1. Market Background

In Russia, the automotive, construction and cable industries generate steady and growing demand for aluminum ingots. Ingot quality—hydrogen content, inclusions and chemical homogeneity—directly affects the stability of downstream casting and rolling processes. Many plants operate relatively simple ingot casting lines with limited investment in degassing and filtration, making it difficult to systematically address hydrogen and inclusion issues in molten aluminum and leading to higher defect rates downstream.

2. Customer & Application Scenario

The customer is an ingot producer supplying multiple industries. Its existing ingot line had limited length, with degassing and filtration units scattered and loosely integrated. As end users tightened their quality specifications, the existing setup struggled with melt cleanliness, ingot dimensional consistency and line throughput. The customer sought a full-line upgrade, combining melt purification and ingot casting in a single, integrated solution.

3. Our Solution (Product & Specifications)

The new system centers on a 9 m ingot casting machine, a mobile in-line degassing unit and a filtration box, forming a complete ingot casting solution:

• The 9 m ingot caster provides stable ingot forming and cooling rhythm, supporting continuous casting;

• The mobile in-line degasser is positioned upstream of the ingot caster, using argon or nitrogen purging to reduce hydrogen content in the molten aluminum;

• The filtration box houses ceramic filter media to remove non-metallic inclusions and improve melt cleanliness.

With carefully designed elevation and flow paths, molten aluminum flows through filtration and degassing before entering the ingot caster, effectively integrating “purification + casting” into a single line. Rather than optimizing each unit in isolation, the solution focuses on the coordination and layout of all three modules to ensure a coherent upgrade of the entire process.

4. Customer Feedback

After start-up, the customer reported more consistent ingot surface and internal quality. Downstream users observed fewer gas porosity and inclusion-related defects during remelting and secondary casting. The 9 m ingot caster delivered smoother cycle control, and ingot size and weight consistency improved, simplifying packaging and inventory management.
The combination of in-line degassing and filtration allows melt purification settings to be adjusted according to alloy grade and production schedule, and maintenance or filter changes are relatively straightforward. The customer believes this integrated upgrade provides a strong foundation for entering higher-end markets with stricter quality demands.

5. Conclusion

For Russia and other regions with concentrated aluminum processing industries, a complete ingot casting line combining a 9 m ingot caster, in-line degassing and filtration can improve ingot quality at the source and reduce defect rates in downstream operations. This case demonstrates that planning melt purification and ingot casting as a single integrated system yields a better balance between quality and efficiency than upgrading individual pieces of equipment in isolation.