WO2025064898A1 - Système et procédé de fusion par immersion de métal d'aluminium et d'alliages - Google Patents
Système et procédé de fusion par immersion de métal d'aluminium et d'alliages Download PDFInfo
- Publication number
- WO2025064898A1 WO2025064898A1 PCT/US2024/047797 US2024047797W WO2025064898A1 WO 2025064898 A1 WO2025064898 A1 WO 2025064898A1 US 2024047797 W US2024047797 W US 2024047797W WO 2025064898 A1 WO2025064898 A1 WO 2025064898A1
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- WO
- WIPO (PCT)
- Prior art keywords
- metal
- melting
- chamber
- heating
- solid metal
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B3/00—Hearth-type furnaces, e.g. of reverberatory type; Electric arc furnaces ; Tank furnaces
- F27B3/04—Hearth-type furnaces, e.g. of reverberatory type; Electric arc furnaces ; Tank furnaces of multiple-hearth type; of multiple-chamber type; Combinations of hearth-type furnaces
- F27B3/045—Multiple chambers, e.g. one of which is used for charging
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B19/00—Combinations of different kinds of furnaces that are not all covered by any single one of main groups F27B1/00 - F27B17/00
- F27B19/02—Combinations of different kinds of furnaces that are not all covered by any single one of main groups F27B1/00 - F27B17/00 combined in one structure
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B3/00—Hearth-type furnaces, e.g. of reverberatory type; Electric arc furnaces ; Tank furnaces
- F27B3/10—Details, accessories or equipment, e.g. dust-collectors, specially adapted for hearth-type furnaces
- F27B3/18—Arrangements of devices for charging
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B3/00—Hearth-type furnaces, e.g. of reverberatory type; Electric arc furnaces ; Tank furnaces
- F27B3/10—Details, accessories or equipment, e.g. dust-collectors, specially adapted for hearth-type furnaces
- F27B3/20—Arrangements of heating devices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D3/00—Charging; Discharging; Manipulation of charge
- F27D3/0025—Charging or loading melting furnaces with material in the solid state
Definitions
- Induction furnaces use electric energy for melting but typically require a water- cooled copper coil immersed into the melted metal, as well as high voltage cables. Moreover, induction furnaces involve highly complex facilities, which can result in a larger footprint and entail frequent maintenance.
- a melting furnace can include a feeding unit configured to feed solid metal; a heating chamber for heating and maintaining molten metal, where the heating chamber can include a plurality of immersion heaters and each immersion heater can be immersed in and heating the molten metal; a pump configured to circulate the molten metal from the heating chamber into a melting chamber; and the melting chamber configured to receive the solid metal from the feeding unit and the molten metal from the heating chamber.
- the solid metal can be submerged in the molten metal within the melting chamber and melts to create a liquid metal and the liquid metal can circulate from the melting chamber to the heating chamber.
- the feeding unit can include at least one of a walking floor, a vibro feeder, or a pusher unit to load the solid metal with controlled speed.
- the melting chamber can include a recessed bath Attorney Docket No. 6474.028WO1 section for mixing the solid metal in the molten metal.
- the melting chamber can include one or more radiant roof heaters configured to maintain a refractory of the melting chamber above a pre-defined temperature value.
- the one or more radiant roof heaters can have a power of between 15 and 90 kilowatts and the pre-GHILQHG ⁇ WHPSHUDWXUH ⁇ YDOXH ⁇ LV ⁇ & ⁇ [0005]
- the melting chamber can include a first laser for monitoring a charge level of the solid metal; and a second laser for monitoring a height of the liquid metal.
- the melting chamber can include a ramp, wherein the solid metal slides down the ramp and into the recessed bath.
- the melting furnace can include a cleaning chamber for removing dross out of the liquid metal via porous plugs prior to the liquid metal entering the heating chamber.
- the cleaning chamber can include one or more skim damns configured to collect dross from the liquid metal.
- each of the plurality of immersion heaters can have a diameter of between 75 and 135 mm; and the plurality of immersion heaters can have a heating power of between 1000 and 3000 kilowatts.
- a method of operating a melting furnace can include heating molten metal in a heating chamber via a plurality of immersion heaters contacting the molten metal; pumping a portion of the molten metal from the heating chamber to a melting chamber; feeding solid metal into the melting chamber; melting the solid metal by submerging, in the melting chamber, the solid metal in the portion of the molten metal to create a metal mixture; and circulating the metal mixture from the melting chamber to the heating chamber.
- feeding the solid metal into the melting chamber can include feeding the solid metal via at least one of a walking floor, a vibro feeder, or a pusher unit.
- melting the solid metal can include submerging the solid metal in the portion of the molten metal in a recessed bath section of the melting chamber.
- the method can include heating the melting chamber via one or more radiant roof heaters to maintain a refractory of the melting chamber above a pre-defined temperature value.
- the one or more radiant roof heaters can have a power of between 15 and 90 kilowatts and the pre-GHILQHG ⁇ WHPSHUDWXUH ⁇ YDOXH ⁇ LV ⁇ & ⁇ Attorney Docket No. 6474.028WO1 [0008]
- the method can include monitoring a charge level of the solid metal via a first laser; and monitoring a height of the metal mixture via a second laser.
- feeding the solid metal into the melting chamber can include causing the solid metal to slide down a ramp and into the recessed bath.
- the method can include filtering the metal mixture prior to the metal mixture entering the heating chamber.
- filtering the metal mixture can include degassing the metal mixture via one or more porous plugs; and collecting dross from the metal mixture via one or more skim damns.
- each of the plurality of immersion heaters can have a diameter of between 75 and 135 mm; and the plurality of immersion heaters can have a heating power of between 1000 and 3000 kilowatts.
- FIG. 1 is an immersion-based melting furnace according to some examples of the present disclosure.
- FIG. 2 is a melting chamber from the immersion-based melting furnace of FIG. 1 according to some examples of the present disclosure.
- FIG. 3 is a heating chamber from the immersion-based melting furnace of FIG. 1 according to some examples of the present disclosure.
- FIG. 4 is an example method for operating an immersion-based melting furnace according to some examples of the present disclosure.
- Examples of the present disclosure are directed to systems and methods for immersion-based melting of aluminum metal and alloys, for example via an electric immersion-based melting furnace.
- the disclosed furnace utilizes various electric immersion heaters that operate based on resistant heating principles to heat up and maintain a bath of liquid metal, such as aluminum or other alloys.
- the liquid metal can be circulated into a separate chamber that receives solid metal to be melted.
- the liquid metal engulfs the solid metal, melting it, and the resulting mixture can be circulated back into the original chamber for heating via the immersion heaters.
- the disclosed examples provide various benefits, such as the ability to operate without processes cooling water or other complex utilities.
- the footprint of the disclosed furnace is more compact than induction furnaces and entails less maintenance.
- the disclosed furnace can, in the case of aluminum melting, melt up to three to ten metric tons of aluminum per hour.
- the configuration of the disclosed furnace enables easy cleaning and dross removal, which in turn can increase the service life of the unit and quality of the metal generated therefrom.
- the disclosed furnace can be operated with an integrated holding section to feed directly into a casting process for large-scale structure parts.
- the disclosed immersion-based melting furnace can, in the case of aluminum melting, produce between about three and ten tons per hour (t/h) of liquid aluminum alloy per hour. In addition, the disclosed furnace can melt about 5500 kg/h of aluminum cast alloys and can be configured to hold between about fifteen and twenty tons of liquid metal.
- FIG. 1 is an immersion-based melting furnace 100 according to some embodiments of the present disclosure.
- the furnace 100 can include a feeding unit 101 configured to load solid metal into the furnace 100.
- the solid metal can be aluminum, although this is not limiting and is merely exemplary in nature.
- the solid metal can be loaded in the form of ingots, blocks, and/or internal run-around scrap.
- the furnace 100 can include a buffer 102 to allow the furnace Attorney Docket No. 6474.028WO1 to be fed automatically but with an appropriate buffer of time.
- the buffer can be solid metal and can cause there to be a buffer of about one hour. However, one hour of buffering time is not required and the length of the conveyor can vary based on the desired buffer time.
- the feeding unit 101 can have a width of approximately 2.5 times the width of loading blocks.
- the feeding unit 101 can include a walking floor, a vibro feeder, or a pusher.
- the feeding unit 101 can include a heavy-duty walking floor charger with a capacity of twenty tons of more of metal charges.
- the feeding unit 101 can load ingot bundles with a width of about 700mm and a 2m wide conveyor.
- the furnace 100 can include a melting chamber 103 surrounded by refractory walls 109.
- a refractory wall can refer to a material that is generally resistant to decomposition by heat, pressure, and other extreme conditions. Moreover, the walls can retain their form and strength even when exposed to such extreme conditions, such as those present at the inside of a furnace.
- the melting chamber 103 can receive the solid metal from the feeding unit 101. In addition, the melting chamber 103 can receive liquid metal in order to form a bath and melt the solid metal.
- the furnace 100 can include a heating chamber 110 that can receive a mixture from the melting chamber 103, which can be surrounded by a refractory wall 109.
- the mixture can be created from the melting of the solid metal ingots in the melting chamber 103 within the liquid metal.
- the mixture can be fully liquid, although this is not necessarily required and may not always occur. In other words, the entirety of the solid metal may not necessarily become liquid in the melting chamber 103.
- the heating chamber 110 can include porous plugs 104a-c (referred to individually as a ⁇ porous plug 104 ⁇ or collectively as ⁇ porous plugs 104 ⁇ ), which can cause floatation of dross from the mixture received by the melting chamber 103, as well as degassing.
- a porous plug 104 can include ceramic, such as alumina ceramic, with known or controlled porosity that enable and enhance gas flow.
- other types of gas diffusers may Attorney Docket No. 6474.028WO1 be used, as well.
- the porous plugs 104 can force, via floatation, suspended dross and/or oxide films into a dross layer.
- each skim damn can trap the floating or sinking dross, which can ensure easy cleaning of the furnace 100.
- the area containing the porous plugs 104 and the skim damns can be referred to as a ⁇ cleaning section.
- each skim damn can have a length that is about twice the radius of the floatation bubbles reaching the surface of the liquid metal within the furnace.
- the heating chamber 110 can include a plurality of immersion heaters 105. Each of the immersion heaters 105 can be immersed in the liquid metal (or liquid metal mixture prior to complete melting) contained within the heating chamber 110.
- the heating chamber 110 can include a transfer pump 106 configured to circulate the liquid metal around the heating chamber 110.
- the transfer pump 106 can be a mechanical pump or an inductive pump.
- the heating chamber 110 can also include a pump 108 that is configured to pump liquid metal into the melting chamber 103 for melting purposes.
- the furnace 100 can include a holding section 112. In some embodiments, the holding section 112 can be configured to feed directly into a casting process for large-scale structure parts.
- the holding section 112 can include a level pump and degasser 107a-b, as well as a transfer pump 111 that can pump liquid metal for a casting process, such as into a subsequent furnace.
- the holding section 112 can have a capacity of about 15 tons of metal content and can be configured to receive 2750 kg every thirty minutes.
- the holding section 112 can be configured to keep the temperature of the received metal constant within about twelve degrees for an hour.
- FIG. 2 is a melting chamber 103 from the immersion-based melting furnace of FIG. 1 according to some embodiments of the present disclosure.
- the Attorney Docket No. 6474.028WO1 view of FIG. 2 can be taken from the A-A cross-section of FIG. 1.
- the melting chamber 103 can receive aluminum blocks at various stages 201a-d from the feeding unit 101 via the buffer 102.
- the melting chamber 103 can include a swinging door 202, which can be open during melting mode and closed in standby to keep heat within the melting chamber 103.
- the aluminum block 201 can slide down a ramp into a bath 208 of liquid metal.
- the liquid metal in the bath 208 can have been circulated into the melting chamber 103 via the pump 108 of FIG. 1 contained in the heating chamber 110.
- the liquid metal in the bath 208 can be maintained at a level 203 in standby mode and at a second level 204 in melting mode.
- the melting chamber 103 can include a door 205 that enables access to the bath 208 for cleaning purposes.
- the melting chamber 103 can include one or more radiant roof heaters (e.g., resistant heaters) 206 that are configured to heat the melting chamber 103 maintain a pre-defined WHPSHUDWXUH ⁇ OHYHO ⁇ VXFK ⁇ DV ⁇ & ⁇ In some embodiments, each of the radiant heaters 206 can have a power output of between about 15 and 90 kilowatts. In some embodiments, adding heat to the system via the radiant heaters 206 can help reduce the risk of moisture in the metal while aluminum block 201 slides down the ramp.
- the melting chamber 103 can also include a fan (not shown) for convective heating.
- the melting chamber 103 can include one or more lasers 207 for monitoring various characteristics of the melting process. For example, a first laser can monitor the charge level of the aluminum block 201 as it enters the melting chamber 103 and a second laser can monitor the level of the liquid metal mixture within the bath 208.
- FIG. 3 is a heating chamber 110 from the immersion-based melting furnace of FIG. 1 according to some embodiments of the present disclosure. The view of FIG. 3 can be taken from the B-B cross-section of FIG. 1. As discussed in FIG. 2, the melting chamber 103 can include levels 203 and 204 of the liquid metal.
- the heating chamber 110 can include porous plugs 104a-c and the plurality of immersion heaters 105, as discussed in relation to FIG. 1.
- the heating chamber 110 can include two skim damns 301a-b to trap the floating or sinking dross within the liquid metal.
- the heating chamber 110 can include a sloped floor 302 to collect sediments and Attorney Docket No. 6474.028WO1 enable simple draining procedures.
- the heating chamber 110 can maintain the liquid metal at a level between levels 303 and 304. In other words, the heating chamber 110 can utilize a minimum and maximum metal level.
- FIG. 4 is an example method 400 for operating an immersion-based melting furnace according to some embodiments of the present disclosure. At block 401, a bath of liquid metal is maintained in the heating chamber 110 with a plurality of immersion heaters 105.
- a feeding unit 101 loads solid metal into a melting chamber 103.
- the solid metal can be fed in in shape of ingots, blocks, or scrap metal.
- the solid metal can be fed via a walking floor, a vibro feeder, or a pusher unit with controlled speed.
- the solid metal can slide down a ramp (i.e., via gravity) into a bath of the liquid metal, which causes the solid metal to melt. In other words, the solid metal is submerged in the liquid metal, causing the solid metal to heat up until it begins to melt.
- the metal mixture is pumped from the melting chamber 103 to a cleaning section. Once in the cleaning section, at block 405, the mixture is cleaned.
- cleaning the mixture can include degassing the metal mixture via one or more porous plugs 104 and collecting dross from the metal mixture via one or more skim damns.
- the cleaned mixture is further pumped into the heating chamber 110, such as for additional heating to be applied via the immersion heaters 105. Exemplary Aspects.
- Aspect 1 provides a melting furnace comprising: a feeding unit configured to feed solid metal; Attorney Docket No.
- Aspect 2 provides the melting furnace of Aspect 1, wherein the feeding unit comprises at least one of a walking floor, a vibro feeder, or a pusher unit to load the solid metal with controlled speed.
- Aspect 3 provides the melting furnace of any of Aspects 1 or 2, wherein the melting chamber comprises a recessed bath section for mixing the solid metal in the molten metal.
- Aspect 4 provides the melting furnace of Aspect 3, wherein the melting chamber comprises one or more radiant roof heaters configured to maintain a refractory of the melting chamber above a pre-defined temperature value.
- Aspect 5 provides the melting furnace of Aspect 4, wherein the one or more radiant roof heaters have a power of between 15 and 90 kilowatts and the pre-GHILQHG ⁇ WHPSHUDWXUH ⁇ YDOXH ⁇ LV ⁇ & ⁇
- Aspect 6 provides the melting furnace of any of Aspects 3-5, wherein the melting chamber comprises: a first laser for monitoring a charge level of the solid metal; and a second laser for monitoring a height of the liquid metal.
- Aspect 7 provides the melting furnace of any of Aspects 3-6, wherein the melting chamber comprises a ramp, wherein the solid metal slides down the ramp and into the recessed bath.
- Aspect 8 provides the melting furnace of any of Aspects 1-7 comprising a cleaning chamber for removing dross out of the liquid metal via porous plugs prior to the liquid metal entering the heating chamber.
- Attorney Docket No. 6474.028WO1 [0036]
- Aspect 9 provides the melting furnace of Aspect 8, wherein the cleaning chamber comprises one or more skim damns configured to collect dross from the liquid metal.
- Aspect 10 provides the melting furnace of any of Aspects 1-9, wherein: each of the plurality of immersion heaters has a diameter of between 75 and 135 mm; and the plurality of immersion heaters has a heating power of between 1000 and 3000 kilowatts.
- Aspect 11 provides a method of operating a melting furnace comprising: heating molten metal in a heating chamber via a plurality of immersion heaters contacting the molten metal; pumping a portion of the molten metal from the heating chamber to a melting chamber; feeding solid metal into the melting chamber; melting the solid metal by submerging, in the melting chamber, the solid metal in the portion of the molten metal to create a metal mixture; and circulating the metal mixture from the melting chamber to the heating chamber.
- Aspect 12 provides the method of Aspect 11, wherein feeding the solid metal into the melting chamber comprises feeding the solid metal via at least one of a walking floor, a vibro feeder, or a pusher unit.
- Aspect 13 provides the method of any of Aspects 11 or 12, wherein melting the solid metal comprises submerging the solid metal in the portion of the molten metal in a recessed bath section of the melting chamber.
- Aspect 14 provides the method of Aspect 13 comprising heating the melting chamber via one or more radiant roof heaters to maintain a refractory of the melting chamber above a pre-defined temperature value.
- Aspect 15 provides the method of Aspect 14, wherein the one or more radiant roof heaters have a power of between 15 and 90 kilowatts and the pre- GHILQHG ⁇ WHPSHUDWXUH ⁇ YDOXH ⁇ LV ⁇ & ⁇
- Aspect 16 provides the method of any of Aspects 13-15 comprising: monitoring a charge level of the solid metal via a first laser; and monitoring a height of the metal mixture via a second laser.
- Attorney Docket No. 6474.028WO1 [0044]
- Aspect 17 provides the method of any of Aspects 13-16 wherein feeding the solid metal into the melting chamber comprises causing the solid metal to slide down a ramp and into the recessed bath.
- Aspect 18 provides the method of any of Aspects 11-17 comprising filtering the metal mixture prior to the metal mixture entering the heating chamber.
- Aspect 19 provides the method of Aspect 18, wherein filtering the metal mixture comprises: degassing the metal mixture via one or more porous plugs; and collecting dross from the metal mixture via one or more skim damns.
- Aspect 20 provides the method of any of Aspects 11-19, wherein: each of the plurality of immersion heaters has a diameter of between 75 and 135 mm; and the plurality of immersion heaters has a heating power of between 1000 and 3000 kilowatts.
- the disclosed methodology and system are each sufficiently flexible and configurable such that they may be utilized in ways other than that shown.
- the term ⁇ at least one ⁇ may often be used in the specification, claims and drawings, the terms ⁇ a ⁇ , ⁇ an ⁇ , ⁇ the ⁇ , ⁇ said ⁇ , etc. also signify ⁇ at least one ⁇ or ⁇ the at least one ⁇ in the specification, claims and drawings.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Manufacture And Refinement Of Metals (AREA)
- Vertical, Hearth, Or Arc Furnaces (AREA)
Abstract
La présente invention concerne un four de fusion pouvant comprendre une unité d'alimentation conçue pour alimenter en métal solide et une chambre de chauffage pour chauffer et maintenir le métal fondu. La chambre de chauffage peut comprendre une pluralité de dispositifs de chauffage par immersion, chaque dispositif de chauffage par immersion étant immergé dans le métal fondu et le chauffant. Le four de fusion peut en outre comprendre une pompe conçue pour faire circuler le métal fondu de la chambre de chauffage dans une chambre de fusion et une chambre de fusion conçue pour recevoir le métal solide provenant de l'unité d'alimentation et le métal fondu provenant de la chambre de chauffage, le métal solide se fondant dans le métal fondu à l'intérieur de la chambre de fusion et fond pour créer un métal liquide. Le métal liquide peut circuler de la chambre de fusion à la chambre de chauffage.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US202363584705P | 2023-09-22 | 2023-09-22 | |
| US63/584,705 | 2023-09-22 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2025064898A1 true WO2025064898A1 (fr) | 2025-03-27 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US2024/047797 Pending WO2025064898A1 (fr) | 2023-09-22 | 2024-09-20 | Système et procédé de fusion par immersion de métal d'aluminium et d'alliages |
Country Status (1)
| Country | Link |
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| WO (1) | WO2025064898A1 (fr) |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4060408A (en) * | 1977-01-31 | 1977-11-29 | Aluminum Company Of America | Melting process |
| US4989841A (en) * | 1988-04-21 | 1991-02-05 | Honda Foundry Co., Ltd. | Metal continuously melting and retaining furnace |
| US20010028136A1 (en) * | 2000-03-24 | 2001-10-11 | Hertwich Engineering Gmbh | Two-chamber furnace for the melt- contact smelting of contaminated aluminum scrap |
| JP2020173058A (ja) * | 2019-04-10 | 2020-10-22 | 三建産業株式会社 | 循環式非鉄金属溶解炉及び非鉄金属溶解方法 |
| US20220307768A1 (en) * | 2019-11-15 | 2022-09-29 | Tounetsu Co., Ltd. | Metal melting apparatus, screen plate for metal melting, and method of melting metal |
-
2024
- 2024-09-20 WO PCT/US2024/047797 patent/WO2025064898A1/fr active Pending
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4060408A (en) * | 1977-01-31 | 1977-11-29 | Aluminum Company Of America | Melting process |
| US4989841A (en) * | 1988-04-21 | 1991-02-05 | Honda Foundry Co., Ltd. | Metal continuously melting and retaining furnace |
| US20010028136A1 (en) * | 2000-03-24 | 2001-10-11 | Hertwich Engineering Gmbh | Two-chamber furnace for the melt- contact smelting of contaminated aluminum scrap |
| JP2020173058A (ja) * | 2019-04-10 | 2020-10-22 | 三建産業株式会社 | 循環式非鉄金属溶解炉及び非鉄金属溶解方法 |
| US20220307768A1 (en) * | 2019-11-15 | 2022-09-29 | Tounetsu Co., Ltd. | Metal melting apparatus, screen plate for metal melting, and method of melting metal |
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