Impact of Hydrogen Combustion on Aluminum Melt Quality

This technical report investigates the effects of hydrogen combustion on aluminum melt quality during secondary melting processes. The study focuses on the transition from conventional natural gas to hydrogen as a fuel in melting furnaces, particularly the implications for dross formation and melt characteristics. Experiments were conducted using a custom-designed test furnace equipped with oxy-fuel burner technology, allowing for controlled studies of various fuel combinations. The report details the methodology, including the use of X-ray diffraction and Scanning Electron Microscopy to analyze the slag layer and core metal. Results indicate that hydrogen combustion leads to a higher concentration of superheated water vapor in the furnace atmosphere, which can influence the amount of dissolved hydrogen in the aluminum melt. The findings suggest that while the total oxides formation remains similar between hydrogen and natural gas combustion, the characteristics of the dross and melt quality are affected by the combustion atmosphere. This research contributes to understanding the potential of low-carbon fuels in reducing the carbon footprint of aluminum production.