Mobile Loading Plane for Furnace First Charge Distribution
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Solution Overview
Problem
Current metal melting processes, particularly in electric arc furnaces, require complex and costly procedures for the initial charge, involving baskets and additional equipment, which prolong the melting cycle and increase operational costs due to the need for specific loading systems and inefficient distribution of scrap material.
Innovation Solution
A mobile loading plane on a connection conveyor system that can assume different positions within the furnace, allowing for the first charge to be introduced and distributed evenly without the need for baskets, using vibration, inclination, and trap doors to control the unloading and distribution of material, and incorporating additives like coal for improved melting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a basket loading system is used for the first charge, then the furnace bottom can be properly covered and distributed, but the melting cycle becomes longer and equipment complexity increases
Solution Approach 1:
The connection conveyor is designed to perform multiple functions: it serves both for continuous loading during normal operation and for the first charge distribution when positioned in the retracted state. This eliminates the need for separate basket equipment while maintaining proper charge distribution capability.
Solution Approach 2:
The connection conveyor is made mobile with selective positioning capability - it can be positioned flush with the furnace wall for continuous loading or retracted inside the furnace volume for first charge distribution. This dynamic repositioning allows a single device to replace multiple specialized loading systems.
2Reliability
If a basket loading system is used for the first charge, then the furnace can be properly initialized, but the melting cycle time increases
Solution Approach 1:
The system enables continuous loading operation without interrupting the cycle for separate first charge operations. The connection conveyor remains in position throughout, allowing material to be continuously fed while the furnace processes the first charge, thereby eliminating idle time associated with basket loading and repositioning operations.
Solution Approach 2:
The connection conveyor is positioned and prepared in advance within the furnace volume before the first charge is introduced. This preliminary positioning eliminates the time required for basket insertion, material dumping, and equipment withdrawal during the critical furnace initialization phase.
3Quantity of substance
If basket loading is used, then the first charge can be loaded, but additional equipment and operations are required
Solution Approach 1:
The connection conveyor serves dual purposes: it functions as the continuous loading interface during normal operation and as the first charge distribution mechanism when retracted. This eliminates the need for separate basket equipment, reducing the number of operations required and simplifying the overall loading process.
Solution Approach 2:
The patent merges the first charge loading function with the continuous loading system by integrating the connection conveyor's retraction capability. This consolidation eliminates the need for separate basket loading operations, reducing operational complexity and equipment requirements while maintaining the ability to properly introduce and distribute the first charge material.
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 simplifies the initial charge process, reduces equipment usage, shortens the melting cycle, and allows for flexible distribution of scrap, enhancing the operational efficiency and cost-effectiveness by using existing continuous loading equipment and eliminating the need for pre-heating and cooling systems.
Implementation Method 1
the vibration imparted thereto determines the advance and the subsequent fall of the scrap inside the furnace
Implementation Method 2
a mobile loading plane... in order to be inserted into the melting furnace, during the first step when the melting cycle is started
Data Source
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AI summary
Device for feeding metal material (35) into a melting plant, in particular into a melting furnace (11) comprising a hearth and at least a lateral aperture, wherein the device comprises feed means (15) to feed the metal material (35) terminally associated with a connection conveyor (16) comprising a loading plane (50) and cooperating with translation and positioning means, the connection conveyor (16) being able to assume at least a first position at least during the continuous loading step, in which its front terminal end is located substantially flush with the internal wall of the furnace (11) through the aperture, so as to introduce the metal material (35) inside the furnace (11), and a second position distanced from the wall of the furnace (11), assumed at least during the tapping step of the liquid metal from the furnace (1 1). The connection conveyor (16) also has a third position, assumed in the step of first loading of the furnace, with the furnace switched off, in which the front end of its loading plane (50) is positioned inside the volume of the furnace (1 1) so as to be disposed in a position of proximity with respect to the distal internal wall opposite the proximal internal wall of the furnace, in order to unload and distribute a quantity of charge such as to cover at least part of the bottom surface of the furnace (11).