A global reference in the development of solutions for the ferrous and non-ferrous metals industry, Insertec presents its technologies for aluminum recycling at Metalurgia. Combining energy efficiency, sustainability and innovation, solutions such as the IDEX® Decoater and the ALUSWIRLER® vortex fusion process are aimed at recovering aluminum from post-consumer scrap.
The company operates on two complementary fronts: Insertec Refratários do Brasil, specialized in engineering and manufacturing of refractory materials tailored to foundries, and Insertec Fornos Industriais, responsible for the development of high-performance furnaces and equipment.
Aluminum is one of the most recycled metals in the world, but its reuse involves major technical challenges. Scrap metal arrives at foundries in different formats such as beverage cans, window profiles, painted sheets and industrial parts, often contaminated by paints, plastics, oils and other organic materials. These conditions require a rigorous pre-treatment and cleaning process, capable of ensuring the quality of the recovered metal and reducing losses in the melting process. In addition, the industry faces the growing need to decrease energy consumption and reduce the carbon footprint, in line with global environmental demands.
DIFFERENTIALS OF PATENTED TECHNOLOGIES FOR ALUMINUM RECYCLING
Through patented technologies that revolutionize the aluminum recycling cycle, the IDEX® Decoater starts the process with an efficient scrap pretreatment. The stage includes grinding for size standardization, magnetic separation to remove ferrous elements, sieving by sizes to separate grain sizes, separation of non-metals by eddy currents and densimetric tables or X-rays to remove heavy metals.
This care results in aluminum with a high degree of purity, but which still needs to go through the crucial stage of unraveling. Here comes another exclusive technology from Insertec, the Decoater IDEX.® This solution is a patented controlled thermal delacquer system that removes paints, plastics, oils, moisture and volatile organic compounds from the surface of aluminum. The process is highly efficient because, in addition to cleaning the metal, it takes advantage of the gases resulting from the burning of paints and varnishes as fuel, significantly reducing the consumption of natural gas or electricity.
This energy reuse reduces operating costs and reduces carbon emissions, placing sustainability at the center of the operation. Another differential is safety, as the controlled process reduces risks, generates more stable conditions in the foundry and ensures greater reliability.
After passing through the IDEX® Decoater, the cleaned and heated aluminum is sent for melting with the ALUSWIRLER® system, based on a vortex generated inside the furnace’s open side pit. This movement accelerates the melting of the metal, resulting in reduced metal losses and maximum use of scrap, less use of saline flows, which means more environmental control, increased productivity of the melting furnace, optimizing process time and greater energy efficiency, ensuring savings for foundries.
REFRACTORY SOLUTIONS
Insertec is also recognized for the development of refractory materials adapted to the needs of each customer. Its portfolio includes products for induction furnaces, cubilos, press-pour, rotary furnaces, reverberations, fuser towers, waiting furnaces, dosers, ladles and prefabricated parts such as chutes, dosing tubes and supply cones. These solutions are designed in partnership between the engineering and laboratory departments, ensuring durability, resistance and the best cost-benefit ratio for each process.
In the field of industrial furnaces, Insertec offers equipment for heat treatment, aluminum injection and recycling, with gas or electric heating options. Among the highlights are Tilting Rotary Furnaces (FARB), Fuser Towers, Waiting Furnaces and Heat Treatment Furnaces. All equipment meets international safety standards, such as NR 12, CQI-9 and Nadcap, in addition to prioritizing energy efficiency and productivity.
ABOUT INSERTEC
With an international presence, headquarters in Bilbao (Spain) and branches in Brazil, Mexico, China, Italy, Russia, India and France, Insertec consolidates itself as a strategic partner for foundries and industries that wish to invest in more modern, profitable and sustainable processes. This global performance, combined with the experience accumulated in more than four decades, guarantees the company the ability to offer complete solutions, from refractories, industrial furnaces and technologies for aluminum recycling, always focusing on energy efficiency, operational safety and environmental commitment.
