The atmosphere above the aluminum feed in the aluminum smelting process comprises two layers, wherein the lower layer covers the aluminum feed and consists of a non-oxidizing gas and the upper layer consists of a combustion gas from one or more burners. The heat from one or more burners heats and fuses the aluminum radiation, while at the same time the underlying layer protects the aluminum from the oxidation that may occur as a result of the aluminum contacting the combustion gases, thereby reducing the amount of scum formation. The method for smelting aluminum feed in a direct flame furnace includes: (A) introducing the feed into the furnace; (B) burning with a burner, thereby supplying heat to the furnace and discharging Combustion gases enter the furnace to form a combustion gas layer in the furnace; (C) smelt the aluminum feedstock to form a molten aluminum bath, wherein the heat radiation is transmitted to the aluminum feedstock; (D) A non-oxidizing gas is introduced into the furnace from between the combustion gas layer and the aluminum to form a non-oxidizing gas layer in the furnace. This layer is used to reduce the possibility of direct contact between the solid aluminum surface and the combustion gas layer. The amount of dross; and (E) the combustion gas is discharged from the furnace at a position above the position where the combustion gas enters the furnace.
