Optimal solutions and systems - founded on robust expertise and Experience

The assurance of delivering not only cutting-edge plant technology but consistently meeting the demands of advanced technological innovation, continuous development and specific customer requirements is attributed to the highly qualified and experienced personnel at OTTO JUNKER.

Quality assurance:

Adhering to the principles of the OTTO JUNKER quality assurance system, our systems are meticulously designed to fulfill the following exacting requirements.

• Safe and economical operation (user and operator-friendly)
• Low overall costs
• Low maintenance costs
• Robust and reliable construction

Each system is meticulously crafted to adhere to the stringent quality standards synonymous with the OTTO JUNKER brand, continually evolving through ongoing dialogue with operators of our systems worldwide.

Process competence:

We offer complex treatment lines from a singular source. OTTO JUNKER’s product range spans the entire process chain from melting furnaces (complex foundry systems, both inductive and fuel-heated) to heat treatment furnaces (preheating, annealing, homogenizing, quenching, artificial aging, handling and adjustment systems).

Technological competence:

Thanks to OTTO JUNKER’s extensive and continuous product development, our systems are characterized by comprehensive and state-of-the-art technology. This achievement is facilitated by a close cooperation with the Rheinisch-Westfälische Technische Hochschule (RWTH) in Aachen, providing crucial innovation impulses, particularly in the fields of metallurgy, materials, electrical and information technology. 

Product range:

• Scrap and block preheating systems
• Charging vehicle
• Melting furnace
• Pouring furnace
• Recycling system
• Spülsteinsystem
• Launder
• Launder preheating system
• Laser-assisted launder filling level control
• Billet transport devices
• Homogenization furnace for extrusion billets and rolling ingots
• Cooling chamber for extrusion billets and rolling ingots
• Burner systems
• Switchgear and control systems
• SCADA system
• Economic calculations
• Furnace optimization
• Furnace modernization

Charging machines for feedstock

OTTO JUNKER offers a wide range of charging machines for scraps and blocks, meticulously designed according to the Thermcon model. These machines significantly contribute to the productivity and safety of aluminum melting operations.

The charging time per batch is minimized to less than three minutes. The design allows the feedstock to be charged deep into the furnace, facilitating the introduction of a substantial material quantity at the beginning of the melting process. 

The charging machines are bespoke for existing or new furnaces, seamlessly combining with wide (over 7 m) and long containers for nearly all furnace configurations. A wide container eliminates the need to crush extrusion scraps. The containers can either be fixedly mounted on the machine or designed as a mobile part of the operational scrap collection system, minimizing the effort for transporting scrap.

The machine’s drive and operation are fully hydraulic, facilitated by the hydraulic unit mounted on the machine. The integration of load cells and connections to the higher-level SCADA system of the foundry can be embedded in the machine’s control system. 

De-slagging machines:

OTTO JUNKER’s de-slagging machines, Thermcon model, replace primitive slag removal methods by means of forklift with a long rake, executing the process more efficiently and rapidly.

All machine movements, including shifting and all movements of the telescopic boom, are hydraulic. Importantly, hydraulic parts do not extend into the furnace. Due to their telescopic arm, these machines feature a space-saving design.

Additional Benefits:

• Safety – the operator is well-protected in the cab.
• More sensitive operation, as the operator can control the movements of the telescopic boom (up, down, forward, backward, sideways swiveling) with precision.
• More efficient slag removal, as the delicate operation results in less free metal being removed from the furnace with the slag.
• The forces exerted on the furnace lining are restricted by force limitation systems to minimize damage to the lining, a common issue with stirring using a forklift.

Multi-chamber melting furnaces (recycling):

Multi-chamber melting furnaces with integrated flue gas treatment and heat recovery for preheating feedstock are predominantly supplied to the secondary aluminum industry.

These environmentally friendly recycling plants are suitable for the recycling of contaminated aluminum. They not only meet but surpass the strictest air pollution control regulations, including those pertaining to dioxin emissions.

The melting rate of such furnaces can reach up to 10 t/hr, depending on charge composition and bath capacity (usually 50 to 130 t of liquid metal).

Charging in this type of furnace can occur at three locations: block material for forming the heel during start-up, for analysis correction or improving the melting rate can be charged onto the dry ramp in the heating chamber, where the burners are mounted. Scrap bundles and freely scattered lightweight scrap can be fed into the enclosed forehearth. Charging with small scrap (e.g. trim or punch scrap, chips, etc.) can occur via the charging hearth.

The metal circulation between the chambers is ensured by an electromagnetic or mechanical pump, depending on the application and budget. Charging into the forehearth can be done by a special charging machine that fits tightly against the furnace, preventing smoke from escaping into the shop during charging. All flue gases are directed to the integrated thermal afterburning system and then discharged outdoors through the flue gas filtration system.

Hearth melting furnaces

OTTO JUNKER delivers a wide range of custom-made melting furnaces for all manufacturing processes in the aluminum industry - whether for continuous casting of rolling ingots, T-profiles and extrusion billets or sheets, for wire production or for conventional block casting, etc.

Dry hearth furnace systems are suitable for the safe melting of block material, ingots and heavy scraps containing free iron (e.g. castings from the automotive industry). The iron content is recovered from the dry hearth after melting aluminum scrap.

• Melting rates: 1 - 30 t/hr
• Capacity: 2 - 150 t
• Available burner systems:
  • Recirculating burners
  • Recuperative burners
  • Regenerative burners
  • O² burners

Design features:

• Minimal energy consumption through appropriate furnace design
• Proven furnace pressure control systems
• Doors of special modular design
• Sealing for excellent tightness
• Prefabricated refractory lining in the door area for minimal maintenance effort

Accessory program:

• Charging machines
• De-slagging machines
• Electromagnetic stirrers 
• Syphon systems for filling with liquid metal
• Semi-automatic casting systems for stationary furnaces
• Laser-assisted launder filling level control for tiltable furnaces

Holding and pouring furnaces:

OTTO JUNKER offers a wide range of customized holding and pouring furnaces for all manufacturing processes in the aluminum industry - whether for continuous casting of ingots, T-profiles and extrusion billets or sheets, for wire production or for conventional block casting, etc. The furnaces can be either stationary or tiltable and are suitable for alloying, holding and pouring.

• Capacity: 2 - 150 t
• Available heating systems:
  • Cold air burners for gas, light or heavy oil
  • Electric heating elements

Design features:

• Cascade-free pouring of molten metal through pouring nozzle systems in the tilting axis of the furnaces
• Minimal energy consumption through appropriate furnace design
• Proven furnace pressure control systems
• Modularly constructed doors
• Clamping ensuring excellent sealing
• Prefabricated refractory lining in the door area for minimal maintenance effort

Accessory program:

• De-slagging machines
• Electromagnetic stirrers
• siphon systems for filling with liquid metal
• Semi-automatic casting systems for stationary furnaces
• Laser-guided launder filling level controls for automatic tilting in tiltable systems

Launder systems for transferring molten metals

Launder systems are an integral part of every foundry operation. Optimal launder design plays a crucial role in ensuring a smooth and economical production process, especially when a rapid transfer between furnace systems is essential. Clean launders with minimal turbulence of the melt are crucial in the production of high-quality products.

OTTO JUNKER possesses comprehensive experience in the design and installation of launder systems. This expertise is supported by in-house developed software for the layout of open and closed launder systems, the use of state-of-the-art lining materials and heating and preheating systems ranging from gas-fired solutions for launders to electric heating devices for launders.

Launder systems are fundamentally dimensioned for the required transfer or casting capacity. The accessory and equipment program includes laser-assisted level control for (semi-) automatic metal transfer and automatic casting, metal probes for overflow protection, thermocouples for fine-tuning the casting temperature and more.