width.