Melting device and melting method
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Solution Overview
Problem
Existing flexible tank systems require significant effort and cost to install heat exchangers due to the need for custom-made valves with larger diameters, as conventional pipes cannot be easily inserted through standard valves.
Innovation Solution
A double pipe system is used, where the inner pipe serves as a discharge pipe and the outer pipe as a suction pipe, allowing the entire inner pipe to function as a flow path for the melt, enabling discharge without enlarging the diameter, and the system can be easily attached to standard valves without removing existing ones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single large melting furnace is used to melt large-volume ingots, then the melting capacity is sufficient, but the heat efficiency is low and energy consumption is high
Solution Approach 1:
The invention divides the melting process into multiple smaller melting furnaces instead of using one large furnace. Each small furnace melts a portion of the total charge, and the molten metal is collected in a common pool. This segmentation reduces the surface area to volume ratio for each melting zone, improving heat efficiency and reducing energy consumption while maintaining the total melting capacity.
Solution Approach 2:
The invention nests multiple smaller melting furnaces within a larger structural framework that includes a common molten metal pool. The small furnaces are positioned to discharge into the shared pool, creating a nested configuration where the individual melting zones are contained within the overall melting system. This allows efficient use of space and heat while maintaining high melting capacity.
2Loss of energy
If multiple small melting furnaces are used to improve heat efficiency, then energy consumption is reduced, but the device complexity increases
Solution Approach 1:
The invention merges multiple small melting furnaces into a unified system by providing a common molten metal pool that receives output from all furnaces. The furnaces share common structural elements, control systems, and the pooled molten metal is directed to a single refining and casting system. This merging approach maintains the energy efficiency benefits of small furnaces while reducing operational and structural complexity.
3Device complexity
If conventional melting methods are used, then the process is simple, but harmful factors such as oxidation and inclusion generation occur
Solution Approach 1:
The invention introduces an inert or reducing atmosphere into the melting furnaces to prevent oxidation of the molten metal during the melting process. The atmosphere control system maintains appropriate gas composition in each small furnace and in the common pool, eliminating harmful oxidation reactions and reducing inclusion formation while keeping the melting process relatively simple.
4Productivity
If large ingots are melted in a single furnace, then the production flow is continuous, but the casting section becomes a bottleneck
Solution Approach 1:
The invention segments the molten metal supply into multiple streams from different small furnaces, which are fed into the common pool and then distributed to multiple casting positions. This segmentation allows parallel casting operations to proceed simultaneously, eliminating the bottleneck that occurs when a single large furnace must serve all casting positions sequentially.
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
The double pipe system allows efficient discharge of the melt into the tank while maintaining a small diameter, reducing installation effort and cost, and facilitates easy detachment for maintenance, with the option to use the melt as priming oil for resumed melting.
Implementation Method 1
melting furnaces for melting charge materials
Implementation Method 2
melt the charge materials in the melting furnaces
Implementation Method 3
common molten metal pool into which the melting furnaces discharge the melted charge materials
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
Provided is a melting device for discharging a melt of a substance to the inside of a tank to melt the substance stored in the tank, the melting device being capable of discharging a desired amount of the melt into the tank, while reducing the diameter of a discharge pipe that discharges the melt of the substance. The melting device 1 of the present invention comprises a suction pipe 2 and a discharge pipe 3 that are attached to the wall T of a tank; and a circulation flow path 4 that is disposed outside the tank T. The inside of the tank T and the inside of one end 4a of the circulation flow path 4 communicate with each other through the inside of the suction pipe 2. The inside of the tank T and the inside of the other end 4b of the circulation flow path 4 communicate with each other through the inside of the discharge pipe 3. A pump 5 is provided at a midway position of the circulation flow path 4. By driving the pump 5, a melt Ma of substance M that is present inside the tank T can be suctioned into the suction pipe 2, circulated through the circulation flow path 4, and discharged from the inside of the discharge pipe 3 to the inside of the tank T; and the entirety of the inside of the discharge pipe 3 is used as a flow path for the melt Ma.