Ingot Mould Melting and Solidification Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing processes for producing metal ingots by melting and solidification are energy-intensive and inefficient, leading to economic losses and safety concerns due to metal losses during pouring and the need for high energy consumption to heat molds from ambient temperature.
Innovation Solution
A process and apparatus where metal ingots are produced by melting a solid metal charge directly in the ingot moulds, with specific temperature control steps to minimize energy consumption, including heating to a temperature higher than the melting point and cooling to a temperature below the melting point but above ambient for solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the metal charge is melted directly in the ingot mould (melting and pouring process), then energy expenditure is reduced, but metal losses occur during pouring operations
Solution Approach 1:
The patent combines the melting and solidification operations into a single integrated process by melting the metal charge directly in the ingot mould. This eliminates the separate pouring operation, thereby preventing metal losses while maintaining energy efficiency. The mould serves dual functions as both the melting chamber and the solidification container.
2Ease of operation
If the metal charge is melted directly in the ingot mould, then safety measures are simplified, but energy consumption increases to heat moulds from ambient temperature
Solution Approach 1:
The patent implements continuous production by maintaining the ingot moulds at elevated temperatures between cycles. The moulds are heated to melting temperature, used for melting and solidification, then quickly cooled for extraction and refilling, and immediately reheated for the next cycle. This continuous operation eliminates the need to heat cold moulds from ambient temperature, significantly reducing energy consumption while maintaining safety.
3Ease of operation
If the moulds are cooled to ambient temperature after solidification, then handling safety is improved, but production efficiency decreases due to recirculation time
Solution Approach 1:
The patent employs periodic action by rapidly cooling the moulds to extraction temperature after solidification, extracting the ingot, and immediately preparing the mould for the next cycle. The moulds are cooled only to the necessary extraction temperature (not full ambient cooling), then quickly reheated for the next melting operation. This periodic heating-cooling-extraction cycle maintains handling safety while minimizing downtime and maximizing production efficiency.
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 process achieves significant energy savings of up to 50% compared to traditional methods, enhances production efficiency, and ensures high-quality ingots that meet industry standards, while also simplifying the apparatus design and reducing operational costs.
Implementation Method 1
heating an ingot mould filled with a metal charge in the solid state up to a heating temperature Trs that is higher than or equal to the melting temperature Tf of said metal charge until the metal charge melts
Implementation Method 2
cooling an ingot mould containing said molten metal charge to a cooling temperature Trf that is lower than said melting temperature Tf and higher than ambient temperature Ta until said molten metal charge is solidified
Data Source
Figure 1
Figure 2A~2C
Figure 2D~2F
AI summary
A process for producing metal ingots (L) comprising at least the following steps: a) filling at least one ingot mould (11) with at least one metal charge (CM) in the solid state for the formation of at least one respective ingot (L), wherein said metal charge (CM) has a melting temperature (Tf) that is higher than ambient temperature (Ta), b) melting said at least one metal charge (CM) in the solid state by heating said at least one ingot mould (11) filled with said at least one metal charge (CM) in the solid state up to a heating temperature (Trs) that is higher than or equal to the melting temperature (Tf) of said at least one metal charge (CM) until the metal charge melts, c) solidifying or letting solidify said at least one molten metal charge (CM) into a respective ingot (L) by cooling or letting cool said at least one ingot mould (11) containing said at least one molten metal charge (CM) to a cooling temperature (Trf) that is lower than said melting temperature (Tf) and higher than ambient temperature (Ta) until said molten metal charge (CM) is solidified into said respective ingot (L), d) extracting said ingot (L) from said at least one ingot mould (11), e) reiterating said steps from a) to d), wherein, at steady state, said extracting d) and filling a) steps are carried out when said at least one ingot mould (11) is respectively at an extraction temperature (Te) and at a filling temperature (Trp) each of which is lower than or equal to said cooling temperature (Trf) and higher than said ambient temperature (Ta).