Success stories
Separation of aluminum and zinc cathodes with steam
Project description
Installation of a steam solution for a customer specialized in aluminum processing that required to separate 20,000 cathode plates composed of aluminum and zinc.
Original situation:
Challenges posed by the client:
The customer is a specialized aluminum processor that was faced with the challenge of separating 20,000 cathode plates made of aluminum and zinc.
For the customer, this process is essential to recover valuable materials and optimize the recycling or reuse of these metal components.
The project had to meet the following requirements:
- Process based on a manual method: the process was to be carried out by a manual method based on steam heating, carefully applied both on the joint between the aluminum and the zinc and on the entire surface of the plate.
- Steam heating: Steam heating is the method chosen by the customer due to its effectiveness in vapor transfer and being able to separate both metals without compromising their quality and properties.
Proposed solution:
Customized steam solution developed by Giconmes.
Proposed solution:
- Steam generator NGV3020 (20 kW) manufactured with the boiler in A-304: Giconmes proposed the use of a steam generator with a 20 kW stainless steel boiler, capable of generating more than 25 kg/hour of steam.
- Thermally insulated steam pipe with lance and steam gun: the use of a thermally insulated steam pipe with lance and application gun was proposed to effectively apply steam on aluminum and zinc plates.
- Water treatment system: due to the specific conditions of the client’s location, the installation of a water treatment system was also required to ensure the correct operation of the electric boiler.
Technology used:
- NGV3020
- Thermally insulated steam pipe, with steam lance and steam gun
- Water treatment system
CHALLENGES
We meet customer requirements
Solution to a very specific challenge to separate 20,000 cathode plates made of aluminum and zinc at a processing customer specializing in aluminum.
Manual method as a preliminary step towards a future industrialization phase, where the task will be carried out as automatically and efficiently as possible.
Steam heating is chosen for vapor transfer to separate the two metals without compromising their quality and properties.
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FAQs
We understand that many questions may arise. Here are some of the most common ones.
There are no emissions beyond those produced during the electricity production process. Consequently, emissions can be neutral depending on the electricity mix. Electric steam boilers are the present and the future.
Absolutely. In fact, it is recommended to achieve maximum efficiency. There is no problem with remote control as long as it complies with current regulations.
A steam generator is a pressure vessel that, together with the piping network, is subject to regulatory control and complementary technical instructions, according to the regulations published in Royal Decree 809/2021, of September 21. Maintenance is divided into a part that can be easily fulfilled by the owner:
- Know and apply the manufacturer’s instructions regarding use, safety measures, and maintenance.
- Not to put the installation into service or prevent the operation of pressure equipment if the requirements of the Regulation are not met.
- Having at least the following documentation for the pressure equipment while they are installed: Declaration of conformity, manufacturer’s instructions (if applicable), and, if necessary, installation certificate, along with other supporting documentation (such as installation project, record of the last periodic inspection, certifications of equipment repairs or modifications, and any other documentation required by the relevant technical instruction complementary to this regulation). For detailed contents, refer to Annex IV of the regulation. Making this documentation available to the competent authority of the autonomous community and the companies responsible for maintenance, repair, or periodic inspections.
- Use the pressure equipment within its intended operating limits as specified by the manufacturer and take it out of service if it no longer meets the necessary safety requirements.
- Perform maintenance on the installations, pressure equipment, safety accessories, and control devices in accordance with the operating conditions and manufacturer’s instructions, and examine them at least once a year.
- Arranging for the necessary periodic inspections as required by Article 6 of the regulation.
- Having and maintaining an up-to-date record of pressure equipment categories I to IV, as defined in RD 709/2015, of July 24, or equipment similar to these categories according to Article 3.2 of the regulation, as well as their installations.
It is known that by applying heat to water, it transforms into steam at the boiling point and atmospheric pressure. From there, depending on the required saturation degree of steam for its proper application, we need to increase the pressure to obtain a higher temperature. To change the temperature and saturation degree of steam, we always need to modify the pressure.
It is a unit of pressure equivalent to 1 kg/cm2, 0.98 atmospheres, or 14.50 PSI.
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