HK1247180A1 - Basalt processing via electric induction heating and melting - Google Patents

Description

Basalt processing by electric induction heating and melting

Cross Reference to Related Applications

This application claims priority from U.S. provisional application No. 62/195,828 filed on 23/7/2015, which is incorporated herein by reference in its entirety.

Technical Field

The present invention relates to electric induction heating and melting of basalt for producing molten basalt, useful in a production process for producing molten basalt articles including cast basalt articles, and a continuous basalt casting process for producing basalt articles such as fibers and filaments.

Background

Basalt (basalt) is a hard, dense volcanic rock that has been used as a raw material in casting processes to make bricks and panels. Cast iron basalt liners are also used for steel pipes, since the liners exhibit very high wear resistance in industrial applications. Basalt in comminuted form may also be used as aggregate in concrete.

Basalt is also used for fiber reinforcement of composite materials and other applications where drawn basalt filaments are used to make other articles. Mined basalt is first crushed, then cleaned and loaded into a bin connected to a feeder which moves the material into a molten pool in a gas furnace. When the crushed basalt enters the gas heating furnace, the material liquefies at a temperature of about 1500 ℃. Opaque basalt absorbs infrared energy and therefore the gas burners used in conventional furnaces are more difficult to heat uniformly the entire basalt mixture. Therefore, the molten basalt must be maintained in the furnace for a long time to ensure a uniform temperature. Attempts to promote uniform basalt heating have included dipping the electrodes into a bath. However, gas heating tends to be employed despite the increase in manufacturing costs. Another two-stage gas heating scheme is characterized by separate zones with independently controlled heating systems, wherein only the temperature control system in the outlet zone of the gas furnace supplying the basalt filament extrusion lining requires precise temperature control, so that less complex temperature control systems can be used in the initial gas heating zone. The extruded basalt filament, e.g., fiber, fabric, or other article, can then be further processed.

It is an object of the present invention to provide an alternative apparatus and method for heating and melting basalt to produce molten process basalt for basalt articles.

It is another object of the present invention to provide an alternative apparatus and method for heating and melting basalt to produce molten process basalt for use in continuously casting basalt articles.

It is another object of the present invention to provide an alternative apparatus and method for heating and melting basalt for use in continuously casting basalt fibers or filaments.

Disclosure of Invention

The invention is an apparatus and method for electric induction melting and heating of basalt charge for producing molten process basalt for use in a process for producing basalt articles. In some embodiments of the invention, the basalt process is a continuous casting of basalt articles comprising basalt fibers or filaments.

The above and other aspects of the invention are set out in the present description and in the appended claims.

Drawings

The accompanying drawings, which are briefly summarized below, are provided for illustrative understanding of the present invention and do not limit the invention as further set forth in this specification.

FIG. 1 illustrates one example of an electric induction system and process for melting and heating a basalt charge to form molten process basalt for producing basalt articles.

Fig. 2 illustrates another example of an electric induction system and process for melting and heating a basalt charge to form molten process basalt for producing basalt articles.

Fig. 3(a) and 3 fig. 3(b) illustrate another example of an electric induction system and process for melting and heating a basalt charge to form molten process basalt for producing basalt articles.

DETAILED DESCRIPTION OF EMBODIMENT (S) OF INVENTION

FIG. 1 illustrates one example of an electric induction system 50 for melting and heating a basalt charge for use in producing molten process basalt for use in a process for producing a basalt article including a continuously cast basalt article.

In one embodiment of the present invention, the high temperature molten basalt induction furnace 60 and the molten process basalt induction furnace 70 are both cold crucible electric induction furnaces. In embodiments of basalt articles, such as fibers or filaments, the furnace 70 is also referred to as a caster (or casting) furnace.

The basalt charge is supplied as feedstock to the high temperature cold crucible induction furnace 60 by a suitable cold crucible induction furnace charging system which transfers the basalt charge from the feedstock feed zone to the furnace 60 where it is inductively heated by supplying AC electrical power from a suitable Alternating Current (AC) power supply, which in one embodiment of the invention is in the range of about 600kW and 300kHz to 800kHz, to one or more induction coils 62 around the exterior height of the high temperature cold crucible induction furnace.

Cold crucible induction furnace 60 may melt an initial batch of solid basalt charge to establish a molten basalt batch in the furnace, where the solid basalt charge may be continuously added for a continuous basalt casting process. Auxiliary removable heating devices (such as one or more susceptors or plasma torches) may be used to assist in melting the initial batch of the solid basalt charge. Alternatively, the process may begin by supplying an initial batch of molten basalt to the furnace 60.

Once the batch of molten basalt is established in the high temperature cold crucible induction furnace 60 (depicted as a substantially complete furnace in fig. 1), the furnace maintains the high temperature at which the batch of molten basalt is heated within the range of about 1500 ℃ to 2000 ℃, as required by the particular molten process basalt application in one embodiment of the invention. The term "high temperature" as used herein refers to the temperature of the heated molten basalt maintained in the high temperature cold crucible induction furnace before the heated molten basalt is transferred to the molten process basalt cold crucible induction furnace 70. The heated molten basalt temperature is typically higher than the "molten process basalt temperature" in a molten process basalt cold crucible induction furnace.

A temperature measuring device 64, such as a non-contact pyrometer, monitors the temperature at the surface of the molten basalt batch material in furnace 60, wherein heated molten basalt flows gravitationally out of the high temperature cold crucible induction furnace 60 into the molten process basalt cold crucible induction furnace 70 via a furnace mouth dump lip assembly 60a, as indicated by the flow 91 of heated molten basalt between furnaces 60 and 70.

In one embodiment of the present invention, the continuous gravity dumping of heated molten basalt is maintained in the approximate range of 1500 ℃ to 1800 ℃ by variably controlling the ac power supplied to the one or more induction coils 62 from the ac power supply 80a and the time rate of the basalt charge of molten basalt batch material charged into the high temperature cold crucible induction furnace 60.

In an alternate embodiment of the present invention, the high temperature cold crucible induction furnace 60 may be a tilting furnace, such that the gravity flow rate of the heated molten basalt from the high temperature cold crucible induction furnace may also be controlled by a controllable tilt angle of the furnace 60 from horizontal.

In some embodiments of the invention, an underflow baffle 66 is provided in the high temperature cold crucible induction furnace 60 to separate the basalt surface area of the basalt furnace charge receiving portion of the furnace (as shown in fig. 1) from the dumping area of the furnace, thereby allowing only fully molten basalt to be dumped from the furnace 60. In other embodiments of the invention, a filter arrangement may be provided in the furnace 60 in place of the underflow baffle, or a filter arrangement may be provided in the furnace 60 in addition to the underflow baffle, performing a similar function as the underflow baffle.

Heated molten basalt gravity poured from the high temperature cold crucible induction furnace 60 into the molten process basalt cold crucible induction furnace 70 is inductively heated via the one or more induction coils 72 around the exterior level of the molten process basalt cold crucible induction furnace 70 by supplying AC electrical power to the one or more induction coils 72 from a suitable AC power source, which in one embodiment of the invention is in the range of about 150kW to 300kW and 300kHz to 800 kHz. In one embodiment of the present invention, the molten process basalt in the molten process basalt cold crucible induction furnace 70 is maintained within a range of about 1400 ℃ to 1500 ℃ by varying the power supply from the AC power source 80b to the one or more induction coils 72. The difference between the "molten process basalt temperature" of the molten process basalt in the molten process basalt cold crucible induction furnace 70 and the "heated molten basalt high temperature" of the heated molten basalt in the high temperature cold crucible induction furnace 60 is that the molten process basalt temperature is within a temperature range required for a particular molten process basalt application, while the heated molten basalt high temperature in the heating furnace 60 is based on the heated molten basalt productivity required for the basalt charge to support the supply of the heated molten basalt to the molten process basalt cold crucible induction furnace.

In one embodiment of the invention, wherein the molten process basalt application is continuous casting, the continuous casting process temperature to heat the molten basalt is maintained at 1800 ℃ in the high temperature cold crucible induction furnace 60 and 1400 ℃ in the molten process basalt cold crucible induction furnace 70.

In some embodiments of the present invention, electromagnetic stirring is used to maintain a uniform molten basalt batch temperature in either or both of the cold crucible induction furnaces 60 and 70 having one or more induction coils to achieve a desired stirring pattern.

In one embodiment of the present invention wherein the molten process basalt cold crucible induction furnace 70 is used in a molten basalt casting application in the casting of basalt filament or basalt fiber, a casting chamber 134 is provided at the bottom of the molten process basalt cold crucible induction furnace 70. The casting chamber 134 typically comprises a platinum alloy liner having a plurality of die holes through which molten basalt at the temperature of the molten process basalt passes by virtue of the gravity and hydrostatic pressure of the molten basalt in the cold crucible induction furnace 70 to exit the cold crucible furnace 70 continuously through each die hole as a basalt filament or basalt fiber.

In some molten basalt casting applications of the invention, a molten process basalt temperature measurement and feedback control system is provided. In one embodiment of the invention, the measurement and control system includes a molten basalt temperature measurement device, such as a thermocouple 92 disposed near the bottom liner of molten process basalt in the cold crucible induction furnace 70, which outputs a temperature signal that is transmitted to a Programmable Logic Controller (PLC) in the process controller 90 via a signal conditioner 92 a. The output of the temperature signal from the temperature measuring device 64 is also transmitted to the programmable logic controller via the signal conditioner 64 a. The process controller is connected to a human-machine interface console (HMI) for an operator to monitor the system and process.

In other embodiments of the invention for use with molten process basalt applications, the molten process basalt cold crucible induction furnace 70 is modified for use with the appropriate process to support the appropriate molten process basalt temperature. For example, in some embodiments of the present invention, cold crucible induction furnace 70 is adapted for bottom pouring through a bottom nozzle assembly, inclined pouring with a closed hearth, or other melt process basalt pouring method from furnace 70 into a mold for making basalt articles. In other embodiments of the invention, furnace 70 is modified for bottom discharge of molten process basalt in forms other than filaments or fibers, for example, to produce solid processed basalt pellets or basalt ingots by open bottom cold crucible with ingot cooling.

In some embodiments of the present invention, the auxiliary process monitoring and control stations 94a and 94b may be located at strategic locations in the process area of the electric induction system.

Auxiliary systems, such as the water cooling system 192 powered by the motor control center 194, may be provided as required by the closed water cooling system required by the process equipment in a particular application.

Fig. 2 shows another example of an electric induction system 10 for melting and heating a basalt charge for producing molten process basalt for use in a process for producing a basalt article including a continuously cast basalt article.

In one embodiment of the present invention, the high temperature molten basalt induction furnace 20 and the molten process basalt induction furnace 30 are both cold crucible electric induction furnaces. In an embodiment of a basalt article (such as a fiber or filament), the furnace 30 may also be referred to as a molten process basalt holding and caster (or casting) furnace.

The interiors of the furnaces 20 and 30 are interconnected by a closed cold crucible launder 40. The cold crucible launder is formed similarly to a cold crucible induction furnace sectional wall section with a horizontally oriented metal sectional wall section without an induction coil wound around its periphery. Like the cold crucible induction furnace, the segmented wall sections have internal passages for the flow of a fluid cooling medium.

The basalt charge is provided as feedstock to the high temperature cold crucible induction furnace 20 by a suitable cold crucible induction furnace charging system which transfers the basalt charge from the feedstock feed zone to the furnace 20, where it is inductively heated by supplying AC electrical power from a suitable AC power source, in one embodiment of the invention in the range of about 600kW and 300kHz to 800kHz, to one or more induction coils 22 around the exterior height of the high temperature cold crucible induction furnace.

The cold crucible induction furnace 20 can melt an initial batch of solid basalt charge to establish a molten basalt batch in the furnace, into which the solid basalt charge can be continuously charged and mixed for use in a continuous basalt casting process. Auxiliary removable heating devices (such as one or more susceptors or plasma torches) may be used to assist in melting the initial batch of the solid basalt charge. Alternatively, the process may begin by supplying an initial batch of molten basalt to the furnace 60.

Once the molten basalt batch is established in the high temperature cold crucible furnace 20, the furnace maintains the high temperature at which the molten basalt batch is heated in the approximate range of 1500 ℃ to 2000 ℃, as required by the particular molten process basalt application in one embodiment of the invention. The term "high temperature" as used herein refers to the temperature of the heated molten basalt maintained in the high temperature cold crucible induction furnace before the heated molten basalt is transferred to the molten process basalt cold crucible induction furnace 30.

In one embodiment of the invention, wherein the molten process basalt application is continuous casting, once the level of the batch of heated molten basalt in the cold crucible induction furnace 20 reaches the closed launder inlet opening 40a, the heated molten basalt is transferred from the high temperature cold crucible induction furnace 20 to the molten process basalt cold crucible induction furnace 30, where it is inductively heated by supplying AC electrical power from a suitable AC power supply, in one embodiment of the invention, in the range of about 150kW to 300kW and 300kHz to 800kHz to one or more induction coils 32 surrounding the outer level of the furnace 30. The continuous casting process temperature of the molten basalt is maintained at about 1500 to 2000 c for the heated molten basalt in the high temperature cold crucible induction furnace 20, and at about 1500 c for the molten process basalt in the molten process basalt cold crucible induction furnace 30. The difference between the "molten process basalt temperature" of the molten process basalt in the molten process basalt cold crucible induction furnace 30 and the "heated molten basalt high temperature" of the heated molten basalt in the high temperature cold crucible induction furnace 20 is that the molten process basalt temperature is within the temperature range required for the specific molten process basalt application, while the heated molten basalt high temperature in the heating furnace 20 is based on the molten basalt productivity required for the basalt charge to support the supply of the heated molten basalt to the molten process basalt cold crucible induction furnace.

In some embodiments of the present invention, electromagnetic stirring is used to maintain a uniform molten basalt batch temperature in either or both of the cold crucible induction furnaces 20 and 30 having one or more induction coils to achieve a desired stirring pattern.

In some embodiments of the invention, the temperature cooling control unit 42 is used to control the temperature of the liquid or gaseous fluid cooling medium flowing through the internal passages of the segmented wall sections of the cold crucible launder 40 so that the molten basalt entering the molten process basalt cold crucible induction furnace 30 at the closed launder outlet 40b is at a temperature low enough to maintain a continuous flow of hot molten basalt from the high temperature cold crucible induction furnace 20 to the molten process basalt cold crucible induction furnace 30 to support a continuous basalt casting process at the molten process basalt temperature.

In some embodiments of the invention, an optional underflow baffle 24 is provided in the high temperature cold crucible induction furnace 20 to separate the basalt surface area of the basalt furnace charge receiving portion of the furnace (as shown in fig. 2) from the closed launder inlet opening 40a, thereby allowing only the fully molten charge, as heated molten basalt, to enter the closed launder inlet opening via the heated molten basalt flow path (as shown by the flow path arrows in fig. 2) below the baffle. In other embodiments of the invention, a filter device may be provided in the oven 20 instead of the baffle, or a filter device may be provided in the oven 20 in addition to the baffle, performing the same function.

In one embodiment of the present invention, where the molten process basalt cold crucible induction furnace 30 is used in a molten basalt casting application for casting basalt filament or basalt fiber, a casting chamber 34 is provided at the bottom of the molten process basalt cold crucible induction furnace 30. The casting chamber 34 typically comprises a platinum alloy liner having a plurality of die holes through which molten basalt at the temperature of the molten process basalt passes by virtue of the gravity feed and hydrostatic pressure of the molten basalt in the furnace 30 to exit the furnace 30 continuously as basalt filaments or basalt fibers through each die hole.

The temperature monitoring and control system 1 used in the embodiment of the invention shown in fig. 1 is also suitable for use in the embodiment of the invention shown in fig. 2 suitably adapted.

In other embodiments of the invention for use with molten process basalt applications, the molten process basalt cold crucible induction furnace 30 is modified for use with the appropriate process to support the appropriate molten process basalt temperature. For example, in some embodiments of the present invention, cold crucible induction furnace 30 is adapted for use in bottom pouring through a bottom nozzle assembly, tilt pouring with a closed hearth, or other melt process basalt pouring method from furnace 30 into molds for making basalt articles. In other embodiments of the invention, furnace 30 is modified for bottom discharge of molten process basalt in forms other than filaments or fibers, for example, to produce solid processed basalt pellets or basalt ingots by open bottom cold crucible with ingot cooling.

The above-described embodiments of the present invention comprising two separate cold crucible induction furnaces have the advantage that the heated molten basalt temperature in the high temperature cold crucible induction furnace and the molten process basalt temperature in the molten process basalt cold crucible induction furnace are maintained with separate temperature control systems and basalt charge impurities can be treated in the high temperature cold crucible induction furnace before reaching the molten process basalt cold crucible induction furnace.

Fig. 3(a) and 3(b) show another example of an electric induction system 120a or 120b for melting and heating a basalt charge for producing molten process basalt for use in a process for producing a basalt article, wherein a single cold crucible electric induction is used both to melt the basalt charge at a high temperature and to maintain the molten process basalt at a molten process basalt temperature.

The electric induction system 120a or 120b utilizes a single cold crucible induction furnace 122a or 122b, shown in fig. 3(a) or fig. 3, respectively, to obtain high temperature molten basalt (in which the basalt charge fed to the single furnace is melted and maintained at the heated basalt melt temperature) at the heated molten basalt temperature in the upper furnace section (melt zone) and to process the molten basalt at the molten basalt process temperature in the lower furnace section (process zone). Utilizing a single cold crucible induction furnace reduces the exposed surface area of the molten basalt, which reduces process heat losses and results in lower electrical power input.

The one or more high temperature upper induction coils 124 induce and heat the basalt in the molten zone to a desired heated molten basalt temperature by variably controlling AC power supplied from an AC power supply to the one or more induction coils 124.

The one or more high temperature upper induction coils 126 induce and heat the basalt in the molten zone to the desired molten process basalt temperature by variably controlling the AC power supplied from the AC power source to the one or more induction coils 124.

The embodiment shown in fig. 3(b), wherein the internal horizontal cross-sectional area of the upper melting zone of the furnace is smaller than the internal cross-sectional area of the lower process zone of the furnace, has the advantage of achieving a molten basalt temperature gradient between the melting zone and the process zone, wherein the transition throat between the smaller and larger cross-sectional areas facilitates the electromagnetic stirring effect of the upper and lower induction coils to maintain the high temperature heated molten basalt above the lower temperature molten process basalt.

In some embodiments of the invention, additional electromagnetic stirring may be used to achieve a temperature gradient between the melt zone and the process zone with one or more induction coils 124 and/or 126 to achieve a desired stirring pattern.

In one embodiment of the invention, where a single cold crucible induction furnace 122a or 1222b is used in a molten basalt casting application for casting basalt filament or basalt fiber, a casting chamber 234 is provided at the bottom of the furnace. The casting chamber 234 typically comprises a platinum alloy liner having a plurality of die holes through which molten basalt at the temperature of the molten process basalt passes by virtue of gravity feed and hydrostatic pressure of the furnace to exit the furnace continuously as basalt filaments or fibers through each die hole.

In other embodiments of the invention for molten process basalt applications, a single cold crucible induction furnace 122a or 122b is modified for the appropriate process to support the appropriate molten process basalt temperature. For example, in some embodiments of the invention, the oven is adapted to be bottom-dumped into a mold for producing basalt articles. In other embodiments of the invention, the furnace is adapted for bottom discharge of molten process basalt in forms other than filaments or fibers, for example, to produce basalt ingots or solid processed basalt pellets.

In the above examples of the invention, a cold crucible induction furnace and launders were utilized. In other embodiments of the invention, an electric induction furnace with a refractory crucible may be used in place of one or more cold crucible induction furnaces or launders with suitable features to contain basalt. For example, lining the interior of a refractory crucible with a lining composition can prevent contamination of molten basalt with refractory materials.

In the description above, for purposes of explanation, numerous specific requirements and several specific details have been set forth in order to provide a thorough understanding of the examples and embodiments. It will be apparent, however, to one skilled in the art that one or more other examples or embodiments may be practiced without some of these specific details. The particular embodiments are not provided to limit the invention but to illustrate it.

For example, reference throughout this specification to "one example or embodiment," "an example or embodiment," "one or more examples or embodiments," or "a different example or embodiment" means that a particular feature may be included in the practice of the invention. In the description, various features are sometimes combined in one example, embodiment, drawing, or description thereof to simplify the present disclosure and to aid in understanding the objectives of various inventive aspects.

The invention has been described in terms of preferred examples and embodiments. Equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the present invention.

Claims (16)

1. An electric induction system for melting and heating a basalt charge to supply molten process basalt to make a basalt article, the electric induction system comprising:

a high temperature cold crucible induction furnace having a high temperature cold crucible induction coil surrounding an exterior height of the high temperature cold crucible induction furnace, the high temperature cold crucible induction coil being supplied with first alternating current power by a first alternating current power source, the high temperature cold crucible induction furnace having a throat dump lip assembly;

a cold crucible induction furnace charging system for supplying the basalt charge to the high temperature cold crucible induction furnace for induction melting of the basalt charge in the high temperature cold crucible induction furnace to produce heated molten basalt in the high temperature cold crucible induction furnace; and

a molten process basalt cold crucible induction furnace for receiving the heated molten basalt from the high temperature cold crucible induction furnace through the throat dump lip assembly and supplying the heated molten basalt for the molten basalt manufacturing process at the molten process basalt temperature, the molten process basalt cold crucible induction furnace having a molten process basalt cold crucible induction coil surrounding the exterior level of the molten basalt cold crucible induction furnace, the molten process basalt cold crucible induction coil being provided with second alternating current power by a second alternating current power supply.

2. The electric induction system of claim 1 wherein the molten basalt manufacturing process comprises continuously casting basalt articles, the electric induction system further comprising a casting chamber for continuously casting basalt filaments or basalt fibers disposed at a bottom of the molten process basalt cold crucible induction furnace.

3. An electric induction system for melting and heating a basalt charge to supply molten process basalt to make a basalt article, the electric induction system comprising:

a high temperature cold crucible induction furnace having a high temperature cold crucible induction coil surrounding an exterior height of the high temperature cold crucible induction furnace, the high temperature cold crucible induction coil being supplied with first alternating current electrical power by a first alternating current power source;

a cold crucible induction furnace charging system for supplying the basalt charge to the high temperature cold crucible induction furnace for induction melting of the basalt charge in the high temperature cold crucible induction furnace to produce heated molten basalt in the high temperature cold crucible induction furnace;

a molten process basalt cold crucible induction furnace for receiving the heated molten basalt from the high temperature cold crucible induction furnace and supplying the heated molten basalt for the molten basalt manufacturing process at the molten process basalt temperature, the molten process basalt cold crucible induction furnace having a molten process basalt cold crucible induction coil surrounding the exterior level of the molten process basalt cold crucible induction furnace, the molten process basalt cold crucible induction coil being provided with second alternating current power by a second alternating current power supply; and

an enclosed cold crucible launder having segmented wall sections with internal passageways, said enclosed cold crucible launder having an enclosed launder interior inlet opening connected with the interior of the high temperature cold crucible induction furnace and an enclosed launder interior outlet connected with the interior of the molten process basalt cold crucible induction furnace for conveying the heated molten basalt from the high temperature cold crucible induction furnace to the molten process basalt cold crucible induction furnace.

4. The electric induction system of claim 3 further comprising a temperature cooling control unit for controlling a fluid cooling medium flowing through the internal passage of the segmented wall portion of the enclosed cold crucible launder to control the temperature of the heated molten basalt flowing through the enclosed cold crucible.

5. The electric induction system of claim 3 wherein the molten basalt manufacturing process comprises continuously casting basalt articles, the electric induction system further comprising a casting chamber disposed at the bottom of the molten process basalt cold crucible induction furnace to continuously cast basalt filaments or basalt fibers.

6. An electric induction system for melting and heating a basalt charge to supply molten process basalt to make a basalt article, the electric induction system comprising:

a molten basalt cold crucible induction furnace comprising:

an upper basalt melt zone having one or more high temperature induction coils surrounding an outer height of the upper basalt melt zone to inductively melt and heat the basalt charge supplied to the molten basalt cold crucible induction furnace to a heated molten basalt temperature; and

a lower basalt process zone having one or more molten process basalt temperature induction coils surrounding an exterior height of the lower basalt process zone to inductively heat the molten basalt in the lower basalt process zone to a molten process basalt temperature for the molten basalt manufacturing process and a molten process basalt temperature.

7. The electric induction system of claim 6 further comprising the upper basalt melt zone having an upper horizontal cross-sectional interior area that is less than a lower horizontal cross-sectional interior area of the lower basalt process zone to form a transition throat horizontal cross-sectional region between the upper basalt melt zone and the lower basalt process zone.

8. The electromagnetic induction system of claim 6 wherein the molten basalt manufacturing process comprises continuously casting basalt articles, the electric induction system further comprising a casting chamber disposed at a bottom of the molten basalt cold crucible induction furnace for continuously casting basalt filaments or basalt fibers.

9. A method of melting and heating a basalt charge with electric induction to provide a molten process at a molten process basalt temperature for a basalt article manufacturing process, the method comprising:

inductively heating a basalt charge in a high temperature cold crucible induction furnace to form heated molten basalt in the high temperature cold crucible induction furnace;

making the heated molten basalt flow from the high temperature cold crucible induction furnace into a molten process basalt cold crucible induction furnace by using gravity; and

inductively heating the heated molten basalt in the molten process basalt cold crucible induction furnace to form molten process basalt in the molten process basalt cold crucible induction furnace.

10. The method of claim 9 further comprising casting the molten process basalt through a casting plenum at the bottom of the molten process basalt cold crucible induction furnace to form a basalt filament or a basalt fiber.

11. A method of melting and heating a basalt charge with electric induction to provide a molten process at a molten process basalt temperature for a basalt article manufacturing process, the method comprising:

inductively heating a basalt charge in a high temperature cold crucible induction furnace to form heated molten basalt in the high temperature cold crucible induction furnace;

supplying the heated molten basalt from the high temperature cold crucible induction furnace to a molten process basalt cold crucible via an enclosed cold crucible launder; and

inductively heating the heated molten basalt in the molten process basalt cold crucible induction furnace to form molten process basalt in the molten process basalt cold crucible induction furnace.

12. The method of claim 11, further comprising the steps of: controlling the temperature of the heated molten basalt in the enclosed cold crucible launder by flowing a fluid cooling medium through the internal channels of the segmented wall sections of the enclosed cold crucible launder.

13. The method of claim 12 further comprising casting the molten process basalt through a casting plenum at the bottom of the molten process basalt cold crucible induction furnace to form a basalt filament or a basalt fiber.

14. A method of melting and heating a basalt charge with electric induction for providing a molten process at a molten process basalt temperature for a basalt article manufacturing process, the method comprising:

providing a basalt charge to a molten basalt cold crucible induction furnace, the basalt cold crucible induction furnace comprising:

an upper basalt melt zone having one or more high temperature induction coils surrounding an outer height of the upper basalt melt zone; and

a lower basalt process zone having one or more molten process basalt temperature induction coils surrounding an exterior height of the lower basalt process zone;

induction melting and heating the basalt charge supplied to the molten basalt cold crucible induction furnace to a heated molten basalt temperature in the upper basalt melting zone by variably controlling a first alternating current electric power supplied from a first alternating current power supply to the one or more high temperature induction coils; and

inductively heating the molten basalt in the lower basalt process zone to a molten process basalt temperature for a molten basalt manufacturing process by variably controlling a second alternating current power supplied from a second alternating current to the one or more molten process basalt temperature induction coils.

15. The method of claim 14 further comprising forming a transitional throat horizontal cross-sectional area between the upper basalt melt zone and the lower basalt process zone, wherein the upper basalt melt zone has an upper horizontal cross-sectional interior area that is smaller than a lower horizontal cross-sectional interior area of the lower basalt process zone.

16. The method of claim 14 further comprising casting the molten process basalt through a casting plenum at the bottom of the molten basalt cold crucible induction furnace to form a basalt filament or a basalt fiber.