100-Ton Aluminum Melting System for a Korean Manufacturer

Project Overview

Denova Thermal Technology (Suzhou) Co., Ltd. (?Denova?), together with Suzhou Zhonglian Zhongxin Thermal Technology Co., Ltd., is delivering a customized 100-ton aluminum melting system for a leading Korean aluminum manufacturer.

The Denova-Zhonglian Consortium is responsible not only for the main melting furnace, but also for overall production-line planning, automation integration, and coordination with supporting equipment from multiple international suppliers.

Designed for a melting capacity of up to 10 tons per hour, the system is engineered to support large-scale, continuous aluminum production while meeting the customer’s requirements for efficiency, automation, safety, and plant integration.

Key Project Data

• 100tFurnace Capacity
• 10 t/hMelting Capacity
• 600+ tTotal Operating Weight
• 40+Containers for Transportation
• 20%Reduced Equipment Footprint
• <250°CExhaust Gas Temperature

Engineering Requirements

The project combines several demanding requirements within an existing production facility.

The customer required a high-capacity melting system with limited available workshop space, while also expecting stable thermal performance, dual-fuel flexibility, high levels of automation, and integration with equipment from suppliers across Korea, Japan, and other markets.

The scale of the system also introduced significant requirements for structural design, transportation, installation, and operational safety.

Our Solution

To meet the customer’s production and plant-layout requirements, the Denova-Zhonglian Consortium developed a customized furnace configuration that reduces the overall equipment footprint by approximately 20% while maintaining the required melting capacity.

The furnace incorporates a Denova-developed dual-fuel combustion system, compatible with both natural gas and fuel oil, providing greater flexibility for long-term operation.

A centralized heat-exchange system is integrated to improve thermal efficiency and support stable combustion performance. Under specified operating conditions, natural gas consumption is designed to reach approximately 60 m³/t, with exhaust gas temperature controlled below 250°C.

The system is also designed for highly automated operation, incorporating functions such as:

• Self-diagnostics
• Automated start-up
• Continuous monitoring
• Automatic data transmission
• Plant-level control integration

The consortium is also responsible for coordinating interfaces between the main furnace system and surrounding equipment, ensuring that the complete production line operates as an integrated system rather than as separate individual machines.

Project Value

This project expands Denova’s engineering capabilities from precision molten aluminum dosing to 100-ton-scale melting and integrated thermal systems.

It also demonstrates the Denova-Zhonglian Consortium’s ability to combine large-scale furnace engineering, automation, structural design, international equipment integration, and project coordination within a single customized solution.

For Denova, the project represents an important step in strengthening its capabilities in large-scale aluminum processing and complex international thermal engineering projects.

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