Metal smelting reverberatory furnace system with waste heat recovery function

Abstract

The invention discloses a metal smelting reverberatory furnace system with a waste heat recovery function, which relates to the field of non-ferrous metal smelting and comprises a reverberatory furnace, a furnace door is arranged on the reverberatory furnace, a slag guide plate is arranged on the lower edge of the furnace door, slag can be conveniently guided into a slag box during slagging-off, and a lifting mechanism for controlling the furnace door to be opened is arranged at the top of the reverberatory furnace. A gas control valve set and a combustor are arranged on the side of the reverberatory furnace, the combustor is connected with a heat exchanger through a first pipeline, and an electromagnetic stirrer is arranged at the bottom of the reverberatory furnace. According to the metal smelting reverberatory furnace system with the waste heat recovery function, effective recovery of waste heat is achieved, the comprehensive utilization rate of energy is increased, the production cost is reduced, thermal pollution of waste gas emission to the environment is reduced, a steel structure of the reverberatory furnace is reinforced, a multi-layer furnace lining structure is optimally matched, and high-temperature-resistant and anti-erosion materials of all parts are selected; the rigidity, the air tightness and the durability of the reverberatory furnace are obviously enhanced, the equipment failure rate is reduced, and the service life of equipment is prolonged.

Description

Technical Field

[0001] The present invention relates to the field of nonferrous metal smelting, and in particular to a metal smelting reverberatory furnace system with waste heat recovery. Background Art

[0002] Reverberatory furnaces have the advantages of simple structure, convenient operation, easy control, strong adaptability to raw materials and fuels, low water consumption, high operating efficiency, and suitability for large-scale production. Traditional reverberatory furnaces have disadvantages such as high fuel consumption, low thermal efficiency, high consumption of refractory materials, and serious environmental pollution caused by flue gas.

[0003] Due to the high temperatures of reverberatory furnaces, high flue gas temperatures, and high heat consumption, a flue gas waste heat recovery device is required. However, due to the harsh environment and high impurity content of the flue gas, heat exchangers can easily become clogged, creating a significant challenge for waste heat recovery. Traditional metal heat exchanger structures can partially recover waste heat, but if the flue temperature reaches above 800 degrees Celsius, the metal heat exchanger will be damaged by the high temperature, shortening its service life. Ceramic heat exchangers, while resistant to high temperatures and corrosion, are prone to impurities and are easily damaged during cleaning.

[0004] Therefore, it is necessary to make improvements to the above problems. Summary of the Invention

[0005] The purpose of the present invention is to address the above problems and provide a metal smelting reverberatory furnace system with waste heat recovery. In response to the problem of large-scale waste heat loss in traditional reverberatory furnaces, this solution aims to achieve effective recovery of waste heat, improve the comprehensive utilization rate of energy, reduce production costs, and reduce the thermal pollution of waste gas emissions to the environment. The steel structure of the reverberatory furnace is reinforced, the multi-layer lining structure is optimized, and high-temperature resistant and corrosion-resistant materials are selected for various parts. The rigidity, airtightness and durability of the reverberatory furnace are significantly enhanced, the equipment failure rate is reduced, the equipment service life is extended, the maintenance cost and downtime are reduced, and the continuity and stability of production are guaranteed. The reasonable design and precise control of the electromagnetic stirrer enable the molten metal to produce regular eddy motion in the molten pool, ensure uniform composition, accelerate the smelting speed, improve production efficiency, ensure stable product quality, and meet the process requirements for the production of high-quality metal materials.

[0006] To achieve the above object, the technical solution adopted by the present invention is: A metal smelting reverberatory furnace system with waste heat recovery includes a reverberatory furnace. The steel structure of the reverberatory furnace is welded from steel plates and steel sections. The furnace shell is reinforced in an appropriate form to withstand thermal and mechanical stresses and has good rigidity and airtightness. A furnace door is provided on the reverberatory furnace, and a slag guide plate is provided at the bottom edge of the furnace door to facilitate the introduction of slag into the slag box when slagging. A lifting mechanism for controlling the opening of the furnace door is provided on the top of the reverberatory furnace. A gas control valve group and a burner are provided on the side of the reverberatory furnace. The burner is connected to the heat exchanger through a first pipeline. An electromagnetic stirrer is provided at the bottom of the reverberatory furnace. The electromagnetic stirrer is bottom-mounted and installed in a tunnel below the reverberatory furnace. When working, it can be started with one button, automatically enters the designated working position, and rises to the working position. It automatically operates according to the set stirring intensity. After stirring, it automatically descends and moves to the maintenance position for standby. The stirring, lifting and moving of the electromagnetic stirrer are all complete. The electromagnetic stirrer mainly consists of a variable frequency power supply and an inductor. The variable frequency power supply converts the 50 / 60Hz industrial frequency AC power into a low frequency power supply with a frequency of 0.5-5.0Hz. When the power supply is passed into the inductor coil, a traveling wave magnetic field will be generated. This traveling wave magnetic field penetrates the stainless steel plate lining and acts on the zinc melt, causing the zinc melt to move regularly, thereby achieving the purpose of circulating or stirring the metal liquid. By changing the current, frequency and phase sequence of the variable frequency power supply, the magnitude and direction of the stirring force can be changed.

[0007] As a further improvement of the above scheme, the reverberatory furnace includes a furnace roof, furnace walls, a molten pool, a furnace bottom and a furnace door. The furnace bottom and the molten pool are respectively made of a working layer, an anti-seepage layer and a thermal insulation layer from the inside to the outside. The working layer is made by casting the castable in blocks, and grooved joints are left to prevent leakage. When the castable is cast in blocks, a mortise and tenon structure is used between the blocks to ensure that the furnace lining has a good service life. The anti-seepage layer is made of anti-seepage material, and the thermal insulation layer is made of high-quality aluminum silicate backing board, which has a certain strength and excellent thermal insulation performance. The furnace wall and furnace roof above the molten pool adopt a double-layer structure of working layer and thermal insulation layer. The furnace door is made of high-strength castable with anchors.

[0008] As a further improvement of the above solution, the lifting mechanism includes a motor, the motor output shaft is connected to the rotating shaft through a reducer, a chain is matched with the sprocket on the rotating shaft, and the lower end of the chain is connected to the furnace door.

[0009] As a further improvement of the above solution, the rollers arranged on the sides of the furnace door are arranged to roll in the guide rails.

[0010] As a further improvement of the above solution, the burner includes a combustion seat, an observation port and an igniter are provided on the combustion seat, an expansion joint is provided between the combustion seat and the first pipeline, and the gas control valve group includes a fuel pipeline, a control valve and a pressure sensor are provided on the fuel pipeline.

[0011] As a further improvement of the above solution, the heat exchanger includes a casing, a heat exchange core is arranged above the casing, an air outlet arranged on the side of the heat exchange core is connected to an air regulating valve, and the air regulating valve is connected to the first pipeline.

[0012] As a further improvement of the above solution, a plurality of inner heat exchange tubes arranged in the heat exchange core extend downward into the outer heat exchange tubes.

[0013] As a further improvement of the above solution, the air inlet provided on the heat exchange core is connected to the second pipe, and the second pipe is connected to the air outlet of the fan.

[0014] As a further improvement of the above solution, a smoke outlet is provided above the machine casing, and a smoke inlet is provided below the machine casing and is connected to the reverberatory furnace through a smoke duct.

[0015] As a further improvement of the above solution, a heat-insulating cone and supporting legs are provided below the casing.

[0016] As a further improvement of the above scheme, the air regulating valve includes an air flange body and a branch flange body, an upper shaft sleeve body is arranged on the air flange body, a transmission shaft is arranged in the upper shaft sleeve body, the upper part of the transmission shaft is connected to the electric actuator, a bracket is arranged between the electric actuator and the upper shaft sleeve body, a gasket, a skeleton oil seal, and a sealing member are arranged between the upper shaft sleeve body and the transmission shaft, a reinforcing rib and a valve plate are arranged at the lower part of the transmission shaft, a connecting sleeve is arranged between the transmission shaft and the valve plate, a baffle body is arranged below the valve plate, a slot is arranged on the baffle body, and a partition and a bottom plate are arranged below the baffle body.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: in response to the problem of large-scale loss of waste heat in traditional reverberatory furnaces, this solution aims to achieve effective recovery of waste heat, improve the comprehensive utilization rate of energy, reduce production costs, and reduce the thermal pollution of waste gas emissions to the environment. The reinforcement of the steel structure of the reverberatory furnace, the optimization of the multi-layer lining structure, and the selection of high-temperature resistant and corrosion-resistant materials in various parts significantly enhance the rigidity, airtightness and durability of the reverberatory furnace, reduce the equipment failure rate, extend the equipment service life, reduce maintenance costs and downtime, and ensure the continuity and stability of production. The reasonable design and precise control of the electromagnetic stirrer enable the molten metal to produce regular eddy motion in the molten pool, ensure uniform composition, accelerate the smelting speed, improve production efficiency, ensure stable product quality, and meet the process requirements for the production of high-quality metal materials.

[0018] 1. After the combustion air is preheated by the flue gas waste heat recovery device, it enters the burner for premixing and then participates in combustion, which can improve the combustion efficiency and reduce NO X Emissions, combustion is more stable, the energy consumption of zinc alloy reverberatory furnace is reduced to 30Nm 3 / t, reaching the advanced level of the industry.

[0019] 2. The furnace body is designed with thermal insulation layers and the castable is cast in blocks, which has excellent thermal insulation performance and service life.

[0020] 3. The electromagnetic stirring solution has a good vortex effect, can be remotely controlled, has a high degree of automation, is simple and convenient to operate, has low operating costs, and saves electricity and energy.

[0021] 4. The flue gas temperature entering the heat exchanger of the flue gas waste heat recovery device is close to the furnace temperature. The inner and outer tube structure heat exchange tube has a good cooling effect. The pipe temperature is less than 800℃, with a long service life and easy cleaning. The flue gas temperature at the heat exchanger outlet is about 500-650℃, the hot air temperature is 200-350℃, and the heat recovery effect is good. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the main structure of the present invention.

[0023] Figure 2 for Figure 1 Side view structural diagram.

[0024] Figure 3 for Figure 1 Schematic diagram of the structure viewed from above.

[0025] Figure 4 It is a structural schematic diagram of the furnace door position of the present invention.

[0026] Figure 5 It is a schematic diagram of the cross-sectional structure of the reverberatory furnace of the present invention.

[0027] Figure 6 This is a schematic diagram of the main structure of the heat exchanger of the present invention.

[0028] Figure 7 for Figure 6 Side view structural diagram.

[0029] Figure 8 This is a schematic diagram of the main structure of the heat exchange core of the present invention.

[0030] Figure 9 for Figure 6 Schematic diagram of the structure viewed from above.

[0031] Figure 10 It is a structural schematic diagram of the positions of the inner heat exchange tube and the outer heat exchange tube of the present invention.

[0032] Figure 11 This is a schematic diagram of the main structure of the air control valve of the present invention.

[0033] Figure 12 for Figure 11 Side view structural diagram.

[0034] Figure 13 for Figure 12 Schematic diagram of the cross-sectional structure at BB in the middle.

[0035] Figure 14 for Figure 12 A partial enlarged schematic diagram of point A in the middle.

[0036] The text labels in the figure are as follows: 1. burner; 2. expansion joint; 3. first pipeline; 4. reverberatory furnace; 5. furnace door; 6. lifting mechanism; 7. air control valve; 8. heat exchanger; 9. second pipeline; 10. fan; 11. electromagnetic stirrer; 12. gas control valve group; 101. observation port; 102. igniter; 103. combustion seat; 401. furnace top; 402. furnace wall; 403. molten pool; 404. furnace bottom; 405. furnace door; 601. roller; 602. guide rail; 603. chain; 604. sprocket; 605. rotating shaft; 606. reducer; 607. motor; 701. air flange; 702. upper shaft sleeve; 703. connecting rod ;704, bracket;705, electric actuator;706, gasket;707, skeleton oil seal;708, seal;709, drive shaft;710, reinforcement rib;711, valve plate;712, partition;713, bottom plate;714, connecting sleeve;715, branch flange body;716, baffle body;717, slot;801, heat exchange core;802, inner heat exchange tube;803, outer heat exchange tube;804, machine casing;805, support leg;806, insulation cone;807, air inlet;808, flue gas outlet;809, flue gas inlet;810, air outlet;1201, fuel pipeline;1202, pressure sensor;1203, control valve. DETAILED DESCRIPTION

[0037] In order to enable those skilled in the art to better understand the technical solution, the present invention is described in detail below in conjunction with embodiments. The description in this section is only exemplary and explanatory and should not have any limiting effect on the scope of protection of the present invention.

[0038] like Figures 1-10As shown, the specific scheme of this embodiment is: a metal smelting reverberatory furnace system with waste heat recovery, including a reverberatory furnace 4, the steel structure of the reverberatory furnace 4 is welded by steel plates and steel sections, and the furnace shell is reinforced in an appropriate form to withstand thermal stress and mechanical stress, and has good rigidity and airtightness. A furnace door 5 is provided on the reverberatory furnace 4, and a slag guide plate is provided at the lower edge of the furnace door 5, which can facilitate the slag to be introduced into the slag box when slagging. A lifting mechanism 6 for controlling the opening of the furnace door 5 is provided on the top of the reverberatory furnace 4, a gas control valve group 12 and a burner 1 are provided on the side of the reverberatory furnace 4, and the burner 1 is connected to the heat exchanger 8 through a first pipe 3. An electromagnetic stirrer 11 is provided at the bottom of the reverberatory furnace 4, and the electromagnetic stirrer 11 is bottom-mounted and installed in a tunnel below the reverberatory furnace 4. When working, it can be started with one button, automatically enter the designated working position, and rise to the working position. It automatically operates according to the set stirring intensity. After stirring is completed, it automatically descends and moves to the maintenance position for standby. The stirring, lifting and moving of the electromagnetic stirrer 11 all adopt mechanical transmission, which is reliable, safe, environmentally friendly and has a low failure rate. The forward and reverse rotation speed and time are arbitrarily adjustable during stirring, and the solution vortex effect is good. It is equipped with a control system, which can realize remote control and has a high degree of automation. The applicable ambient temperature is: -10-65°, suitable for circular furnaces and rectangular furnaces, and the overall service life of the equipment is more than 10 years. The electromagnetic stirrer 11 is mainly composed of a variable frequency power supply and an inductor. The variable frequency power supply converts the 50 / 60Hz industrial frequency AC power into a low-frequency power supply with a frequency of 0.5-5.0Hz. After the power supply is passed into the inductor coil, a traveling wave magnetic field will be generated. This traveling wave magnetic field penetrates the stainless steel plate lining and acts on the zinc melt, causing the zinc melt to move regularly, thereby achieving the purpose of circulating the metal liquid or stirring the metal liquid. By changing the current, frequency and phase sequence of the variable frequency power supply, the magnitude and direction of the stirring force can be changed.

[0039] like Figure 1-Figure 5 As shown, as a preferred embodiment of the above embodiment, the reverberatory furnace 4 includes a furnace top 401, a furnace wall 402, a molten pool 403, a furnace bottom 404 and a furnace door 405. The furnace bottom 404 and the molten pool 403 adopt a working layer, an anti-seepage layer and a thermal insulation layer from the inside to the outside. The working layer is cast by casting the castable in blocks, and grooved joints are left to prevent leakage. When the castable is cast in blocks, a tenon structure is used between the blocks to ensure that the furnace lining has a good service life. The anti-seepage layer is made of anti-seepage material, and the thermal insulation layer is made of high-quality aluminum silicate backing board, which has certain strength and excellent thermal insulation performance. The furnace wall 402 and the furnace top 401 above the molten pool 403 adopt a double-layer structure of working layer and thermal insulation layer. The furnace door 405 is cast by high-strength castable with anchors.

[0040] like Figures 1-4As shown, as a preferred embodiment of the above embodiment, the lifting mechanism 6 includes a motor 607, the output shaft of the motor 607 is connected to the rotating shaft 605 through a reducer 606, a chain 603 is matched with the sprocket 604 on the rotating shaft 605, and the lower end of the chain 603 is connected to the furnace door 5.

[0041] like Figures 1-4 As shown, as a preferred embodiment of the above embodiment, the roller 601 provided on the side of the furnace door 5 is rotatably provided in the guide rail 602 .

[0042] like Figure 1-Figure 2 As shown, as a preferred embodiment of the above embodiment, the burner 1 includes a combustion seat 103, an observation port 101 and an igniter 102 are provided on the combustion seat 103, an expansion joint 2 is provided between the combustion seat 103 and the first pipeline 3, and the gas control valve group 12 includes a fuel pipeline 1201, and a control valve 1203 and a pressure sensor 1202 are provided on the fuel pipeline 1201.

[0043] like Figure 1 、 Figure 2 、 Figure 3 、 Figure 6 、 Figure 7 、 Figure 8 、 Figure 9 、 Figure 10 As shown, as a preferred embodiment of the above embodiment, the heat exchanger 8 includes a casing 804, a heat exchange core 801 is arranged above the casing 804, and an air outlet 810 arranged on the side of the heat exchange core 801 is connected to the air regulating valve 7, and the air regulating valve 7 is connected to the first pipe 3.

[0044] like Figure 8 、 Figure 10 As shown, as a preferred embodiment of the above embodiment, a plurality of inner heat exchange tubes 802 provided in the heat exchange core 801 extend downward into the outer heat exchange tube 803 .

[0045] like Figure 8 、 Figure 10 As shown, as a preferred embodiment of the above embodiment, the air inlet 807 provided on the heat exchange core 801 is connected to the second pipe 9 , and the second pipe 9 is connected to the air outlet of the fan 10 .

[0046] like Figures 6-10 As shown, as a preferred embodiment of the above embodiment, a smoke outlet 808 is provided above the machine housing 804 , and a smoke inlet 809 provided below the machine housing 804 is connected to the reverberatory furnace 4 through a smoke duct.

[0047] like Figure 6-Figure 8 As shown, as a preferred embodiment of the above embodiment, a heat-insulating cone 806 and support legs 805 are provided below the housing 804 .

[0048] like Figure 11-14As shown, as a preferred embodiment of the above embodiment, the air regulating valve 7 includes an air flange body 701 and a branch flange body 715, an upper shaft sleeve body 702 is provided on the air flange body 701, a transmission shaft 709 is provided in the upper shaft sleeve body 702, the upper part of the transmission shaft 709 is connected to the electric actuator 705, a bracket 704 is provided between the electric actuator 705 and the upper shaft sleeve body 702, a gasket 706, a skeleton oil seal 707, and a sealing member 708 are provided between the upper shaft sleeve body 702 and the transmission shaft 709, a reinforcing rib 710 and a valve plate 711 are provided at the lower part of the transmission shaft 709, a connecting sleeve 714 is provided between the transmission shaft 709 and the valve plate 711, a baffle body 716 is provided below the valve plate 711, a slot 717 is provided on the baffle body 716, and a partition 712 and a bottom plate 713 are provided below the baffle body 716. More specifically, the air regulating valve 7 is designed with an internal three-way structure and driven by an electric actuator 705. The opening between the valve plate 711 and the slot 717 is adjusted according to the combustion air volume demand (the combustion air volume demand is determined by the gas volume and air-fuel ratio). When the combustion air demand is large, the bypass flue gas volume is reduced so that most or all of the flue gas passes through the heat exchanger 8 for heat exchange with the combustion air, preheating the combustion air and reducing energy consumption; when the combustion air demand is small, the bypass flue gas volume is increased to utilize the waste heat of the flue gas. At the same time, it prevents insufficient combustion air volume under low load conditions from cooling the heat exchange tubes, resulting in high-temperature damage to the heat exchanger 8. The setting of the air regulating valve 7 can extend the service life of the metal heat exchanger 8.

[0049] The specific working principle of the present invention is: The steel structure of reverberatory furnace 4 is welded from steel plates and sections. Through the rational design of the weld structure and reinforcement methods, the rigidity of the furnace shell is enhanced, enabling it to withstand the thermal and mechanical stresses generated during the smelting process, preventing shell deformation and ensuring normal operation of the equipment. The airtight treatment of the furnace shell effectively prevents cold air infiltration and hot gas leakage, reducing energy loss while ensuring a safe production environment.

[0050] The lining of the furnace bottom 404 and the molten pool 403 adopts a three-layer structure consisting of a working layer, an anti-seepage layer, and an insulation layer. The working layer is cast in blocks using castables, and a tenon-shaped structure is used between the blocks. This not only facilitates construction and maintenance, but also enhances the integrity and leakage resistance of the furnace lining, prevents damage caused by direct contact between the molten metal and the furnace shell, and extends the service life of the furnace lining. The anti-seepage layer uses anti-seepage material to further block the penetration of the molten metal and improve the safety factor. The insulation layer uses high-quality aluminum silicate backing board with good thermal insulation performance and a certain strength, which effectively reduces heat loss to the outside of the furnace, reduces fuel consumption, and maintains the required temperature for smelting. The furnace door 405 uses high-strength castables with anchors to ensure the structural strength of the furnace door 405 when it is frequently opened and in high-temperature environments, and prevents damage to the furnace door 405, which may lead to large-scale heat loss and operational safety risks.

[0051] The furnace door 5 is located on the reverberatory furnace 4 and is equipped with a slag guide plate at its lower edge. During slagging operations, the furnace door 5 is opened and the slag slides along the slag guide plate into the slag box. This facilitates operation, improves work efficiency, reduces the labor intensity and time cost of manual slag cleaning, and prevents slag scattering from contaminating and potentially hazardous the area around the furnace door 5 and in front of the furnace.

[0052] A lifting mechanism 6, mounted on top of the reverberatory furnace 4, controls the opening and closing of the furnace door 5. The motor 607 is the power source of the lifting mechanism 6. Its output shaft, after being reduced in speed and increased in torque by a reducer 606, drives the rotating shaft 605. A sprocket 604 on the rotating shaft 605 cooperates with a chain 603 to convert the rotational motion of the motor 607 into the lifting motion of the chain 603. The lower end of the chain 603 is connected to the furnace door 5, ensuring smooth opening and closing of the furnace door 5. Rollers 601, mounted on the sides of the furnace door 5, roll within guide rails 602, providing guidance and support for the furnace door 5. This ensures that the furnace door 5 remains vertical during the lifting process, preventing it from tilting and colliding with the furnace wall 402. This extends the service life of the furnace door 5 and the furnace wall 402, ensures the sealing performance of the furnace door 5, and reduces heat loss.

[0053] The burner 1 is arranged on the side of the reverberatory furnace 4 and is connected to the heat exchanger 8 through the first pipe 3. The combustion seat 103 of the burner 1 is provided with an observation port 101, which allows the operator to observe the combustion status and adjust the combustion parameters in a timely manner to ensure sufficient and stable combustion. The igniter 102 is used to ignite the gas, realize the automatic ignition function, and improve the convenience and safety of operation. An expansion joint 2 is provided between the combustion seat 103 and the first pipe 3. Due to the large temperature changes when the burner 1 is operating, the pipe will produce thermal expansion. The expansion joint 2 can effectively compensate for the expansion and contraction of the pipe, avoid damage to the pipe due to thermal stress, and ensure the reliability and safety of the connection.

[0054] The gas control valve assembly 12 includes a fuel pipeline 1201, equipped with a control valve 1203 and a pressure sensor 1202. The control valve 1203 regulates the gas flow rate, enabling precise control of combustion intensity to meet the heat requirements of different smelting stages. The pressure sensor 1202 monitors the gas pressure in real time. When pressure is abnormal, it issues an alarm and initiates measures to prevent combustion interruptions caused by insufficient gas pressure or safety incidents caused by excessive pressure, thus ensuring the stable operation of the combustion system.

[0055] The heat exchanger 8 comprises a housing 804, with a heat exchange core 801 positioned above it. Multiple inner heat exchange tubes 802 within the heat exchange core 801 extend downward into outer heat exchange tubes 803, forming a highly efficient heat exchange structure. Flue gas from the reverberatory furnace 4 enters the flue gas inlet 809 below the housing 804 through the flue gas duct. It then flows upward through the gaps between the outer heat exchange tubes 803 and the inner heat exchange tubes 802 outside the heat exchange core 801, transferring heat to the air within the tubes. Air enters through a second pipe 9, which connects to the outlet of a fan 10, which blows air into the heat exchanger 8. After being heated by the flue gas within the heat exchange core 801, the air exits through an air outlet 810 and connects to the first pipe 3 via an air control valve 7. This high-temperature air is then delivered to the burner 1, serving as combustion air to enhance combustion efficiency. The air control valve 7 regulates the amount of air entering the burner 1, precisely controlling the air flow according to combustion requirements, optimizing the combustion process, and reducing pollutants generated by incomplete combustion.

[0056] More specifically, the thermal insulation cone 806 and the housing 804 are connected by detachable bolts or screws, which can better facilitate the maintenance, installation and replacement of various components therein by the staff from the bottom position of the housing 804.

[0057] In addition, if Figure 9 As shown, a folded plate arranged at an obtuse angle is provided within the heat exchange core 801, dividing the upper cavity of the heat exchange core 801 into two uneven chambers. Flue gas from the reverberatory furnace 4 enters the flue gas inlet 809 below the housing 804 through the flue gas duct, flows upward through the gap between the outer heat exchange tube 803 and the inner heat exchange tube 802 outside the heat exchange core 801, and transfers heat to the air within the tube. Air enters through the second pipe 9, which is connected to the outlet of the fan 10, which blows the air into the heat exchanger 8. After being heated by the flue gas within the heat exchange core 801, the air flows out through the air outlet 810 and is connected to the first pipe 3 through the air control valve 7. The high-temperature air is then delivered to the burner 1 as combustion air to improve combustion efficiency. The air control valve 7 is used to adjust the amount of air entering the burner 1, precisely controlling the air flow according to combustion requirements.

[0058] The flue gas outlet 808 above the housing 804 discharges the low-temperature flue gas after heat exchange, reducing thermal pollution to the environment caused by exhaust emissions. The insulating cone 806 below the housing 804 reduces downward heat loss and guides incoming flue gas, evenly distributing it around the heat exchange core 801 and improving heat exchange efficiency. Support legs 805 support the entire heat exchanger 8, ensuring its stable placement.

[0059] The electromagnetic stirrer 11 is bottom-mounted, installed in the tunnel beneath the reverberatory furnace 4. It activates with a single button, automatically ascending to its designated working position via a mechanical transmission system, operating at the set stirring intensity. After stirring is complete, it automatically descends and moves to a maintenance position for standby use. Compared to hydraulic or pneumatic transmission, this mechanically driven stirring, lifting, and movement method offers advantages such as simple structure, reliable operation, safety, low failure rate, easy maintenance, and environmental friendliness. It adapts to the harsh environment of the smelting workshop and is unaffected by interference factors such as temperature and dust, ensuring the stability and continuity of the stirring operation.

[0060] The electromagnetic stirrer 11 primarily consists of a variable-frequency power supply and an inductor. The variable-frequency power supply converts 50 / 60Hz industrial-frequency AC power into a low-frequency power supply of 0.5-5.0Hz, adapting to varying stirring requirements and offering a wide adjustment range. The low-frequency power is fed into the inductor coil, generating a traveling-wave magnetic field that penetrates the stainless steel furnace lining and acts on the molten zinc. The magnetic lines of force of the traveling-wave magnetic field cut through the molten zinc, inducing eddy currents within the molten zinc. The interaction of the eddy currents and the magnetic field generates a Lorentz force, which drives the molten zinc to move in a regular pattern, achieving circulation and stirring of the metal liquid. By varying the current, frequency, and phase sequence of the variable-frequency power supply, the magnitude and direction of the stirring force can be flexibly adjusted to meet the stirring intensity and flow requirements of different smelting processes. For example, in the initial stages of smelting, a higher current and lower frequency can be used to generate a stronger stirring force and accelerate the melting of the metal material. During the refining stage, the current is reduced and the frequency is increased, resulting in gentle stirring that promotes the floating of impurities and the discharge of gases.

[0061] The electromagnetic stirrer 11 can be adjusted to any desired speed and time for alternating forward and reverse rotation, resulting in a significant eddy current effect in the solution. The eddy current can fully mix the melt, break down component segregation, ensure uniform composition of the molten metal, and improve product quality. It also promotes heat and material exchange between the melt and the furnace lining and slag, accelerating smelting, shortening production cycles, and improving production efficiency.

[0062] The control system equipped with the electromagnetic stirrer 11 realizes remote control. The operator can remotely start and stop the stirrer in the control room, adjust the stirring parameters, and monitor the operating status of the stirrer in real time, thereby improving the degree of automation, reducing the intensity of manual operation and safety risks, and adapting to the intelligent needs of modern production. The equipment is applicable to a wide range of ambient temperatures. The operating temperature range of -10-65°C enables it to cope with climatic conditions and workshop environment changes in different regions, ensuring that the equipment can operate stably in cold winters or hot summers. It is suitable for circular furnaces and rectangular furnaces, has strong versatility, and can be widely used in the renovation and new construction projects of various metal smelting reverberatory furnaces 4. The overall service life is more than 10 years, which reduces the cost of equipment renewal and improves the economic benefits and market competitiveness of the enterprise.

[0063] More specifically, the furnace's steel structure is welded from 8-10mm thick steel plates (Q235-A) and section steel. Appropriate reinforcement is employed to the furnace shell to withstand thermal and mechanical stresses, ensuring excellent rigidity and airtightness. A slag guide plate is located at the bottom edge of the furnace door 5 to facilitate slag removal and direct it into the slag box. Bolts connect the slag guide plate to the front wall steel structure, facilitating its maintenance and replacement. A magnetic stirring window, made of stainless steel, is located in the furnace bottom 404.

[0064] To facilitate mechanical charging and slag removal, the furnace door features a large structure (1200x1000 cm internal cavity). This eliminates any "hidden" corners in the molten pool 403, making surface cleaning easier and more thorough. The furnace door 5 is lined with refractory castables and zinc silicate fiberboard. Manufactured using proprietary technology, the aluminum silicate modules in the door's compression area are adjustable, providing a large sealing area and allowing for adjustment after wear, ensuring long-term airtightness. The door opens vertically and is electrically driven at a speed of 3-5 m / min. Each lift limit is controlled and interlocked with the combustion system. When the door is raised, the burner's main flame automatically adjusts to a low setting; when the door is closed, the flame level is automatically controlled. The door's steel structure is segmented, connected by bolts and disc washers, effectively mitigating thermal expansion and ensuring long-term operation under high-temperature conditions. The door's sealing frame utilizes a segmented construction and a specially formulated alloy (RQTSi5). The furnace door frame is made of heat-resistant cast iron (RQTSi5), connected in sections and bolted to the furnace steel structure.

[0065] It should be noted that, in this article, the terms include, comprise or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. Specific examples are used herein to illustrate the principles and implementation methods of the technical solution of the present invention. The above examples are only used to help understand the method of the present invention and its core idea. The above is only a preferred embodiment of the present invention. It should be pointed out that due to the limitations of textual expression and the objective existence of infinite specific structures, ordinary technicians in this technical field can make several improvements, modifications or changes without departing from the principles of the present invention, and can also combine the above technical features in an appropriate manner; these improvements, modifications, changes or combinations, or the direct application of the inventive concept and technical solution to other occasions without improvement, should all be regarded as the scope of protection of the present invention.

Claims

1. A metal smelting reverberatory furnace system with waste heat recovery, characterized in that: The invention comprises a reverberatory furnace (4), a furnace door (5) is provided on the reverberatory furnace (4), a lifting mechanism (6) for controlling the opening of the furnace door (5) is provided on the top of the reverberatory furnace (4), a gas control valve group (12) and a burner (1) are provided on the side of the reverberatory furnace (4), the burner (1) is connected to a heat exchanger (8) through a first pipeline (3), and an electromagnetic stirrer (11) is provided at the bottom of the reverberatory furnace (4).

2. The metal smelting reverberatory furnace system with waste heat recovery according to claim 1, characterized in that: The reverberatory furnace (4) comprises a furnace top (401), a furnace wall (402), a molten pool (403), a furnace bottom (404) and a furnace door (405). The furnace bottom (404) and the molten pool (403) are sequentially provided with a working layer, an anti-seepage layer and a thermal insulation layer from the inside to the outside. The furnace wall (402) and the furnace top (401) above the molten pool (403) are provided with a double-layer structure of a working layer and a thermal insulation layer.

3. The metal smelting reverberatory furnace system with waste heat recovery according to claim 1, characterized in that: The lifting mechanism (6) includes a motor (607), an output shaft of the motor (607) is connected to a rotating shaft (605) via a reducer (606), a chain (603) is matched with a sprocket (604) on the rotating shaft (605), and a lower end of the chain (603) is connected to the furnace door (5).

4. The metal smelting reverberatory furnace system with waste heat recovery according to claim 3, characterized in that: The roller (601) provided on the side of the furnace door (5) is rotatably arranged in the guide rail (602).

5. The metal smelting reverberatory furnace system with waste heat recovery according to claim 1, characterized in that: The burner (1) comprises a combustion seat (103), an observation port (101) and an igniter (102) are provided on the combustion seat (103), an expansion joint (2) is provided between the combustion seat (103) and the first pipeline (3), and the gas control valve group (12) comprises a fuel pipeline (1201), a control valve (1203) and a pressure sensor (1202) are provided on the fuel pipeline (1201).

6. The metal smelting reverberatory furnace system with waste heat recovery according to claim 1, characterized in that: The heat exchanger (8) comprises a housing (804), a heat exchange core (801) is arranged above the housing (804), an air outlet (810) arranged on the side of the heat exchange core (801) is connected to an air regulating valve (7), and the air regulating valve (7) is connected to the first pipeline (3).

7. The metal smelting reverberatory furnace system with waste heat recovery according to claim 6, characterized in that: The plurality of inner heat exchange tubes (802) arranged in the heat exchange core (801) extend downward into the outer heat exchange tube (803).

8. The metal smelting reverberatory furnace system with waste heat recovery according to claim 7, characterized in that: The air inlet (807) provided on the heat exchange core (801) is connected to the second pipe (9), and the second pipe (9) is connected to the air outlet of the fan (10).

9. The metal smelting reverberatory furnace system with waste heat recovery according to claim 8, characterized in that: A smoke outlet (808) is provided above the housing (804), a smoke inlet (809) is provided below the housing (804) and is connected to the reverberatory furnace (4) via a smoke duct, and a heat-insulating cone (806) and supporting legs (805) are provided below the housing (804).

10. The metal smelting reverberatory furnace system with waste heat recovery according to claim 6, characterized in that: The air regulating valve (7) comprises an air flange body (701) and a branch flange body (715); an upper shaft sleeve body (702) is provided on the air flange body (701); a transmission shaft (709) is provided in the upper shaft sleeve body (702); the upper part of the transmission shaft (709) is connected to the electric actuator (705); a bracket (704) is provided between the electric actuator (705) and the upper shaft sleeve body (702); and a support (704) is provided between the upper shaft sleeve body (702) and the transmission shaft (709). A gasket (706), a skeleton oil seal (707), and a sealing member (708) are provided. A reinforcing rib (710) and a valve plate (711) are provided at the lower portion of the transmission shaft (709). A connecting sleeve (714) is provided between the transmission shaft (709) and the valve plate (711). A baffle body (716) is provided below the valve plate (711). A slot (717) is provided on the baffle body (716). A partition (712) and a bottom plate (713) are provided below the baffle body (716).

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