Patent Grant
7858022
The present invention relates to a crucible-type continuous melting furnace for melting aluminum, copper, zinc and like nonferrous metals.
As conventional nonferrous-metal furnaces using a melting crucible furnace, batch-type furnaces that have one melting crucible positioned in a cylindrical furnace, which is heated with a heating burner, have mainly been used. The applicant of the present invention proposes a “continuous type” melting and holding furnace (refer to Patent Document 1, for example).
As shown in
Usually, when the continuous type melting and holding furnace 120 is operated, combustion gas is supplied from the heating burner 105 into a melting crucible chamber 103 to heat the melting crucible 104, and is introduced into the preheating tower 100 to preheat the material (a) in the form of a solid, and then is discharged from an exhaust port 100A. Molten metal (b) that results from heating the material (a) in the melting crucible 104 is supplied to the holding crucible 107 of the holding crucible furnace 102.
On the other hand, the combustion gas supplied from the holding burner 105A to the holding crucible chamber 106 heats the holding crucible 107 to maintain the temperature of the molten metal (b), and then is introduced into the melting crucible chamber 103 to join with the combustion gas from the heating burner 105. In such a way, the mixed combustion gas is used as the preheating source of the material (a).
[Patent Document 1] Japanese Unexamined Patent Publication No. 2000-130948
In order to increase the melted amount of the material (a) in the continuous type melting and holding furnace 120 as explained above, it is conceivable to increase the combustion amount of the heating burner 105 or increase the combustion amount of the holding burner 105A. However, enhancing the combustion amount of the heating burner 105 leads to local overheating of the melting crucible 104 or a larger temperature difference in the vertical direction of the melting crucible 104, resulting in cracks or damage in the melting crucible 104. On the other hand, the combustion amount of the holding burner 105A should be controlled depending on operating conditions, such as the type of the material (a), the amount of remaining molten metal, the casting temperature, casting frequency, etc.; therefore, the controllable range of the combustion amount of the holding burner 105A will naturally be limited. From these reasons, it is difficult to control the melted amount of the material (a) by controlling the heating burner 105 and the holding burner 105A in the conventional melting furnace.
An object of the present invention is to provide a crucible-type continuous melting furnace that can easily control the melted amount of a material.
The object of the present invention can be achieved by a crucible-type continuous melting furnace that comprises: a preheating tower for storing a material to be melted and having an exhaust port on the top thereof; a melting crucible furnace disposed below the preheating tower and having a melting crucible to which the material to be melted is supplied from the preheating tower; a heating burner for heating the melting crucible; the melting crucible furnace having an introduction portion for introducing a combustion gas from the heating burner into the preheating tower; and the melting crucible having an outlet for discharging the molten metal material on the side wall, wherein the crucible-type continuous melting furnace further comprises a preheating burner disposed higher than the heating burner for preheating the material to be melted.
According to the crucible-type continuous melting furnace of the invention, it is preferable that the preheating burner be disposed so as to eject the combustion gas to a portion higher than the molten metal outlet of the melting crucible in the melting crucible furnace.
Alternatively, it is preferable that the preheating burner be mounted to the preheating tower.
It is also preferable that the crucible-type continuous melting furnace further include an iron pot disposed in the melting crucible, wherein the iron pot is provided with molten metal discharge holes for discharging the molten metal disposed so as to have a space between itself and the melting crucible.
It is also preferable that the iron pot be provided with a storage portion in the bottom thereof for storing a metal having a high specific gravity.
Moreover, it is preferable that the introduction portion lead the introduced combustion gas in a downward direction. For example, by providing a guiding member that projects toward the inside of the melting crucible on the bottom surface of the furnace lid of the melting crucible furnace, the introduction portion can be formed between the melting crucible and the guiding member.
Alternatively, by further providing a cylindrical crucible joint sandwiched between the bottom surface of the furnace lid of the melting crucible furnace and the top surface of the melting crucible, the introduction portion can also be formed from a plurality of holes provided in the crucible joint.
The introduction portion can also be formed from a plurality of holes provided in the higher portion than the molten metal outlet in the side wall of the melting crucible.
It is also preferable that the crucible-type continuous melting furnace further have a transferring member connected to the molten metal outlet, wherein the transferring member is formed of a material having high thermal conductivity.
Furthermore, in each of the above crucible-type continuous melting furnaces, it is preferable that the melting crucible be a graphite crucible.
Each of the above crucible-type continuous melting furnaces may further have a holding crucible furnace disposed in parallel to the melting crucible furnace. In this case, it is preferable that the holding crucible furnace be provided with a holding crucible for storing the molten metal discharged from the molten metal outlet and a holding burner for maintaining the temperature of the molten metal stored in the holding crucible, wherein the holding crucible furnace communicates with the melting crucible furnace via a communicating member, and a combustion gas from the holding burner is introduced into the melting crucible furnace.
The crucible-type continuous melting furnace of the present invention can easily control the melted amount of a material.
Embodiments of the present invention are explained below with reference to the attached drawings.
As shown in
The cylindrical preheating tower 31 is provided with an opening and closing lid 33 with an exhaust port 34 formed therein. The opening and closing lid 33 is provided with a thermocouple 35 that detects the temperature of the combustion gas passing through the exhaust port 34. The opening and closing lid 33 can be opened and closed by operating an automatic opening and closing mechanism (not shown) provided with a driving unit. The preheating tower 31 has a truck 36 in the lower portion thereof and is movable on a rail 39 located on the melting crucible furnace 11.
Examples of materials usable as the material (a) include aluminum, zinc, copper alloy, lead and like nonferrous metal ingots; recycled materials, metal chips, empty cans, door/window-sash materials and like scraps; scraps having their volume reduced by the application of pressure; nonferrous materials having iron, lead, rubber, plastic or a like component; etc.
The melting crucible furnace 11 is provided with a melting crucible chamber 12 and has a furnace lid 14 on the top thereof. The melting crucible chamber 12 is a cylindrical space formed of a lightweight insulating material, and communicates with the inside of the preheating tower 31 via the opening of the furnace lid 14. In the upper portion of the melting crucible chamber 12, a ring-shaped concave portion 16 is formed by notching the internal surface of the melting crucible furnace 11. The melting crucible furnace 11 is also provided with a melting crucible 71 mounted on a crucible base 72, and a heating burner 3 and preheating burner 4 mounted on the side wall thereof.
In the present embodiment, the melting crucible 71 is a graphite crucible, which has excellent durability, oxidation resistance, heat resistance, etc., and is provided with a molten metal outlet 74 for discharging a molten metal (b) obtained from the material (a). The diameter of the melting crucible 71 is larger than the inside diameters of the preheating tower 31 and the opening of the furnace lid 14. When the material (a) is zinc or a like material having a low melting point, the material for the melting crucible 71 may be iron, cast iron, etc., which have excellent thermal conductivity, heat resistance, strength, and cost-reduction properties. The molten metal (b) discharged from the molten metal outlet 74 can be continuously supplied to the outside via a transferring member 75 connected to the molten metal outlet 74. The transferring member 75 is formed of a material having excellent thermal conductivity, preferably iron, cast iron, stainless steel, or a like metal. The transferring member 75 may also be formed of the same refractory material as the graphite crucible; alumina; silicon carbide and like refractory ceramic materials; etc. A ceramic coating agent may be applied to the surface of the transferring member 75.
The heating burner 3 is disposed in the lower portion of the side wall of the melting crucible furnace 11 so that the combustion gas is circulated around the crucible base 72. In contrast, the preheating burner 4 is disposed in the upper portion of the side wall of the melting crucible furnace 11 so that the combustion gas is ejected to a portion higher than the molten metal outlet 74 and then circulates around the melting crucible 71. In the present embodiment, the preheating burner 4 is disposed in the concave portion 16 of the melting crucible chamber 12 in order to prevent the internal pressure of the melting crucible chamber 12 from being excessively increased due to the preheating burner 4 coming unduly close to the external surface of the melting crucible 71.
A cylindrical crucible joint 73 formed of a refractory material lies between the bottom surface of the furnace lid 14 and the top of the melting crucible 71 via a cushioning material and a heat-resistant adhesive (both not shown) so that the space between the bottom surface of the furnace lid 14 and the top of the melting crucible 71 is sealed. A plurality of ventholes 73a for exchanging a combustion gas are formed in the side wall of the crucible joint 73.
As shown in
The material for the crucible joint 73 may be the same as that of the graphite crucible; those having excellent oxidation resistance and/or abrasion resistance, such as silicon carbide (SiC), silicon nitride (Si3N4), sialon (Si3N4—Al2O3 solid solution); a backed or sintered object of molten silica; etc. From an economical standpoint, an alumina-silica (Al2O3—SiO2)-based refractory material is preferable, but the material for the crucible joint 73 may be selected depending on the type of material (a), operating conditions, etc.
Having the above-described structure, the crucible-type continuous melting furnace 1 of the present invention operates as described below.
A material (a) is melted using the crucible-type continuous melting furnace 1 of the present invention in the manner described below. First, the preheating tower 31 is transferred in such a manner that the upper portion of the melting crucible furnace 11 is opened. Thereafter, the material (a) is placed into the melting crucible 71, and then the preheating tower 31 is returned and mounted to the top of the melting crucible furnace 11. Subsequently, an opening and closing lid 33 is opened to supply a desired amount of the material (a) to the preheating tower 31, and then melting of the material (a) is started by operating the heating burner 3.
The combustion gas ejected by operating the heating burner 3 heats the lower portion of the melting crucible 71 so as to obtain a molten metal (b) by melting the material (a) accommodated therein. Because the melting crucible 71 is a graphite crucible, an iron container or the like which has excellent thermal conductivity, the material (a) can be easily melted. The ejected combustion gas moves upward while circulating in the melting crucible chamber 12, passes through the ventholes 73a, and is discharged outside from the exhaust port 34 via the inside of the melting crucible 71 and the preheating tower 31. During this process, in order to make the material (a) melt easily, the combustion gas preheats the material (a) before the material (a) is dipped into the molten metal (b). The combustion amount of the heating burner 3 can be selected depending on the amount of the molten material (a). For example, in order to increase the amount of the melted material (a), the combustion amount of the heating burner 3 should be increased. At this time, if the combustion amount of the heating burner 3 rapidly increases, a temperature difference occurs in the vertical direction of the melting crucible 71, damaging the melting crucible 71. In order to prevent the melting crucible 71 from being damaged, the combustion amount of the preheating burner 4 should also be controlled.
The combustion gas ejected by operating the preheating burner 4 heats the upper portion of the melting crucible 71 and cancels the temperature difference of the melting crucible 71 in the vertical direction. The combustion gas ejected from the preheating burner 4 joins with the combustion gas ejected from the heating burner 3 and preheats the material (a). It is preferable that the combustion amount of the preheating burner 4 be controlled within the range in which the material (a) does not melt above the surface of the molten metal (b) and oxidation of the material (a) does not rapidly progress.
When the combustion gases ejected from the heating burner 3 and the preheating burner 4 passes through the ventholes 73a, the combustion gas is guided in the downward direction in the melting crucible 71 along the slant, so that the material (a) in the vicinity of the surface of the molten metal can be efficiently heated. Furthermore, because a plurality of ventholes 73a are formed both in the circumferential and vertical directions to facilitate a smooth flow of the combustion gas, the material (a) stored in the preheating tower 31 and the melting crucible 71 can be extensively and uniformly preheated in the portion above the surface of the molten metal, and an excessive increase in the internal pressure of the melting crucible chamber 12 can be prevented.
In contrast, the molten metal (b) is continuously discharged from the molten metal outlet 74 as the material (a) in the melting crucible 71 melts, and is then supplied to a holding crucible furnace, a brick holding furnace, or a conveyance ladle (not shown) through transferring member 75. At this time, the temperature of the molten metal (b) passing through the transferring member 75 is maintained by the transferring member 75. As described above, because the molten metal (b) is continuously discharged, the height of the surface of the molten metal in the melting crucible 71 can be maintained at a certain level. Most of the combustion gas energy ejected from the heating burner 3 is consumed to melt the material (a) and only a small amount thereof is used to increase the temperature of the molten metal (b), and therefore the temperature of the molten metal (b) can be maintained at a level only slightly higher than the melting point of the material (a) and the generation of oxide can be prevented. Furthermore, because the transferring member 75 is formed of a material having excellent thermal conductivity, the temperature of the molten metal (b) on the transferring member 75 can be readily maintained.
As the material (a) melts, the material (a) in the preheating tower 31 gradually moves downward, and eventually is dipped in the molten metal (b) in the melting crucible 71. When the material (a) in the preheating tower 31 gradually decreases, the combustion gas energy is not consumed by preheating, and therefore the temperature of the combustion gas in the preheating tower 31 increases. When the temperature of the combustion gas exceeds a predetermined point (for example, 500° C.), the thermocouple 35 detects such excess and sends a signal to supply the material (a). In accordance with this signal, an opening and closing mechanism (not shown) then opens an opening and closing lid 33 and turns off the heating burner 3 and preheating burner 4. Subsequently, the material (a) is automatically supplied from the opening of the preheating tower 31. When the supply is completed, the opening and closing lid 33 is closed, and then the heating burner 3 and the preheating burner 4 are re-operated.
In a crucible-type continuous melting furnace 1 having the above structure, by controlling the combustion amount of the heating burner 3 and the preheating burner 4, the melted amount of the material (a) can be easily controlled. This structure also cancels the temperature difference in the vertical direction in the melting crucible 71, and therefore can reliably prevent damage to the melting crucible 71. Furthermore, by controlling the two burners, a large amount of material can be melted without supplying a combustion gas from a holding burner as in known techniques described above.
One embodiment of the present invention is explained above, but the embodiments of the present invention are not limited to this. For example, in the present embodiment, the preheating burner 4 is attached to the melting crucible furnace 11; however, as long as the supplied material (a) can be efficiently preheated, there are no limitations to the location of the preheating burner 4. For example, as shown in
When the preheating burner 4 is attached to the preheating tower 31, the crucible-type continuous melting furnace 1 may be provided with an iron pot 61 in the melting crucible 71 as shown in
As shown in
The crucible-type continuous melting furnace 1 may have a construction wherein each of two preheating burners 4 is attached to the melting crucible furnace 11 and preheating tower 31 as shown in
In the present embodiment, the crucible joint 73 is located between the lower surface of the furnace lid 14 and the melting crucible 71; however, the location of the crucible joint 73 is not limited to this as long as the combustion gas smoothly flows in the downward direction in the melting crucible 71. For example, as shown in
It is also possible to employ a construction wherein the ventholes 73a, which serve as the introduction portion of the combustion gas, are formed in the side wall of the melting crucible 71, and the top end of the melting crucible 71 is brought into contact with the lower surface of the furnace lid 14. In this construction, because the ventholes 73a and the melting crucible 71 are integrally formed, the combustion gas reliably passes through the ventholes 73a. In this case, in order to prevent the molten metal (b) from falling outside the melting crucible 71, it is preferable that the ventholes 73a be formed at a location higher than the molten metal outlet 74 that is formed in the side wall of the melting crucible 71.
When the melting crucible 71 is formed of iron, alumite coating may be applied to the surface thereof.
The height of the molten metal outlet 74 in the melting crucible 71 can be selected as desired.
The present embodiment is just one example of a continuous melting furnace which can continuously supply the molten metal (b) obtained by melting the material (a); however, the crucible-type continuous melting furnace 1 of the present invention may also be applicable to a continuous melting and holding furnace 2 as shown in
The holding crucible furnace 51 is disposed in parallel to the melting crucible furnace 11 of the crucible-type continuous melting furnace 1, and provided with a holding crucible chamber 52 and a pressing lid 54 formed on top thereof. The holding crucible furnace 51 has a holding crucible 76 mounted on a crucible base 77 and a holding burner 5 attached to the side wall thereof. The holding crucible 76 is, for example, a graphite crucible, and may be formed of iron, cast iron or the like depending on its purpose.
The holding crucible chamber 52 contains a cylindrical space formed by a lightweight insulating material, and communicates with the melting crucible chamber 12 via the inside of the communicating member 81.
The communicating member 81 is formed between the melting crucible furnace 11 and the holding crucible furnace 51 in such a manner as to cover the transferring member 75.
Having the above-described construction, the continuous melting and holding furnace 2 operates as described below. The explanation of the operation of the crucible-type continuous melting furnace 1 is omitted here as it is the same as that described above.
The molten metal (b) that is melted in the crucible-type continuous melting furnace 1 is discharged from the outlet 74 of the melting crucible 71 and supplied to the holding crucible 76 through the transferring member 75.
The combustion gas ejected from the holding burner 5 heats the holding crucible 76 while moving upward and circulating in the holding crucible chamber 52. The combustion gas is then introduced into the melting crucible chamber 12 after passing through the inside of the communicating member 81 while maintaining the temperature of the molten metal (b) contained in the holding crucible chamber 52. The combustion gas introduced into the melting crucible 71 joins with the combustion gases from the heating burner 3 and preheating burner 4. Subsequently, the combustion gas is introduced into the preheating tower 31 after moving upward in the melting crucible 71 and then discharged to the outside from the exhaust port 34. During this process, the combustion gas preheats the material (a). The combustion amount of the holding burner 5 is selected depending on the type of the material (a) and the amount and temperature of the remaining molten metal (b).
In this construction, since the combustion gas from the holding burner 5 is added, the melting amount can be readily controlled by controlling each burner independently.
In the present embodiment, the holding crucible furnace 51 is used as a stationary type but may also be used as a mobile type. By employing such a construction, the size of the holding crucible furnace 51 can be selected depending on the amounts of the material melted and held.
The present invention is explained in detail in reference with an Example and Comparative Examples. However, the present invention is not limited to the Example.
Die casting alloy ADC12 was melted in a continuous melting and holding furnace 2 (Example) shown in
The sizes of the melting furnaces of the Example and Comparative Examples 1 and 2 were substantially the same. Specifically, the dimensions of the preheating towers 31 and 100 were 550 mm (inside diameter)×1000 mm (height), those of the melting crucibles 71 and 104 were 718 mm (diameter of the opening)×520 mm (height), and those of the holding crucibles 76 and 107 were 855 mm (diameter of the opening)×845 mm (height).
A crucible joint 73 having the dimensions of 718 mm (inside diameter)×260 mm (height) was provided on top of the melting crucible 71. The ventholes 73a formed in the crucible joint 73 were holes inclined 30° relative to the surface of the molten metal and having a diameter of 30 mm. Sixteen or eight holes were formed in a row in the circumferential direction of the crucible joint 73, and 5 rows each (16 or 8 holes) were formed alternately in the height direction, making total of 120 holes.
The direct-heating centralized melting furnace 210 of Comparative Example 3 was provided with a preheating tower 200 and a melting furnace 201 disposed below the preheating tower 200, wherein the melting furnace 201 was provided with a melting chamber 202, a storage chamber 203, two heating burners 205 and 205A, and a temperature-raising burner 206.
When the direct-heating centralized melting furnace 210 was operated, the material (a) placed in the preheating tower 200 was melted in the melting chamber 202 disposed in the lower portion thereof by the combustion gases ejected from the two heating burners 205 and 205A, and then supplied into the storage chamber 203. The molten metal (b) supplied into the storage chamber 203 was heated to a predetermined temperature by the combustion gas from the temperature-raising burner 206, and then extracted by a ladle, etc.
A comparison of the relationships between the combustion amounts of the burners and the melted amount of the material was conducted between the Example and the Comparative Examples. Table 1 shows the combustion amount of each burner and the melted amount of the material in each furnace of the Example and the Comparative Examples.
The material was melted in each furnace of the Example and Comparative Example 1 with the combustion amount of each burner set as shown in Table 1. As shown in Table 1, the melted amounts of the material in the Example and Comparative Example 1 were 1 t/h and 300 kg/h respectively. It is clear that the melted amount in the Example was larger than that of the Comparative Example 1.
In the furnace of Comparative Example 2, the total combustion amount of the burner was set at the same level as that in the Example as shown in Table 1 so as to obtain the same melted amount as in the Example, and then melting was conducted. As a result, the melting crucible 104 was damaged during melting, and therefore the same melted amount as in the Example was not obtained in Comparative Example 2.
In the furnace of Comparative Example 3, melting was conducted with the melting amount set at 1 t/h, which is the same as that in the Example. At this time, the temperature of the molten metal (b) stored in the holding crucible 76 and storage chamber 203 was made to be the same and maintained at 700° C. As a result, as is clear from Table 1, the total combustion amount of Comparative Example 3 was larger than that of the Example.
Regarding the space occupied by the melting furnace, a comparison was made between the Example and Comparative Example 3. Table 2 shows the height (the height from the floor level to the topmost part of the melting furnace), the area occupied (the footprint of the melting furnace), the volume occupied (the height of the melting furnace×the footprint), and the combustion amount of the Example when the corresponding values for Comparative Example 3 are set to 100. As is clear from Table 2, the Example reduced the space and energy necessary compared to Comparative Example 3 for which the melted amount was the same.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2005-169013 | Jun 2005 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2006/311500 | 6/8/2006 | WO | 00 | 11/30/2007 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2006/132309 | 12/14/2006 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 4033562 | Collin | Jul 1977 | A |
| 4581063 | Oyabu et al. | Apr 1986 | A |
| 6549558 | Okada et al. | Apr 2003 | B1 |
| Number | Date | Country |
|---|---|---|
| A-01-210794 | Aug 1989 | JP |
| A-2000-130948 | May 2000 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20090130619 A1 | May 2009 | US |
