TECHNOLOGY

— Die casting is a precision casting process that uses high pressure to force molten metal into a complex metal mold; it is particularly well-suited for the mass production of thin-walled non-ferrous metal castings and represents a vital manufacturing process in modern industry. Driven by the trend toward lightweight and integrated chassis designs in new energy vehicles, die casting technology is rapidly advancing into the era of high-tonnage, large-scale die casting.

— Aluminum is the most common material used, with such castings finding widespread application in the automotive sector. Magnesium, valued for its low weight, is also frequently used.

— In the casting process, molten metal is mechanically forced into a mold at high pressure and speed. To facilitate the easy separation of the casting from the mold and to ensure surface quality, a release agent is sprayed onto the mold; in some cases, additional lubrication is also required. When the molten metal is injected, the release agent heats up, volatilizes, partially burns, and rises as smoke.

— This is where Tenzon technology comes into play, efficiently capturing and separating this smoke.

— Depending on the layout of the client's die-casting production lines and environmental compliance requirements, two approaches to managing die-casting fumes can be considered: centralized collection and purification, or standalone unit purification. The former typically involves installing purification equipment outdoors and discharging emissions via a stack, whereas the latter usually entails constructing a steel platform above the die-casting machine to house a high-efficiency purification unit (often a wet electrostatic precipitator) and releasing the treated air into the workshop as fugitive emissions. Each approach has its own advantages and disadvantages; it is recommended that the choice be made based on a comprehensive assessment of actual conditions.

Centralized collection and purification

Centralized System — A single separator (with an airflow capacity of up to 180,000 m³/h) serves multiple die-casting machines.

— Advantages: Lower investment costs; low maintenance requirements.

— Disadvantages: Despite the use of automatic variable-frequency operation, energy consumption remains relatively high; additionally, the collection ductwork is bulky.

For centralized purification systems, Tenzon offers three solutions tailored to specific operating conditions:

TESP Wet Electrostatic Purifier, EMC Oil Mist Purifier, and VTDS Venturi Wet Dust Collector.

Standalone purification

Stand-alone system — One separator per die-casting machine (air volume: 1,000 – 60,000 m³/h)

— Advantages: Each system operates independently; lower energy consumption and operating costs.

— Disadvantages: Higher initial investment cost.

For stand-alone purification systems, Tenzon offers two solutions:

The TESP wet electrostatic precipitator and the EMC oil mist purifier.