Induction Heating Storage Bin for Molten Iron Thermal Loss
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Solution Overview
Problem
The blast furnace process for molten iron production incurs high investment and manufacturing costs due to the need for additional facilities and environmental pollution control, and the direct iron ore smelting reduction process experiences significant thermal losses during the transportation of high-temperature reduced iron, leading to increased fuel costs.
Innovation Solution
A molten iron manufacturing apparatus and method that includes a gasification melting furnace, a reducing furnace, a storage bin with an induction heating device, and an electric power generating device to recover energy from exhaust gases, which supplies heat to agglomerated reduced iron to compensate for thermal losses and reduce coal consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the direct iron ore smelting reduction process is used to avoid additional facilities and environmental control costs, then investment costs are reduced, but thermal loss during HCI transportation increases fuel costs
Solution Approach 1:
The patent applies preliminary action by heating the HCI in advance within the storage bin using an induction heating device before it is conveyed to the gasification melting furnace. This pre-heating compensates for the thermal loss that will occur during transportation, thereby reducing the fuel consumption needed in the melting furnace while maintaining the cost-effective direct smelting reduction process
2Adaptability or versatility
If HCI is conveyed over a long distance to the gasification melting furnace, then the direct iron ore smelting reduction process can be implemented, but temperature decreases by about 200°C causing increased fuel consumption
Solution Approach 1:
The storage bin equipped with induction heating performs preliminary heating of the HCI before conveyance. This ensures that even after long-distance transportation and the expected 200°C temperature drop, the HCI maintains sufficient temperature for efficient melting, preserving process flexibility while mitigating temperature loss
Solution Approach 2:
The patent replaces the conventional thermal conduction heating method with induction heating technology in the storage bin. This electromagnetic heating method provides more efficient and controllable temperature maintenance during the storage and conveyance process, better preserving HCI temperature over long distances
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 improves thermal efficiency and reduces coal consumption, thereby lowering working costs and enhancing the overall efficiency of the molten iron manufacturing process.
Implementation Method 1
a heat supply device which is installed on the storage bin and supplies heat to the reduced iron in the storage bin
Implementation Method 2
an electric power generating device which is connected to the reducing furnace and recovers energy of exhaust gas discharged from the reducing furnace
Data Source
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AI summary
Disclosed are a molten iron manufacturing apparatus and a molten iron manufacturing method, and the molten iron manufacturing apparatus may include: a gasification melting furnace into which reduced iron and a lump carbon material are inputted to manufacture molten iron; a reducing furnace which is connected to the gasification melting furnace and manufactures reduced iron powder from fine iron ore by using reducing gas discharged from the gasification melting furnace; a storage bin which is connected to the gasification melting furnace and provides the reduced iron to the gasification melting furnace; and a heat supply device which is installed on the storage bin and supplies heat to the reduced iron in the storage bin.