Induction Heater for Metallurgical Spout Freezing
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Solution Overview
Problem
The existing slide closure systems on metallurgical vessels, such as copper anode furnaces, face issues where the melt in the spout channel can freeze when the closure is closed or restricted, leading to operational interruptions and rapid wear of refractory materials, requiring manual drilling and melting with a lance.
Innovation Solution
A removable induction heater with an induction coil surrounding the refractory inner casing is provided to keep the melt warm, preventing freezing and allowing controlled melting, along with a cooling system to prevent overheating and a supporting body with a graphite insert to enhance heating efficiency and protect the inner casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the slide closure is closed or greatly restricted, then the melt flow is controlled, but the melt in the spout channel freezes
Solution Approach 1:
The induction heater is activated before closing the slide closure to preheat the melt in the spout channel, preventing freezing during the subsequent closure period. This preliminary heating action ensures the melt remains liquid and operational capability is maintained even when the closure is closed or restricted for extended periods.
Solution Approach 2:
The induction heater provides continuous heating to the melt in the spout channel throughout the pouring process, ensuring uninterrupted melting action. This continuous thermal input prevents the melt from freezing during closure periods and maintains operational capability without interruption.
2Productivity
If the slide closure is open, then the melt flows freely, but the melt freezes in the spout channel
Solution Approach 1:
The induction heater operates continuously during the pouring process to maintain melt temperature in the spout channel, ensuring the melt remains liquid and flowable even when the slide closure is open and melt is actively pouring through the system.
3Reliability
If a plugging mass is used to close the outlet channel, then the spout is sealed, but rapid wear of refractory materials occurs
Solution Approach 1:
The mechanical action of drilling out plugging mass and using lances for melting is replaced by an electromagnetic induction heating system. The induction heater melts frozen melt and slag through electromagnetic induction, eliminating the need for mechanical drilling and lance-based melting, thereby preventing rapid wear of refractory materials while maintaining spout sealing capability.
4Strength
If the induction coil is surrounded by the furnace lining, then the coil is protected, but the coil overheats
Solution Approach 1:
A water-cooled copper braid is introduced as an intermediary between the induction coil and the refractory lining. This braid serves dual functions: it provides thermal coupling to transfer induction heating energy to the melt, while simultaneously acting as a heat sink through water cooling to prevent the coil from overheating, thus protecting the coil while enabling effective heating.
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 solution ensures continuous operational capability during pouring, extends the service life of refractory materials, eliminates the need for plugging masses and lance-based melting, and allows for targeted solidification and protection against rupture.
Implementation Method 1
a removable induction heater, having at least one induction coil at least partially surrounding the at least one refractory inner casing outside of and/or within the housing
Implementation Method 2
the induction coil at least partially surrounding the at least one refractory inner casing... the melt located in the outlet channel of the spout sufficiently warm
Implementation Method 3
the induction coil is embedded in a supporting body made of ferritic material and that the cooling system is provided with a cooling chamber that encloses the supporting body peripherally
Implementation Method 4
the cooling system is provided with a cooling chamber that encloses the supporting body peripherally and with a cooling chamber adjacent to the side wall of the supporting body directed towards the furnace
Implementation Method 5
an annular insert having appropriate electrical and thermal properties, such as for example made of graphite or material containing graphite
Implementation Method 6
an annular insert having appropriate electrical and thermal properties... the heating effect of the induction coil upon the melt and/or the slag located within the spout channel is thus increased
Data Source
AI summary
Slide closure unit on the spout of a metallurgical vessel, preferably a copper-anode furnace, includes a housing in which refractory closure plates, as well as at least one connecting refractory inner casing, are arranged. A removable induction heater is provided, having at least one induction coil surrounding the refractory inner casing outside of the housing. In this way, it is possible to constantly keep the melt located in the outlet channel of the spout sufficiently warm so that it does not freeze before and/or during the pouring of the melt, or that any frozen metal and/or slag can be melted in the spout.