Disposable Wire-Mesh Scrap Containers for Furnace Charging
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Solution Overview
Problem
Conventional methods for collecting and delivering scrap materials to furnaces result in a significant percentage of inert materials and undesirable metals being introduced, leading to off-specification final products, inefficiencies in the melting process, and maintenance challenges with scrap buckets.
Innovation Solution
A method involving pre-packaged charges in disposable metal containers made of interconnecting wire, allowing contaminants to be removed through gaps, and attachment members for lifting and releasing into furnaces, ensuring segregated and clean scrap delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional methods of collecting and delivering scrap are used, then scrap can be delivered to furnaces, but approximately 25-40% of the charge becomes inert material and undesirable metals
Solution Approach 1:
The scrap charging process is segmented into separate functional components: the disposable container holds and transports the scrap, while the gaps in the container structure allow inert materials to be separated during delivery. This segmentation enables the scrap to be delivered while simultaneously removing contaminants.
Solution Approach 2:
Inert materials and undesirable metals are extracted from the scrap charge by allowing them to fall through the gaps in the disposable container during transport and positioning over the furnace. This extraction occurs before the scrap is charged into the furnace, ensuring cleaner material input.
2Object-affected harmful factors
If disposable metal containers with gaps are used for scrap delivery, then contaminants are removed, but the container structure must be designed with interconnecting wires and attachment members
Solution Approach 1:
The container is designed as a disposable unit made from inexpensive metal containers with interconnecting wires forming a gap structure. After use, the container is discarded along with any remaining scrap, eliminating the need for complex cleaning and maintenance of permanent containers. The simplicity of the disposable structure reduces overall system complexity.
Solution Approach 2:
The container structure incorporates gaps formed by interconnecting wires, creating a porous-like structure that allows inert materials to pass through while retaining the scrap. This gap structure achieves the separation function without requiring complex filtering mechanisms.
3Object-affected harmful factors
If pre-packaged charges are used, then nearly 100% clean scrap is delivered, but additional steps for forming and handling pre-packaged charges are required
Solution Approach 1:
The scrap is pre-packaged in disposable containers at a location remote from the furnace, allowing contaminants to be removed in advance during the forming process. This preliminary action ensures clean scrap delivery while enabling the main furnace operation to focus on melting rather than sorting and cleaning.
Solution Approach 2:
The disposable container structure serves multiple functions simultaneously: it holds the scrap, provides the gap structure for contaminant removal, and acts as the charging vehicle. This self-service approach reduces the need for separate handling equipment and simplifies the overall process.
4Productivity
If conventional scrap buckets are used, then scrap can be charged into furnaces, but maintenance challenges arise from contaminants and debris
Solution Approach 1:
The disposable container is used for scrap delivery and charging, then discarded after a single use. This eliminates the accumulation of contaminants and debris in permanent furnace charging equipment, significantly reducing maintenance requirements and improving ease of repair for the furnace system.
Solution Approach 2:
Inert materials and contaminants are extracted from the scrap charge by allowing them to fall through the gaps in the disposable container before charging. This pre-removal of contaminants prevents them from entering the furnace, thereby reducing wear and maintenance needs on furnace components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures nearly 100% clean scrap is delivered, reducing energy loss, maintaining furnace efficiency, and minimizing maintenance needs by eliminating contaminants and debris, thereby improving the quality and yield of the final product.
Implementation Method 1
the pre-packaged charge is free of dirt, debris and other contaminants which freely drop through the plurality of gaps defined in the container
Implementation Method 2
the method can include melting the disposable metal container with the scrap material
Data Source
AI summary
A method of charging a pre-packaged charge in a metallurgical or refining furnace includes providing a disposable metal container having at least one attachment member and forming a pre-packaged charge by loading scrap material into the metal container. The method also includes releasably coupling the at least one attachment member of the container to a lifting device, and then de-coupling the pre-packaged charge from the lifting device so that the combination of the scrap material and the disposable metal container are charged in the furnace.