Multi-Flame Charge Melting on Inclined Surfaces for Uniform Heating
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Solution Overview
Problem
Existing melting methods face challenges in achieving uniform and efficient heating of unmelted charges with low thermal conductivity due to uneven energy distribution from flames, leading to heterogeneous heating and reduced production rates.
Innovation Solution
A method where unmelted charges form a pile with an inclined free surface, heated by flames directed at various acute angles to create multiple impact zones at different vertical levels, with regulated power and momentum to optimize melting without damaging the pile's structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single flame is used to heat the inclined free surface of the pile, then the heating process is simple, but the energy distribution is uneven resulting in heterogeneous heating
Solution Approach 1:
The single flame is divided into multiple flames directed at different angles towards the inclined free surface of the pile. Each flame creates a specific impact zone, distributing thermal energy more uniformly across the surface. This segmentation of the heating source resolves the contradiction by maintaining operational simplicity while achieving homogeneous melting through multi-directional heating.
2Productivity
If the charging rate is increased to improve production, then productivity increases, but complete melting cannot be ensured due to heterogeneous heating
Solution Approach 1:
By segmenting the heating into multiple directed flames covering different zones of the pile, the system can maintain higher charging rates while ensuring complete melting. The multi-directional approach prevents energy concentration in specific areas, allowing the increased charge volume to be processed uniformly without compromising melting completion.
Solution Approach 2:
The heating approach transitions from a single-direction (horizontal) flame to multi-directional flames impacting the inclined surface at various angles. This dimensional change in heating orientation enables comprehensive coverage of the pile surface, ensuring that material at different positions receives adequate thermal energy even at higher charging rates.
3Device complexity
If flames are directed horizontally at the pile, then the flame geometry is simple, but the intersection with the target surface is inclined backwards reducing energy distribution to distant parts
Solution Approach 1:
The flame direction is changed from purely horizontal to multi-directional angles relative to the horizontal plane. This dimensional change in flame orientation allows the energy to be distributed more effectively across the inclined free surface, with flames directed at various angles ensuring comprehensive coverage including distant parts of the pile surface.
Solution Approach 2:
Different zones of the inclined free surface are targeted by flames with specific directional characteristics. Each flame is oriented to create an impact zone optimized for its local position on the slope, ensuring that energy distribution is adapted to the specific requirements of different areas of the pile surface.
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 enhances melting distribution, increases production efficiency, and reduces energy consumption by optimizing thermal energy use, while preventing mechanical degradation of the unmelted charges.
Implementation Method 1
the unmelted charges in the pile are heated by means of flames directed towards said inclined free surface
Implementation Method 2
Heating the inclined free surface of a pile with a single flame
Implementation Method 3
the momentum of each of these flames is regulated so that the flame impacts the free surface in its impact zone without the flame mechanically damaging the structural integrity of the pile
Data Source
AI summary
The melting method, wherein the unmelted charges form a pile 30 having a free surface 40 that is inclined relative to the vertical in the furnace 10; the unmelted charges are heated by means of flames 51, 52, 53 at a regulated power and momentum and are directed towards the free surface 40 in at least two directions α1, α2, α3 forming various acute angles θ1, θ2, θ3 with the horizontal plane so that the flames 51, 52, 53 define impact zones 41, 42, 43 on the free surface 40 that are located over at least two different vertical levels h1, h2, h3.