How to Melt Aluminum Cans - Using a Propane Torch

1. The aluminium cans should be pulverised. The process of crushing and compacting the cans results in a faster rate of melting. The greater the degree of compaction achieved during the crushing process, the more readily the cans will melt.
The presence of impurities, such as paint, on the surface of the melted aluminium, known as dross, is inevitable regardless of whether the cans have been cleaned prior to crushing. Such material can then be removed and discarded.

2. A substantial quantity of sand should be transferred into a receptacle of considerable capacity, such as a large glass bowl. The sand will act as a heat insulator, preventing the heat from the torch from transferring to the bowl and the ground. Furthermore, it will maintain the stability of the melting chamber. If available, a steel bucket is an optimal choice for melting aluminium.

3. Position a smaller steel cup at the centre of the sand-filled bowl. The diameter of the steel cup must be a minimum of 7.6 cm in order to melt cans. The cup should be inserted into the sand to a depth that ensures stability, while allowing the edge to remain visible above the surface.
It is essential to select a cup made of plain steel, devoid of any coating or paint. It should be noted that the aforementioned materials are susceptible to combustion when exposed to the heat generated by the propane torch.
An alternative method is to place the steel cup, pot, or pan directly onto a non-flammable surface, such as a cinder block.

4. Place an aluminium canister into the cup and subject it to heat generated by the blowtorch. The initial piece of metal will require the longest period of time to achieve the melting point. Once the initial can has fully melted, additional cans can be introduced. It is advisable to have a bucket of cold water readily available in case of any fires.

5. The aluminium should then be poured into the steel muffin tins. Once the aluminium has been melted, it should be poured into a muffin tin to allow it to harden into ingots. Any impurities will adhere to the steel cup, leaving behind pure aluminium ingots. Once the metal has cooled, it can be removed from the mould and stored. Alternatively, the melted aluminium can be poured into a steel mould, if one is available.
It is imperative that materials be handled with care and caution, particularly when they are still hot.