Aluminum ingot melting and heat preservation integrated furnace for producing high-purity aluminum powder
By designing an integrated melting and heat preservation structure in an integrated aluminum ingot melting and heat preservation furnace, combined with a preheating chamber, a guide slope, and nitrogen protection, the problems of high energy consumption and low production efficiency of traditional aluminum ingot melting furnaces have been solved, achieving low-energy and high-efficiency aluminum powder production.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-21
- Publication Date
- 2026-04-14
AI Technical Summary
Traditional aluminum ingot melting and holding furnaces suffer from high energy consumption, low production efficiency, and susceptibility to pollution. In particular, the independent furnace structure leads to high energy consumption and aluminum molten material pollution, while the non-continuous operation of the furnace results in low production efficiency.
Design an integrated aluminum ingot melting and heat preservation furnace. The furnace body is equipped with a melting furnace chamber and a heat preservation furnace chamber, as well as a preheating chamber, a guide slope, a burner, and a detector to achieve continuous melting and heat preservation of aluminum ingots, reduce oxide film formation and splash loss, and use nitrogen to protect the atomization process.
This enables low-energy, high-efficiency aluminum powder production, reduces oxide film formation and metal loss, improves production continuity and efficiency, and ensures the purity and safety of molten aluminum.
Smart Images
Figure CN121855243A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of aluminum powder processing technology, and more specifically to an integrated furnace for melting and holding aluminum ingots for producing high-purity aluminum powder. Background Technology
[0002] The raw material for high-purity aluminum powder is high-purity aluminum ingots. These ingots need to be melted into molten aluminum, then held at a certain temperature for a certain period, refined, and finally atomized to form aluminum powder. Traditional aluminum ingot melting and holding furnace structures are of two types: one where the melting furnace and holding furnace are two separate furnace bodies. After the aluminum ingot is melted, it flows through a trough into the holding furnace for heat treatment before atomization. The other type uses the same furnace chamber for melting and holding. The aluminum ingot is first melted into molten aluminum at high temperature, then the heating source is adjusted to hold the molten aluminum in the melting furnace before atomization. However, the first type of furnace requires separate heating for both furnaces, resulting in high energy consumption. Furthermore, the molten aluminum is easily contaminated when flowing through the external trough, as it forms an oxide film on its surface upon contact with air, leading to oxide inclusions. The second type of furnace structure cannot continuously melt and hold the aluminum, requiring intermittent operation, resulting in lower production efficiency. Summary of the Invention
[0003] To address the existing technical problems, this invention provides an integrated aluminum ingot melting and holding furnace for producing high-purity aluminum powder. This furnace allows the molten aluminum to be transferred within the furnace, reducing contact with air to prevent the formation of an oxide film, and enables continuous melting and holding, thereby improving production efficiency.
[0004] The technical solution adopted in this invention is as follows: An integrated aluminum ingot melting and holding furnace for producing high-purity aluminum powder is provided, including a furnace body. The furnace body is sequentially connected to a melting furnace chamber and a holding furnace chamber. A preheating chamber is provided above the melting furnace chamber. A feeding port is provided at the top of the preheating chamber. A top cover is provided covering the feeding port, and a smoke exhaust pipe is provided on the top cover. A flow channel is connected to the holding furnace chamber, and an atomizer interface is provided at the outlet of the flow channel. A flow guide slope is provided at the position where the melting furnace cavity and the bottom surface of the preheating cavity are connected. A material blocking protrusion extends from the wall surface of the preheating cavity towards the flow guide slope, and a material blocking groove is formed between the material blocking protrusion and the flow guide slope. A first burner is provided in the melting furnace cavity, and a second burner is provided in the heat preservation furnace cavity.
[0005] In some embodiments, the furnace body is connected to the flow channel and a nitrogen generating mechanism is provided; the nitrogen generating mechanism includes a nitrogen generator, a nitrogen compressor and a high-pressure storage tank, the nitrogen generator is connected to the nitrogen compressor, the nitrogen compressor is connected to the high-pressure storage tank, the high-pressure storage tank is connected to the atomizer interface pipe, the nitrogen generator delivers nitrogen to the nitrogen compressor, the nitrogen compressor pressurizes the nitrogen and delivers it to the high-pressure storage tank, and the high-pressure storage tank delivers the high-pressure nitrogen to the atomizer.
[0006] In some embodiments, the first burner is positioned toward the feed slot.
[0007] In some embodiments, the second burner is vertically disposed at the top of the heat-insulating furnace cavity.
[0008] In some embodiments, the height of the feeding slot is less than the height of the aluminum ingot being fed in.
[0009] In some embodiments, a first furnace door and a second furnace door are respectively provided on both sides of the melting furnace cavity.
[0010] In some embodiments, a third furnace door is provided at the location of the heat-insulating furnace cavity.
[0011] In some embodiments, a material level detector is provided at the feeding port.
[0012] In some embodiments, a liquid level detector is provided inside the heat preservation furnace cavity.
[0013] In some embodiments, the steps for using an integrated aluminum ingot melting and holding furnace include: Open the top cover and feed a batch of aluminum ingots into the feeding port. Then close the top cover. After preheating in the preheating chamber, the aluminum ingots can be melted in a short time by the flame of the first burner. The molten aluminum flows into the aluminum channel of the melting furnace chamber. The molten aluminum in the aluminum channel is heated by the furnace wall and the radiation of the flame of the first burner. While the temperature is rising, it flows into the heat preservation furnace chamber. Set the atmosphere temperature in the heat preservation furnace chamber. The molten aluminum is heated and kept warm by the second burner in the heat preservation furnace chamber. After the molten aluminum reaches the required temperature, it is automatically maintained at this temperature. Then, it is atomized and sprayed out from the atomizer interface through the outlet of the flow channel.
[0014] The technical solution provided in this application has the following advantages compared with the prior art: This invention integrates the melting furnace chamber and the heat preservation furnace chamber into a single structure within the furnace body, allowing for continuous operation of melting and heat preservation processes, thereby improving production efficiency.
[0015] The preheating chamber and melting furnace chamber of the present invention can make full use of the convective residual heat of the heat preservation furnace chamber to preheat and melt the aluminum ingots. The melting energy consumption is low, and a medium-speed burner is provided to accelerate the melting rate.
[0016] The present invention uses a guide slope set at the bottom of the melting furnace chamber to prevent splashing of molten aluminum and semi-molten materials, thereby reducing pollution, oxide film and splash loss.
[0017] This invention ensures timely material feeding and a reasonable aluminum liquid level by setting up material level detectors and liquid level detectors, thus avoiding problems such as material shortage and aluminum overflow. Attached Figure Description
[0018] The present invention will be described by way of example and with reference to the accompanying drawings, wherein: Figure 1 It is the traditional first type of furnace body structure; Figure 2 It is the traditional second type of furnace body structure; Figure 3 This is a front view of the integrated aluminum ingot melting and holding furnace used in the production of high-purity aluminum powder according to the present invention. Figure 4 This is a side view of the integrated aluminum ingot melting and holding furnace used in the production of high-purity aluminum powder according to the present invention. Figure 5 This is a top view of the integrated aluminum ingot melting and holding furnace used in the production of high-purity aluminum powder according to the present invention.
[0019] The markings in the diagram are as follows: 1-melting furnace cavity, 2-insulating furnace cavity, 3-preheating cavity, 4-feeding port, 5-top cover, 6-flow channel, 7-atomizer interface, 8-first burner, 9-second burner, 10-guide slope, 11-material blocking protrusion, 12-material jamming groove, 13-first furnace door, 14-second furnace door, 15-third furnace door. Detailed Implementation
[0020] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be described in detail below with reference to the accompanying drawings. The description in this part is only exemplary and explanatory, and should not be used to limit the scope of protection of the present invention in any way.
[0021] It should be noted that similar labels in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.
[0022] It should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of the invention is in use. They are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. In addition, the terms "first," "second," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.
[0023] Furthermore, terms such as "horizontal," "vertical," and "sag" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.
[0024] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.
[0025] like Figure 3-5 As shown, this embodiment provides an integrated aluminum ingot melting and holding furnace for producing high-purity aluminum powder. The furnace body includes a melting chamber 1 and a holding chamber 2 connected sequentially within it. By integrating the melting chamber 1 and the holding chamber 2 into a single structure within the furnace body, melting and holding processes can be performed simultaneously, enabling continuous operation and improving production efficiency. A preheating chamber 3 is located above the melting chamber 1, with a feeding port 4 at its top. A top cover 5 covers the feeding port 4 and has an exhaust pipe on it. The holding chamber 2 is connected to a flow channel 6, with an atomizer interface 7 at its outlet. A first burner 8 is provided in the melting furnace chamber 1, and a second burner 9 is provided in the heat preservation furnace chamber 2. The heat generated by the first burner 8 melts the aluminum ingot in the melting furnace chamber 1, and the heat generated by the second burner 9 keeps the molten aluminum in the heat preservation furnace chamber 2 warm. A guide slope 10 is provided at the position where the bottom surface of the melting furnace chamber 1 connects with the preheating chamber 3. A baffle protrusion 11 extends from the wall of the preheating chamber 3 in the direction of the guide slope 10. A material-blocking groove 12 is formed between the baffle protrusion 11 and the guide slope 10. The height of the material-blocking groove 12 is less than the height of the aluminum ingot, which can effectively block the aluminum ingot.
[0026] In this embodiment, the melting furnace chamber 1 and the heat preservation furnace chamber 2 are integrated into the furnace body. During operation, aluminum ingots are fed into the melting furnace chamber 1 through the feeding port 4 of the top cover 5. The top cover 5 with a smoke exhaust pipe allows for smoke exhaust while keeping the preheating chamber 3 warm during non-feeding periods. At the same time, the guide slope 10 at the bottom of the melting furnace chamber 1 forms a narrowing structure at the bottom of the melting furnace chamber 1. The material-holding groove 12 formed between the material-blocking protrusion 11 and the guide slope 10 ensures that the fed aluminum ingots are held in place and do not fall. The heat generated by the first burner 8 melts the suspended aluminum ingots. The first burner 8 is positioned directly opposite the material-holding groove 12. Combined with the preheating effect in the preheating chamber 3, the first burner 8 can melt the aluminum ingots in a short time, reducing heat loss.
[0027] This application can make full use of the convective residual heat of the holding furnace chamber 2 to preheat and melt the aluminum ingots through the preheating chamber 3 and the melting furnace chamber 1, resulting in low melting energy consumption, and is equipped with a medium-speed burner to accelerate the melting rate.
[0028] When using this device, open the top cover 5, put a batch of aluminum ingots into the feeding port 4, and then close the top cover 5. After the preheating effect of the preheating chamber 3, the aluminum ingots can be melted in a short time by the flame of the first burner 8. The molten aluminum flows into the aluminum channel of the melting furnace chamber 1. The aluminum in the aluminum channel is heated by the furnace wall of the furnace body and the radiation of the flame of the first burner 8, and flows into the heat preservation furnace chamber 2 while the temperature is rising. Set the atmosphere temperature in the heat preservation furnace chamber 2. The aluminum liquid is heated and kept warm in the heat preservation furnace chamber 2 by the second burner 9. After the aluminum liquid reaches the required temperature, it is automatically maintained at this temperature and then atomized and sprayed out from the outlet of the flow channel 6 through the atomizer interface 7.
[0029] During this process, the aluminum ingot is preheated as it descends in the preheating chamber 3, reaching a temperature of 350-400℃ when it reaches the melting furnace chamber 1. This greatly reduces fuel consumption. The aluminum ingot is then melted directly in the melting furnace chamber 1 by the flame of the first burner 8, which is very close to the burner. The molten aluminum flows into the aluminum channel of the melting furnace chamber 1 in a direction perpendicular to the burner. The molten aluminum in the aluminum channel is heated by the radiation of the furnace wall and the flame of the first burner 8, and flows into the heat preservation furnace chamber 2 while the temperature rises.
[0030] By combining the preheating effect inside the furnace, the first burner 8 flame can melt the aluminum ingot in a short time. Because the aluminum ingot is in contact with high temperature for a very short time, the oxidation rate can be greatly reduced and metal loss can be reduced.
[0031] In this application, the first burner 8 adopts a medium-speed burner and is combined with the guide slope 10, so that the aluminum liquid and semi-molten material will not splash. In addition, by selecting appropriate furnace materials, the aluminum liquid can flow smoothly into the heat preservation furnace cavity 2, thereby reducing the loss of aluminum liquid splashing.
[0032] In order to reduce metal loss and slag formation caused by oxidation, the atmosphere temperature of the heat preservation chamber 2 is set to the optimal value so that the heat transfer area of the aluminum liquid surface is at the optimal value, thereby reducing oxidation.
[0033] Subsequently, the molten aluminum formed after the aluminum ingots are melted in the melting furnace chamber 1 flows naturally from the guide slope 10 to the heat preservation furnace chamber 2. The heat generated by the second burner 9 keeps the molten aluminum in the heat preservation furnace chamber 2 warm. The second burner 9 is vertically set at the top of the heat preservation furnace chamber 2. The heat generated by the second burner 9 acts directly on the upper surface of the molten aluminum to prevent it from oxidizing. This allows for continuous operation of melting and heat preservation inside the furnace, improving production efficiency. Furthermore, the molten aluminum is directly transferred inside the furnace, reducing contact with air and the formation of an oxide film.
[0034] The molten aluminum is heated and kept warm in the heat-preserving furnace chamber 2 by the second burner 9. After the molten aluminum reaches the required temperature, it is automatically maintained at this temperature before being discharged. The temperature control accuracy of the molten aluminum can reach ±20℃.
[0035] This application uses a guide slope 10 at the bottom of the melting furnace chamber 1 to prevent splashing of molten aluminum and semi-molten materials, thereby reducing pollution, oxide film, and splashing losses.
[0036] Finally, the molten aluminum in the heat preservation furnace chamber 2 flows through the flow channel 6 and is then sprayed at high speed from the atomizer interface 7 at the outlet of the flow channel 6 to complete the atomization and production of aluminum powder.
[0037] In this application, a first furnace door 13 and a second furnace door 14 are respectively provided on both sides of the melting furnace chamber 1 for cleaning and process treatment of the furnace chamber. A third furnace door 15 is provided at the position of the heat preservation furnace chamber 2 for cleaning treatment of molten aluminum and other process treatment. The first furnace door 13, the second furnace door 14 and the third furnace door 15 make daily operation and maintenance simpler and more convenient, without any blind spots.
[0038] Furthermore, a material level detector is installed at the feeding port 4. When the material level in the preheating chamber 3 drops, a feeding permission status indicator light will notify the material to be fed in, so that the material pile is always kept at the full level, which improves the filling efficiency in the preheating chamber 3. In addition, a liquid level detector is installed in the heat preservation furnace chamber 2. Once the liquid level detector detects that the aluminum liquid level has reached the upper limit position, the first burner 8 will stop burning to prevent overflow and ensure safety.
[0039] In another embodiment, a nitrogen generating mechanism is provided in connection with the furnace body and the flow channel 6; the nitrogen generating mechanism includes a nitrogen generator, a nitrogen compressor and a high-pressure storage tank. The nitrogen generator is connected to the nitrogen compressor, the nitrogen compressor is connected to the high-pressure storage tank, and the high-pressure storage tank is connected to the atomizer interface pipe. The nitrogen compressor pressurizes the nitrogen and delivers it to the high-pressure storage tank, and the high-pressure storage tank delivers the high-pressure nitrogen to the atomizer, so that the entire process of injection and atomization is under nitrogen protection.
[0040] The above are merely preferred embodiments of the present invention and do not limit the patent scope of the present invention. Any equivalent structural transformations made under the concept of the present invention using the description and drawings of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.
Claims
1. An integrated furnace for melting and holding aluminum ingots to produce high-purity aluminum powder, characterized in that, The furnace includes a furnace body, which is connected in sequence to form a melting furnace chamber and a heat preservation furnace chamber. A preheating chamber is provided above the melting furnace chamber. A feeding port is provided at the top of the preheating chamber. A top cover is provided to cover the feeding port, and a smoke exhaust pipe is provided on the top cover. A flow channel is connected to the heat preservation furnace chamber, and an atomizer interface is provided at the outlet of the flow channel. A flow guide slope is provided at the position where the melting furnace cavity and the bottom surface of the preheating cavity are connected. A material blocking protrusion extends from the wall surface of the preheating cavity towards the flow guide slope, and a material blocking groove is formed between the material blocking protrusion and the flow guide slope. A first burner is provided in the melting furnace chamber, and a second burner is provided in the heat preservation furnace chamber.
2. The integrated aluminum ingot melting and holding furnace for producing high-purity aluminum powder according to claim 1, characterized in that, The furnace body is connected to the flow channel and is equipped with a nitrogen generating mechanism; the nitrogen generating mechanism includes a nitrogen generator, a nitrogen compressor and a high-pressure storage tank, the nitrogen generator is connected to the nitrogen compressor, the nitrogen compressor is connected to the high-pressure storage tank, and the high-pressure storage tank is connected to the atomizer interface pipe.
3. The integrated aluminum ingot melting and holding furnace for producing high-purity aluminum powder according to claim 1, characterized in that, The first burner is positioned toward the feed groove.
4. The integrated aluminum ingot melting and holding furnace for producing high-purity aluminum powder according to claim 1, characterized in that, The second burner is vertically positioned at the top of the heat-insulating furnace cavity.
5. The integrated aluminum ingot melting and holding furnace for producing high-purity aluminum powder according to claim 1, characterized in that, The height of the feeding slot is less than the height of the aluminum ingot being fed in.
6. The integrated aluminum ingot melting and holding furnace for producing high-purity aluminum powder according to claim 1, characterized in that, A first furnace door and a second furnace door are respectively provided on both sides of the melting furnace cavity.
7. The integrated aluminum ingot melting and holding furnace for producing high-purity aluminum powder according to claim 1, characterized in that, A third furnace door is provided at the location of the heat preservation furnace cavity.
8. The integrated aluminum ingot melting and holding furnace for producing high-purity aluminum powder according to claim 1, characterized in that, A material level detector is installed at the feeding port.
9. The integrated aluminum ingot melting and holding furnace for producing high-purity aluminum powder according to claim 1, characterized in that, A liquid level detector is installed inside the insulation furnace cavity.
10. The integrated aluminum ingot melting and holding furnace for producing high-purity aluminum powder according to any one of claims 1-9, characterized in that, The operating steps of the integrated aluminum ingot melting and holding furnace include: Open the top cover and feed a batch of high-purity aluminum ingots into the feeding port. Then close the top cover. After preheating in the preheating chamber, the aluminum ingots can be melted in a short time by the flame of the first burner. The molten aluminum flows into the aluminum channel of the melting furnace chamber. The molten aluminum in the aluminum channel is heated by the furnace wall and the radiation of the flame of the first burner. While the temperature is rising, it flows into the holding furnace chamber. Set the atmosphere temperature in the holding furnace chamber. The molten aluminum is heated and held in the holding furnace chamber by the second burner. After the molten aluminum reaches the required temperature, it is automatically maintained at this temperature. The aluminum is then atomized and sprayed out from the atomizer interface through the outlet of the flow channel.