Multi-purpose pump system for metal furnaces and related methods

Abstract

A pump system for a metal furnace includes a tank and a magnetic stirrer. The tank includes a tank chamber configured to receive a fluid, such as a molten material. The tank is positioned above the magnetic stirrer and such that the magnetic stirrer is external to the tank chamber. The magnetic stirrer includes a rotating permanent magnet configured to generate a moving magnetic field in the molten material in the tank chamber, the moving magnetic field inducing movement in the molten material.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 62 / 981,282, filed on February 25, 2020, and entitled “MULTI-PURPOSE PUMP SYSTEM FOR AMETAL FURNACE AND RELATED METHODS,” the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present application relates to metal furnaces and, more particularly, to pumps for metal furnaces. Background Art

[0004] A typical metal furnace includes a closed main chamber that holds molten material (such as molten metal), and includes a heating element that generates heat sufficient to maintain a molten state. The molten material can be poured into a casting machine to produce a metal ingot. In some cases, a charging well and a separate pump with a pumping well are in fluid communication with the main chamber. The pump generally includes a component that directly contacts the molten material to circulate the molten material. In particular, the pump can extract the molten material from the main chamber of the metal furnace, and then force the molten material to enter the charging well and return to the main chamber of the metal furnace. Metal scrap can be introduced into the molten material in the charging well, where the scrap melts and becomes a part of the molten material. The charging well generally includes an impeller that rotates in the charging well to promote mixing and immersion of the scrap introduced into the molten material. A separate slag well can be provided between the charging well and the main chamber, and slag can be collected from the upper surface of the molten material in the slag well before the molten material is recycled to the main chamber. Summary of the invention

[0005] The embodiments covered by this patent are defined by the following claims rather than by this summary. This summary is a high-level summary of various embodiments and introduces some concepts that will be further described in the following detailed description section. This summary is not intended to identify the key features or essential features of the claimed subject matter, nor is it intended to be used to determine the scope of the claimed subject matter alone. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all of the drawings, and each claim.

[0006] According to certain embodiments, a pump system for a metal furnace includes a tank and a magnetic stirrer. The tank includes a tank chamber configured to receive a fluid, such as a molten material. The tank is positioned above the magnetic stirrer and such that the magnetic stirrer is outside the tank chamber. The magnetic stirrer includes a rotating permanent magnet, and the magnetic stirrer is configured to generate a moving magnetic field in the molten material in the tank chamber to induce movement in the molten material.

[0007] According to some embodiments, a pump system for a metal furnace includes a tank, the tank including a tank chamber, an inlet and an outlet. The tank chamber is configured to receive a fluid, such as a molten material. The inlet is in fluid communication with the tank chamber and defines a flow path to the tank chamber for molten material to enter the tank chamber. The outlet is in fluid communication with the tank chamber and defines a flow path from the tank chamber for molten material to leave the tank chamber. The transverse dimension of the tank chamber near the inlet is different from the transverse dimension of the tank chamber near the outlet.

[0008] According to various embodiments, a pump system for a metal furnace includes a tank and a mixer. The tank includes a tank chamber configured to receive a fluid, such as a molten material. The mixer is selectively positionable in and removable from the tank chamber, and includes a body including one or more fins along an edge of the body.

[0009] According to some embodiments, a pump system for a metal furnace includes a tank and a mixer. The tank includes a tank chamber configured to receive a fluid, such as a molten material. The mixer is selectively positionable in and removable from the tank chamber, and the mixer includes a body defining a supply passage having at least one opening along a vertical edge of the body. The mixer is configured to selectively supply an injectable material into the tank chamber via the supply passage and the at least one opening.

[0010] According to certain embodiments, a mixer for a pump system for a metal furnace includes a body having an edge extending along a length of the body; at least one fin along the edge of the body; and a supply passage extending at least partially through the body and including at least one opening defined in the edge of the body.

[0011] According to various embodiments, a method includes receiving molten material from a furnace into a tank chamber of a tank of a pump system. The method also includes generating a mixed flow in the molten material in the tank chamber. In some examples, generating the mixed flow includes rotating a permanent magnet of a magnetic stirrer of the pump system to generate a moving magnetic field in the molten material in the tank chamber; and controlling the moving magnetic field to induce movement in the molten material. The method may include discharging the molten material from the tank.

[0012] The various embodiments described herein may include additional systems, methods, features, and advantages that may not necessarily be explicitly disclosed herein but will be apparent to one of ordinary skill in the art after reviewing the following detailed description and accompanying drawings. All such systems, methods, features, and advantages are intended to be included in this disclosure and protected by the following claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The description refers to the following drawings, in which the same reference numerals are used in different drawings to indicate the same or similar components.

[0014] Figure 1 is a diagram of a metal melting system having a metal furnace and a pump system according to an embodiment of the present disclosure.

[0015] Figure 2 is a perspective view of a pump system for a metal melting system according to an embodiment of the present disclosure.

[0016] Figure 3 yes Figure 2 Another perspective view of the pump system.

[0017] Figure 4 yes Figure 2 Exploded assembly diagram of the pump system.

[0018] Figure 5 yes Figure 2 A perspective view of the tank of the pump system.

[0019] Figure 6 yes Figure 2 A cross-sectional view of the tank of the pump system.

[0020] Figure 7 yes Figure 2 A cross-sectional view of the mixer of a pump system mixing system.

[0021] Figure 8 is a side view of a tank and a magnetic stirrer of a pump system according to an embodiment of the present disclosure.

[0022] Fig. 9 yes Figure 8 A perspective view of the tank of the pump system.

[0023] Fig.10 is a perspective view of a pump system according to an embodiment of the present disclosure.

[0024] Fig.11 yes Fig.10 Another perspective view of the pump system.

[0025] Fig.12 is a schematic diagram of a side-pit melting furnace with a pump system according to an embodiment of the present disclosure.

[0026] Fig.13 is a schematic diagram of a dual chamber furnace with a pump system according to an embodiment of the present disclosure.

[0027] Fig.14 Is has Fig.13 Another schematic diagram of the pump system of a double chamber furnace. DETAILED DESCRIPTION

[0028] The subject matter of the embodiments of the present disclosure is specifically described herein to meet statutory requirements, but the description is not necessarily intended to limit the scope of the claims. The claimed subject matter can be embodied in other ways, can include different elements or steps, and can be used in conjunction with other existing or future technologies. The description should not be interpreted as implying any specific order or arrangement among or between the various steps or elements, except for the situation of clearly describing the order of the various steps or the arrangement of the elements. Directional references such as "upper", "lower", "top", "bottom", "left", "right", "front" and "rear" etc. are intended to refer to the orientation shown and described in one (or more) figures referring to parts and directions.

[0029] As used herein, "lateral dimension" refers to the dimension across the widest portion of a component. It should be understood that the lateral dimension may depend on the shape of the component. The diameter of an object is an example of a lateral dimension. In this regard, although the following description may refer to a diameter, it should be understood that the shape of the tank chamber and / or the components of the pump system is not considered to be limiting.

[0030] Pump systems and associated methods for metal furnaces are described herein. In some aspects, pump systems can be used in melting systems for melting various metals, and may be particularly suitable for melting systems for melting aluminum. In some examples, pump systems can be used with a recycling melting furnace, including but not limited to a side-well melting furnace or a double-chamber melting furnace. Such a recycling melting furnace can be designed to handle different forms of waste (e.g., light, medium and heavy). Pump systems as described herein can improve the mixing and melting of metal scraps by improving the immersion of the metal scraps in the molten material. Pump systems can also improve the mixing of such additives to the molten material by improving the immersion of additives (e.g., salts) in the molten material.

[0031] The pump system may include a tank and a magnetic stirrer. The tank includes a tank chamber, and molten material (such as molten metal) may be held in the tank chamber and pumped through the tank chamber. The magnetic stirrer includes a rotating permanent magnet, and the tank is positioned above the magnetic stirrer so that a moving magnetic field generated by the rotating permanent magnet induces movement in the molten material in the tank chamber of the tank.

[0032] The pump system may also include a mixer assembly, the mixer assembly including at least one mixer, the at least one mixer selectively positioned in the tank chamber and removed from the tank chamber for certain processes of the pump system. The mixer has a body, the body having at least one fin along the edge of the mixer, when the mixer is lowered into the tank chamber, the at least one fin can generate flow rotation in the molten material. The mixer may also include a supply passage, the supply passage is at least partially defined in the body and can be used to supply injectable materials (such as salt) to the tank chamber when the mixer is lowered into the tank chamber. In some examples, the mixer can be in a lowered position (or at least partially positioned in the tank chamber) for some processes of the pump system, and can be in an elevated position (or outside the tank chamber) for other processes of the pump system. As some non-limiting examples, the mixer can be in an elevated position for processes such as slag collection and / or some pumping processes, and the mixer can be in a lowered position for processes such as metal addition and / or salt injection. In other examples, the mixer can be in an elevated position and / or a lowered position as needed.

[0033] The pump systems described herein can allow multiple processes to be performed with the same pump system, thereby providing a more compact system that can be used with a metal furnace and / or more easily retrofitted into an existing metal melting system. The pump system can also omit moving parts in the molten material during certain processes (e.g., during certain pumping processes, salt injection, waste addition, etc.).

[0034] Figure 1 An example of a furnace system 100 including a metal furnace 102 and a pump system 104 according to various embodiments is shown. The metal furnace 102 can heat and contain a source of molten material, such as molten metal (e.g., molten aluminum). The metal furnace 102 can be various types of metal furnaces, including but not limited to side-pit melting furnaces, dual-chamber furnaces, etc. The molten metal from the metal furnace 102 can be used to produce metal ingots by various casting techniques.

[0035] The pump system 104 includes a tank 106, a magnetic stirrer 108, and a mixer assembly 110. The tank 106 includes a tank chamber 114 that is in fluid communication with the metal furnace 102 via an inlet conduit 116 and an outlet conduit 118, such that molten material can be supplied to the tank 106 via the inlet conduit 116 and removed from the tank 106 via the outlet conduit 118. In various examples, an inlet 122 of the tank chamber 114 is at a vertical position that is lower than a vertical position of an outlet 124 of the tank chamber 114, such that molten material is pumped into the tank chamber 114 in an upward direction.

[0036] The tank chamber 114 has a chamber wall 126. In various examples, a transverse dimension (such as a diameter) of the chamber wall 126 near the inlet 122 of the tank chamber 114 is different from a transverse dimension of the chamber wall 126 near the outlet 124 of the tank chamber 114. Figure 1 In some examples, the transverse dimension of the chamber wall 126 near the inlet 122 is smaller than the transverse dimension of the chamber wall 126 near the outlet 124. In some aspects, the tank chamber 114 having at least two different transverse dimensions can guide and / or improve the movement of the molten material through the tank chamber 114. The chamber wall 126 having at least two different transverse dimensions can also shape the upper surface of the molten material in the tank chamber 114 (e.g., with a conical shape) at certain pumping speeds to form a collection point for dross and help remove the dross. In some examples, at certain pumping speeds, the chamber wall 126 shapes the molten material so that a collection point is formed in the top surface of the molten material in the tank chamber 114 for dross and helps remove the dross. The collection point can help remove the dross with a dross removal device (such as, but not limited to, a robotic arm, an Archimedean screw assembly, etc.). The chamber walls 126 may also provide better immersion of the waste material within the tank chamber 114 because the chamber walls 126 may generate eddies in the molten material, which may cause the waste material to be immersed in the melt rather than on the surface of the melt. The chamber walls 126 may also promote mixing during mixing processes (e.g., salt injection) because the eddies generated by the chamber walls 126 may cause the added material (e.g., salt) to be immersed below the surface of the melt, which may minimize or reduce salt loss entrapment on the melt surface and result in lower salt consumption. The chamber walls 126 may also optionally allow pumping of the molten material without the need for a drain plug near the drain hole because mixing in the molten material is improved, thereby reducing safety hazards otherwise associated with drain plugs. Although the profile of the chamber walls 126 is Figure 1 126 is shown as linear, but need not be so in other examples, and the specific profile of the chamber wall 126 should not be considered limiting. The geometry of the chamber wall 126 can be selected to improve the flow of the molten metal within the pot chamber 114 and / or to ensure that the molten metal climbs up the chamber wall 126 to be discharged from the outlet 124.

[0037] The magnetic stirrer 108 includes a permanent magnet 120 that is rotatable about an axis so that the permanent magnet 120 generates a moving magnetic field. Figure 1In the example of the embodiment of the present invention, the permanent magnet 120 is rotatable about the vertical axis 130 of the tank chamber 114, but in other examples, the permanent magnet 120 can be rotated about any axis as desired. Although a single permanent magnet 120 is shown, in other examples, the magnetic stirrer 108 can include multiple permanent magnets 120, each of which can be rotated about an axis. In various examples, the tank 106 is supported above the magnetic stirrer 108 so that the moving magnetic field generated by the rotating permanent magnet 120 induces movement in the molten material in the tank chamber 114, thereby pumping the molten material through the tank chamber 114 along a flow path (indicated by arrows 128) and recycling the molten material back to the metal furnace 102.

[0038] The mixer assembly 110 includes at least one mixer 112 and is movable between a lowered position and a raised position (indicated by arrow 132). In various examples, in the lowered position, the at least one mixer 112 may be at least partially positioned within the tank chamber 114 and / or at least partially within the molten metal within the tank chamber 114, and in the raised position, the at least one mixer 112 may be positioned above the molten metal within the tank chamber 114 and / or outside the tank chamber 114. In some cases, the mixer assembly 110 may be in a raised position or a lowered position depending on the process of the pump system 104. As some non-limiting examples, the mixer assembly 110 may be in a raised position for certain pumping and / or slag collection processes, and may be in a lowered position for certain waste addition or mixing processes (e.g., salt injection).

[0039] The mixer assembly 110 may include any number of mixers 112 as desired, so although Figure 1 1, the mixer 112 is shown in FIG. 1 , but the number of mixers 112 should not be considered limiting. When multiple mixers 112 are included, the mixers 112 can be interconnected or integrally formed with a common base 134 so that the mixers 112 can move together between the raised position and the lowered position. In other examples, each mixer 112 can be independently movable between the raised position and the lowered position relative to another mixer 112.

[0040] The mixer 112 can be at various angles relative to the vertical axis 130 of the tank chamber 114. In various aspects, the angle of the mixer 112 relative to the vertical axis 130 can at least partially control the rotational flow characteristics of the molten material within the tank chamber 114. Figure 1In some examples, the mixer 112 is substantially parallel to the vertical axis 130, however, in other examples, it need not be substantially parallel to the vertical axis 130. As some non-limiting examples, in other cases, one or more of the mixers 112 may be at an angle of about 15°, about 30°, about 45°, about 60°, etc. relative to the vertical axis 130. When multiple mixers 112 are utilized, the angle of one mixer 112 relative to the vertical axis 130 may be the same as or different than the angle of another mixer 112 relative to the vertical axis 130. In some cases, the mixers 112 may be fixed at their respective angles relative to the vertical axis 130; however, in other examples, one or more of the mixers 112 may be adjustable so that the mixers 112 may be positioned at an angle relative to the vertical axis 130 as desired.

[0041] As referenced below Figure 7 As discussed in more detail, each mixer 112 can have a supply passage that can be used to add various injectable materials (e.g., salt) to the molten material in the tank chamber 114. In various examples, the mixer 112 with a supply passage can allow the injectable material to be added below the melt surface of the molten material, which can minimize salt loss entrapment on the metal surface and result in lower salt consumption. Additionally or alternatively, and also as described below with reference to Figure 7 As discussed in more detail, each mixer 112 can have one or more fins along the edge of the mixer 112 to generate a rotational flow within the molten material. In various examples, the mixer 112 in the lowered position can maintain its general position within the pot chamber 114 (e.g., it can be stationary within the pot chamber 114). As discussed in more detail below, the molten material flowing within the pot chamber 114 (e.g., achieved by the magnetic stirrer 108) can flow around the mixer 112, and the flow of the molten material around the mixer 112 can generate additional rotational flow within the molten metal.

[0042] Figures 2 to 7 Another example of a pump system 204 is shown in accordance with various embodiments. The pump system 204 is substantially similar to the pump system 104 and includes a tank 206, a magnetic stirrer 208, and a mixer assembly 210.

[0043] The magnetic stirrer 208 is substantially similar to a magnetic stirrer and includes a rotatable permanent magnet (not visible in the illustrated view).

[0044] like Figure 4 As best shown, the refractory material 236 can support the tank 206, and various covering materials 238 (e.g., steel plates or other suitable materials) can surround the tank 206 and the refractory material 236. Figure 5 and Figure 6As best shown, the contour of the chamber wall 226 of the tank chamber 214 is different from Figure 1 The profile of the chamber wall 126 is nonlinear between a portion of the chamber wall 226 near the inlet 222 and a portion of the chamber wall 226 near the outlet 224. Similar to the tank chamber 114, the transverse dimension of the tank chamber 214 near the inlet 222 is smaller than the transverse dimension of the tank chamber 214 near the outlet 224. In various examples, the tank chamber 214 with a reduced transverse dimension near the inlet 222 can promote and / or improve the flow of molten material from the inlet 222 through the tank chamber 214 to the outlet 224. As mentioned, the geometry of the chamber wall of the tank chamber 214 can be selected to improve the flow of molten metal within the tank chamber 214 and / or to ensure that the molten metal climbs up the chamber wall to be discharged from the outlet. The geometry of the chamber walls of the tank chamber 214 can generate eddies in the molten material, which can improve immersion of the scrap within the melt, improve flow of molten metal through the tank (e.g., improved pumping), improve mixing of the molten material within the tank chamber (and reduce solidification of the metal within the tank chamber), and / or improve mixing of the scrap and / or other injectable materials in the melt.

[0045] Compared to the tank 106, the tank 206 also includes a replenishment chamber 240 in fluid communication with the outlet 224 of the tank chamber 214 and a replenishment inlet 242 of the tank chamber 214. In certain optional examples, at least some of the molten material exiting the tank chamber 214 can be transferred to the replenishment chamber 240 via the replenishment inlet 242 and recycled back into the tank chamber 214. In other examples, the replenishment chamber 240 can be omitted.

[0046] As in Figures 2 to 4 and Figure 7 As best shown, similar to the mixer assembly 110, the mixer assembly 210 includes three mixers 212. Each of the mixers 212 includes a body 246 optionally supported on a support 252. In various examples, the body 246 can move along the support 252 so that the mixer 212 can move between a lowered position and a raised position, while in other examples, the body 246 is fixed relative to the support 252 (i.e., non-movable). In the illustrated example, the body 246 is fixed relative to the support 252. In other examples, the support 252 can be omitted and various other suitable devices or mechanisms can be used to support and / or position the body 246 as desired. The body 246 has a first edge 248 and a second edge 250 opposite the first edge 248. The first edge 248 and the second edge 250 can extend along the length of the body 246.

[0047] like Figure 7As best shown, in various examples, the second edge 250 can include one or more fins 256. The fins 256 can be integrally formed with the body 246 or can be separate components coupled to the body 246 by various suitable mechanisms. Figure 7 In the example of the embodiment of the present invention, the second edge 250 includes seven fins 256, however, the number of fins 256 should not be considered limiting. Similarly, the shape, profile or pattern of the fins 256 should not be considered limiting. When the mixer 212 is lowered into the molten material in the tank chamber 214, the fins 256 can generate turbulent and / or rotating flow in the molten material, thereby providing increased mixing and / or pumping of the molten metal flowing through the tank chamber 214. In various aspects, the rotating flow generated by the fins 256 can be controlled by controlling the number of fins 256 on the mixer 212, the profile or pattern of the fins 256, the number of mixers 212 and the mixer assembly 210, the angle of the mixer 212 relative to the vertical axis of the tank chamber 214, the orientation of the second edge 250 with the fins 256 relative to the vertical axis (e.g., the second edge 250 is radially inward, radially outward, in a clockwise circumferential direction, in a counterclockwise circumferential direction, etc.) or one or more of other features of the mixer assembly 210.

[0048] Additionally or alternatively, each mixer 212 can include a supply passage 258 extending at least partially through the body 246 and in fluid communication with one or more openings 260 defined by the body 246. In various examples, the openings 260 can be defined in an edge or side of the body 246 that is not a leading edge or front side in the flow of molten material (e.g., in a trailing edge of the body 246). Figures 2 to 7 In the example of the embodiment of the present invention, the opening 260 is defined in the second edge 250 of the body 246. The number, shape, position and profile of the opening 260 and / or the supply passage 258 should not be considered as limiting. For example, in other cases, each opening 260 may have a dedicated supply passage 258, rather than having a common supply passage 258 for the opening 260. The supply passage 258 may be in fluid communication with the injectable material source 262, so that injectable materials including but not limited to salts can be selectively supplied to the molten material via the supply passage 258 and the opening 260. In the example with multiple mixers 212, all mixers 212 may include a supply passage 258 and an opening 260, or a subset of the mixers 212 may include a supply passage 258 and an opening 260. In some non-limiting examples, when the mixer 212 is in a lowered position, the injectable material can be supplied to the molten material.

[0049] The mixer assembly 210 also includes a dross removal device 244. The dross removal device 244 may be any suitable device or mechanism for removing dross from the molten material in the tank chamber 214. Figures 2 to 7 In the example of , the scum removal device 244 is a robotic arm; however, in other examples, the scum removal device 244 can be any other suitable device. Another non-limiting example of the scum removal device 244 includes an Archimedean screw assembly.

[0050] Figure 8 and Fig. 9 Another example of a portion of a pump system 804 is shown having a tank 806 and a magnetic stirrer 808. Although not shown, a mixer assembly similar to mixer assembly 110 or mixer assembly 210 may be used with pump system 804.

[0051] Tank 806 is substantially similar to tank 206 except that replenishment chamber 240 is omitted. Fig. 9 As best shown, similar to tank 206, the profile of chamber wall 826 of tank chamber 814 of tank 806 is non-linear between a portion of chamber wall 826 near inlet 822 and a portion of chamber wall 826 near outlet 824. Similar to tank chamber 214 and tank chamber 114, the transverse dimension of tank chamber 814 near inlet 822 is smaller than the transverse dimension of tank chamber 814 near outlet 824, such that chamber wall 826 narrows from the top of tank chamber 814 toward the bottom of tank chamber 814.

[0052] Similar to pump system 104 and pump system 204 , the magnetic agitator 808 of pump system 804 includes one or more permanent magnets that can rotate about an axis, and the magnetic agitator 808 is positioned below the tank 806 so that the moving magnetic field generated by the rotating permanent magnets induces movement in the molten material in the tank chamber 814 of the tank 806 .

[0053] Fig.10 and Fig.11 A tank 1006, a magnetic stirrer 1008 and a mixer assembly 1010 (from Fig.11 1024). The pump system 1004 is in fluid communication with the furnace 1002. The tank 1006 is similar to the tank mentioned above and includes a chamber wall 1026 having a non-linear profile between a portion of the chamber wall 1026 near the inlet 1022 and a portion of the chamber wall 1026 near the outlet 1024. The transverse dimension of the tank chamber 1014 near the inlet 1022 is smaller than the transverse dimension of the tank chamber 1014 near the outlet 1024, so that the chamber wall 1026 narrows from the top of the tank chamber 1014 toward the bottom of the tank chamber 1014. Similar to the mixer assembly 110, the mixer assembly 1010 includes three mixers 1012 and can be moved between a raised position and a lowered position so that the mixers 1012 are at least partially within the molten material.

[0054] Fig.12An example of a pump system 1204 is shown having a side-pit melting furnace 1202 including a main furnace chamber 1203. One or more burners 1207 or other suitable heating elements are provided to produce a molten state. The pump system 1204 is substantially similar to the pump systems previously discussed and includes a tank 1206 having a chamber wall having a profile that is non-linear between an inlet 1222 and an outlet 1224. The transverse dimension of the tank chamber near the inlet 1222 is smaller than the transverse dimension of the tank chamber near the outlet 1224, such that the chamber wall narrows from the top of the tank chamber toward the bottom of the tank chamber. Although in Fig.12 1204, but the pump system 1204 also includes a magnetic stirrer and mixer assembly. The flow of molten material is represented by arrows 1205, and the flow path can be from the main furnace chamber 1203 to the tank 1206, and back to the main furnace chamber 1203 or for further processing. Fig.12 As shown, various materials such as scrap metal (represented by arrow 1211) and / or injectable materials (represented by arrow 1209) can be added during the melting process. Compared to existing side-pit melting furnaces, the side-pit melting furnace 1202 with the pump system 1204 can promote better immersion of the scrap 1211 due to the vortex generated in the tank 1206, which may cause the scrap to be immersed inside the melt and not on the surface of the melt. Salt or other injectable materials 1209 are similarly better immersed below the melt surface and mixed, which can minimize salt loss entrapment on the melt surface and result in lower salt consumption. Due to the improved mixing and pumping of the molten material using the tank 1206, the drain plug can be optionally omitted.

[0055] Fig.13 and Fig.14 An example of a pump system 1204 having a dual chamber furnace 1302 is shown, which includes a waste chamber 1313 and a heating chamber 1315. Metal waste 1317 (see Fig.14 ) can be introduced into the waste chamber 1313 (in addition to the metal waste 1211). The flow of molten material is represented by arrows 1305, and the flow path can be from the waste chamber 1313 to the heating chamber 1315, to the tank 1206 and back to the waste chamber 1313. The dual chamber furnace 1302 with the pump system 1204 can promote better immersion of the waste 1211 and / or other injectable materials 1209 compared to existing dual chamber furnaces. The dual chamber furnace 1302 can also be easier to clean than existing dual chamber furnaces because the pump system 1204 can be an open system and easier to access the parts.

[0056] Return to reference Figure 1, a method of processing molten material using a pump system 104 is also provided. Although reference will be made to the pump system 104, it should be understood that the following description is equally applicable to the pump system 204 and the pump system 804 or other pump systems unless otherwise expressly stated.

[0057] The method may include receiving molten material from the furnace 102 into the tank chamber 114 of the tank 106. Receiving the molten material may optionally include drawing the molten material from the furnace 102, through the inlet conduit 116 and the inlet 122, and into the tank chamber 114 by rotating the permanent magnets 120 of the magnetic stirrer 108 so as to generate a rotating flow or a mixed flow within the tank chamber 114.

[0058] In various examples, the method includes controlling the flow of molten material from the inlet 122 through the tank chamber 114 to the outlet 124. In various aspects, controlling the flow of the molten material may include, but is not limited to, controlling one or more of a rotation speed of the permanent magnet 120, a rotation axis of the permanent magnet, a number of permanent magnets, and / or a profile of a chamber wall 126 of the tank chamber 114. In some cases, the profile of the chamber wall 126 is controlled such that a transverse dimension of the tank chamber 114 near the inlet 122 is smaller than a transverse dimension of the tank chamber 114 near the outlet 124.

[0059] In some optional examples, the method includes controlling the flow of the molten material by controlling the magnetic stirrer 108 so that a collection point for dross is formed in the top surface of the molten material in the tank chamber 114 and the removal of the dross is facilitated. The method may include removing dross from the molten material using a dross removal device before the molten material is pumped out of the outlet 124.

[0060] In various examples, the method can include lowering one or more mixers 112 of the mixer assembly 110 from a raised position to a lowered position such that the mixer 112 is at least partially within the molten material. In certain aspects, the method includes substantially maintaining a position of the mixer 112 relative to the tank chamber 114 (e.g., the mixer 112 is stationary within the tank chamber 114).

[0061] In some examples, the edge of the body of each mixer 112 can include one or more fins, and the one or more fins located within the molten material can generate turbulence and / or a supplemental mixed flow (in addition to the flow generated by the magnetic stirrer 108). Optionally, the method can include controlling the supplemental mixed flow generated by the fins of the mixer 112 by controlling one or more of the number of fins on the mixer 112, the profile or pattern of the fins, the number of mixers 112 and the mixer assembly 110, the angle of the mixer 112 relative to the vertical axis 130 of the tank chamber 114, or the orientation of the edge with fins 112 relative to the vertical axis 130, or other features of the mixer assembly 110.

[0062] In some examples, the method may include adding waste material to the molten material in the tank chamber 114 when the mixer 112 is in the lowered position. In various examples, the method may include injecting an injectable material (such as, but not limited to, salt) into the molten material when the mixer 112 is in the lowered position. In some aspects, injecting the injectable material may include supplying the injectable material to a supply passage defined in the body of each mixer 112, and directing the injectable material through the supply passage and out of one or more openings defined in the body of each mixer 112. In various cases, injecting the injectable material may include controlling at least one of the type of injectable material injected into the molten material, the flow rate or supply rate of the injectable material, the number of openings defined in the body of each mixer 112, or other features of the mixer assembly 110. In some aspects, the method may include raising the mixer assembly 110 from the lowered position to the raised position after adding the waste material and / or after injecting the injectable material.

[0063] A collection of exemplary embodiments is provided below, including at least some of the exemplary embodiments explicitly listed as "examples" that provide additional descriptions of various exemplary embodiments according to the concepts described herein. These examples are not meant to be mutually exclusive, exhaustive, or limiting; and the present disclosure is not limited to these exemplary examples, but covers all possible modifications and variations within the scope of the claims set forth and their equivalents.

[0064] Example 1. A pump system for a metal furnace, the pump system comprising: a tank, the tank comprising a tank chamber, the tank chamber being configured to receive a molten material; and a magnetic stirrer, the magnetic stirrer comprising a rotating permanent magnet, wherein the tank is positioned above the magnetic stirrer and such that the magnetic stirrer is outside the tank chamber, and wherein the magnetic stirrer is configured to generate a moving magnetic field in the molten material in the tank chamber to induce movement in the molten material.

[0065] Example 2. A pump system as described in any preceding or subsequent example or combination of examples, wherein the tank further comprises: an inlet fluidly connected to the tank chamber and defining a flow path to the tank chamber for molten material to enter the tank chamber; and an outlet fluidly connected to the tank chamber and defining a flow path from the tank chamber for molten material to leave the tank chamber, wherein a lateral dimension of the tank chamber near the inlet is different from the lateral dimension of the tank chamber near the outlet.

[0066] Example 3. The pump system of any preceding or subsequent example or combination of examples, wherein the vertical position of the inlet is lower than the vertical position of the outlet.

[0067] Example 4. The pump system of any preceding or subsequent example or combination of examples, wherein a chamber surface of the tank chamber comprises a non-linear curve between the inlet and the outlet.

[0068] Example 5. The pump system of any preceding or subsequent example or combination of examples, wherein the transverse dimension of the tank chamber near the inlet is smaller than the transverse dimension of the tank chamber near the outlet.

[0069] Example 6. The pump system of any preceding or following example or combination of examples, further comprising a mixer selectively positionable within and removable from the tank chamber.

[0070] Example 7. The pump system of any preceding or following example or combination of examples, wherein the mixer comprises a body, and wherein the body comprises one or more fins along an edge of the body.

[0071] Example 8. A pump system as described in any preceding or subsequent example or combination of examples, wherein the mixer includes a body, and wherein the body includes: a supply passage extending through at least a portion of the body; and at least one opening defined in an edge of the body, wherein the at least one opening is fluidly connected to the supply passage, and wherein the mixer is configured to selectively supply injectable material into the tank chamber via the supply passage and the at least one opening.

[0072] Example 9. The pump system of any preceding or following example or combination of examples, wherein the rim further comprises one or more fins along the length of the body.

[0073] Example 10. A pump system for a metal furnace, the pump system comprising: a tank, the tank comprising: a tank chamber, the tank chamber being configured to receive molten material; an inlet, the inlet being fluidically connected to the tank chamber and defining a flow path to the tank chamber for molten material to enter the tank chamber; and an outlet, the outlet being fluidly connected to the tank chamber and defining a flow path from the tank chamber for molten material to leave the tank chamber, wherein a lateral dimension of the tank chamber near the inlet is different from the lateral dimension of the tank chamber near the outlet.

[0074] Example 11. The pump system of any preceding or following example or combination of examples, wherein the vertical position of the inlet is lower than the vertical position of the outlet.

[0075] Example 12. The pump system of any preceding or following example or combination of examples, wherein the vertical position of the inlet is lower than the vertical position of the outlet.

[0076] Example 13. The pump system of any preceding or following example or combination of examples, wherein a chamber surface of the tank chamber comprises a non-linear curve between the inlet and the outlet.

[0077] Example 14. The pump system of any preceding or following example or combination of examples, wherein the transverse dimension of the tank chamber near the inlet is smaller than the transverse dimension of the tank chamber near the outlet.

[0078] Example 15. A pump system as described in any preceding or subsequent example or combination of examples, further comprising a magnetic agitator comprising a rotating permanent magnet, wherein the tank is positioned above the magnetic agitator and such that the magnetic agitator is outside the tank chamber, and wherein the magnetic agitator is configured to generate a moving magnetic field in the molten material in the tank chamber to induce movement in the molten material.

[0079] Example 16. The pump system of any preceding or following example or combination of examples, further comprising a mixer selectively positionable within and removable from the tank chamber.

[0080] Example 17. The pump system of any preceding or following example or combination of examples, wherein the mixer comprises a body, and wherein the body comprises one or more fins along an edge of the body.

[0081] Example 18. A pump system as described in any preceding or subsequent example or combination of examples, wherein the mixer includes a body, and wherein the body includes: a supply passage extending through at least a portion of the body; and at least one opening defined in an edge of the body, wherein the at least one opening is fluidly connected to the supply passage, and wherein the mixer is configured to selectively supply injectable material into the tank chamber via the supply passage and the at least one opening.

[0082] Example 19. The pump system of any preceding or following example or combination of examples, wherein the rim further comprises one or more fins along the length of the body.

[0083] Example 20. A pump system for a metal furnace, the pump system comprising: a tank, the tank including a tank chamber, the tank chamber being configured to receive molten material; and a mixer, the mixer being selectively positionable in and removable from the tank chamber, the mixer comprising a body, the body including one or more fins along an edge of the body.

[0084] Example 21. A pump system as described in any preceding or subsequent example or combination of examples, further comprising a magnetic agitator comprising a rotating permanent magnet, wherein the tank is positioned above the magnetic agitator and such that the magnetic agitator is outside the tank chamber, and wherein the magnetic agitator is configured to generate a moving magnetic field in the molten material in the tank chamber to induce movement in the molten material.

[0085] Example 22. A pump system as described in any preceding or subsequent example or combination of examples, wherein the tank further comprises: an inlet fluidly connected to the tank chamber and defining a flow path to the tank chamber for molten material to enter the tank chamber; and an outlet fluidly connected to the tank chamber and defining a flow path from the tank chamber for molten material to leave the tank chamber, wherein a lateral dimension of the tank chamber near the inlet is different from the lateral dimension of the tank chamber near the outlet.

[0086] Example 23. A pump system as described in any preceding or subsequent example or combination of examples, wherein the body further includes: a supply passage extending through at least a portion of the body; and at least one opening defined in an edge of the body, wherein the at least one opening is fluidly connected to the supply passage, and wherein the mixer is configured to selectively supply injectable material into the tank chamber via the supply passage and the at least one opening.

[0087] Example 24. A pump system for a metal furnace, the pump system comprising: a tank, the tank including a tank chamber, the tank chamber being configured to receive molten material; and a mixer, the mixer being selectively positionable in and removable from the tank chamber, the mixer comprising a body, the body defining a supply passage, the supply passage having at least one opening along a vertical edge of the body, wherein the mixer is configured to selectively supply injectable material into the tank chamber via the supply passage and the at least one opening.

[0088] Example 25. A pump system as described in any preceding or subsequent example or combination of examples, further comprising a magnetic agitator comprising a rotating permanent magnet, wherein the tank is positioned above the magnetic agitator and such that the magnetic agitator is outside the tank chamber, and wherein the magnetic agitator is configured to generate a moving magnetic field in the molten material in the tank chamber to induce movement in the molten material.

[0089] Example 26. A pump system as described in any preceding or subsequent example or combination of examples, wherein the tank further comprises: an inlet fluidly connected to the tank chamber and defining a flow path to the tank chamber for molten material to enter the tank chamber; and an outlet fluidly connected to the tank chamber and defining a flow path from the tank chamber for molten material to leave the tank chamber, wherein a lateral dimension of the tank chamber near the inlet is different from the lateral dimension of the tank chamber near the outlet.

[0090] Example 27. The pump system of any preceding or following example or combination of examples, wherein the vertical edge further comprises one or more fins positioned along the length of the body.

[0091] Example 28. A mixer for a pump system for a metal furnace, the mixer comprising: a body including an edge extending along the length of the body; at least one fin along the edge of the body; and a supply passage extending at least partially through the body and including at least one opening defined in the edge of the body.

[0092] Example 29. A method comprising: receiving molten material from a furnace into a tank chamber of a tank of a pump system; generating a mixed flow in the molten material in the tank chamber, wherein generating the mixed flow comprises: rotating a permanent magnet of a magnetic stirrer of the pump system to generate a moving magnetic field in the molten material in the tank chamber; and controlling the moving magnetic field to induce movement in the molten material, wherein the tank is positioned above the magnetic stirrer so that the magnetic stirrer is outside the tank chamber; and discharging the molten material from the tank.

[0093] Example 30. The method of any preceding or subsequent example or combination of examples, further comprising removing dross from the molten material in the tank chamber while generating the mixed flow in the molten material.

[0094] Example 31. A method as described in any preceding or subsequent example or combination of examples, wherein the mixed flow is a secondary mixed flow, and wherein the method further comprises: generating a primary mixed flow in the molten material by lowering a mixer into the tank chamber and at least partially entering the molten material, wherein the mixer comprises a body comprising an edge extending along the length of the mixer, wherein the edge comprises one or more fins.

[0095] Example 32. The method of any preceding or subsequent example or combination of examples, further comprising adding waste material to the tank chamber while generating the main mixed flow.

[0096] Example 33. A method as described in any preceding or subsequent example or combination of examples, further comprising injecting an injectable material into the molten material while generating the mixed flow by: lowering the mixer into the tank chamber and at least partially entering the molten material, wherein the mixer includes a body, the body including a supply passage extending at least partially through the body and including at least one opening defined in an edge of the body; and injecting the injectable material through the supply passage so that it leaves the at least one opening and enters the molten material.

[0097] Example 34. The method of any preceding or subsequent example or combination of examples, further comprising selecting a geometry of the tank chamber to facilitate flow of the molten material from the inlet toward the outlet.

[0098] Example 35. A method as described in any preceding or subsequent example or combination of examples, wherein selecting the geometry includes selecting the transverse dimension of the tank chamber near the inlet to be different from the transverse dimension of the tank chamber near the outlet.

[0099] Example 36. A method as described in any preceding or subsequent example or combination of examples, wherein selecting the geometry includes selecting the transverse dimension of the tank chamber near the inlet to be smaller than the transverse dimension of the tank chamber near the outlet.

[0100] The various aspects described above are merely examples of possible implementations, which are merely set forth for a clear understanding of the principles of the present disclosure. Many changes and modifications may be made to one or more of the embodiments described above without substantially departing from the spirit and principles of the present disclosure. All such modifications and changes are intended to be included within the scope of the present disclosure, and all possible claims regarding various aspects or combinations of elements or steps are intended to be supported by the present disclosure. In addition, although specific terms are employed herein and in the claims that follow, the terms are used only in a general and descriptive sense, and are not intended to limit the embodiments described, nor are they intended to limit the claims that follow.

Claims

1. A pump system for a metal furnace, the pump system comprising: a tank including a tank chamber configured to receive a molten material; as well as A mixer is selectively positionable within and removable from the tank chamber, the mixer comprising a body including one or more fins along an edge of the body.

2. The pump system of claim 1 , further comprising a magnetic stirrer comprising a rotating permanent magnet, wherein the tank is positioned above the magnetic stirrer and such that the magnetic stirrer is outside the tank chamber, and wherein the magnetic stirrer is configured to generate a moving magnetic field in the molten material in the tank chamber to induce movement in the molten material.

3. The pump system of claim 1, wherein the tank further comprises: an inlet in fluid communication with the tank chamber and defining a flow path to the tank chamber for molten material to enter the tank chamber; as well as an outlet in fluid communication with the tank chamber and defining a flow path from the tank chamber for molten material to exit the tank chamber, The transverse dimension of the tank chamber near the inlet is different from the transverse dimension of the tank chamber near the outlet.

4. The pump system of claim 1, wherein the body further comprises: a supply passage extending through at least a portion of the body; as well as At least one opening is defined in an edge of the body, wherein the at least one opening is in fluid communication with the supply passage, and wherein the mixer is configured to selectively supply injectable material into the tank chamber via the supply passage and the at least one opening.

5. A pump system for a metal furnace, the pump system comprising: a tank including a tank chamber configured to receive a molten material; as well as A mixer is selectively positionable in and removable from the tank chamber, the mixer comprising a body defining a supply passage having at least one opening along a vertical edge of the body, wherein the mixer is configured to selectively supply injectable material into the tank chamber via the supply passage and the at least one opening.

6. The pump system of claim 5 further comprising a magnetic agitator comprising a rotating permanent magnet, wherein the tank is positioned above the magnetic agitator and such that the magnetic agitator is outside the tank chamber, and wherein the magnetic agitator is configured to generate a moving magnetic field in the molten material in the tank chamber to induce movement in the molten material.

7. The pump system of claim 5, wherein the tank further comprises: an inlet in fluid communication with the tank chamber and defining a flow path to the tank chamber for molten material to enter the tank chamber; as well as an outlet in fluid communication with the tank chamber and defining a flow path from the tank chamber for molten material to exit the tank chamber, The transverse dimension of the tank chamber near the inlet is different from the transverse dimension of the tank chamber near the outlet.

8. The pump system of claim 5, wherein the vertical edge further comprises one or more fins positioned along the length of the body.

9. A mixer for a pump system of a metal furnace, the mixer comprising: a body including a rim extending along a length of the body; at least one fin along an edge of said body; as well as A supply passage extends at least partially through the body and includes at least one opening defined in an edge of the body.

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