Multiple Flame Melting of Charge Banks for Uniform Furnace Heating
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Solution Overview
Problem
Existing melting methods in furnaces result in heterogeneous heating and imbalanced melting of unmelted charges due to uneven thermal energy distribution, leading to reduced productivity and the presence of unmelted charges in the discharged molten product, particularly when dealing with materials of low thermal conductivity.
Innovation Solution
A method involving multiple flames directed towards the inclined free surface of the unmelted charge bank to create distinct impact zones, with regulated power and momentum to ensure uniform heating and prevent mechanical damage, combined with detection and control systems to maintain the melting front's optimal position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single flame or two flames are directed towards the free surface of the bank, then the heating process is simplified, but heterogeneous heating and imbalanced melting occur
Solution Approach 1:
The heating system is segmented into multiple independent flames (at least three) directed at different locations on the free surface of the bank. Each flame creates a distinct impact zone, allowing independent control of thermal energy distribution across different sections of the bank, thereby achieving homogeneous heating without requiring an overly complex integrated system.
Solution Approach 2:
Different zones of the free surface receive tailored thermal energy from flames positioned at specific locations. The power and momentum of each flame are regulated independently to match the local heating requirements of its impact zone, ensuring that each section of the bank melts uniformly without overheating or cold spots.
2Manufacturing precision
If the free surface of the bank is moved further away from the furnace outlet, then melting homogeneity is improved, but furnace productivity is reduced
Solution Approach 1:
The position of the free surface is actively controlled by adjusting parameters of multiple flames (power, momentum, and directional angles). By dynamically modifying these parameters, the melting front is maintained at an optimal position that ensures homogeneous melting while maximizing productivity, avoiding the need to move the free surface too far from the outlet.
Solution Approach 2:
The system monitors the position and shape of the melting front and adjusts the power and momentum of each flame accordingly. This feedback mechanism allows real-time optimization of the melting process, maintaining the free surface at the ideal distance from the furnace outlet to balance homogeneity and productivity.
3Productivity
If flame power is increased to accelerate melting, then productivity increases, but thermal energy distribution becomes more uneven
Solution Approach 1:
Each flame's power is independently regulated according to the specific heating needs of its impact zone. Zones that require more energy receive higher power from their dedicated flames, while other zones receive appropriate power levels, ensuring overall uniform thermal energy distribution across the entire free surface while maintaining high productivity.
Solution Approach 2:
The power and momentum of each flame are dynamically adjusted during the melting process based on real-time conditions. This dynamic control allows the system to accelerate melting where needed while maintaining uniform thermal energy distribution across different zones, preventing both overheating and underheating.
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 the homogeneity of the melting process, increases furnace productivity, and ensures the absence of unmelted charges in the discharged product, while optimizing thermal energy use and allowing for energy recovery.
Implementation Method 1
the thermal energy required for progressively melting the solid charge in the bank is provided by one or more burners mounted in the furnace... the flames to be directed towards the bank of unmelted charges
Implementation Method 2
the distribution of the thermal energy imparted to the unmelted charges depends on the geometry of the flame and its orientation towards the target surface
Implementation Method 3
when the unmelted charges have low thermal conductivity... the particles of unmelted charges then transfer little or no heat to each other and the combustion heat received by the free surface of the bank does not reach or only slowly reaches the unmelted charges inside the bank
Data Source
AI summary
The invention relates to a melting method, in which method unmelted charges form a bank 30 resting on one side against the upstream wall 11 of the furnace 10 and having, on the opposite side, a free surface 40; the unmelted charges are heated by means of at least three flames 51, 52, 53 at a regulated power and momentum and are directed towards the free surface 40 so as to define impact zones 41, 42, 43 on this free surface 40 over at least three different distances I1, I2, I3 of one of the side walls 13, 13′ of the furnace 10.