Notched Ingot Melting Rate and Dross Reduction
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Solution Overview
Problem
The formation of dross and ingot pile formation at the bottom of the molten metal bath in coating lines leads to reduced productivity and quality issues in coated products.
Innovation Solution
A metallic ingot with a notch configuration that enhances melting rate and reduces ingot pile formation by increasing the surface area to volume ratio and facilitating easier separation and melting of ingots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the coating line productivity is increased, then more products exit the bath and more coating is deposited, but the bath level decreases more rapidly requiring higher feeding rate
Solution Approach 1:
The invention changes the geometric parameters of the ingot by introducing a notch, which modifies the surface area to volume ratio. This parameter change enables faster melting rate, allowing the bath level to be maintained without increasing feeding rate, thus resolving the contradiction between productivity and bath level maintenance
2Productivity
If the ingot melting time is reduced to increase productivity, then the coating line can process more products, but dross formation increases due to cold points in the bath
Solution Approach 1:
The notch geometry changes the thermal parameters of the ingot by increasing surface area exposure to the molten metal bath. This promotes more uniform and faster melting, reducing the formation of cold points that cause dross, while simultaneously improving productivity
3Quantity of substance
If multiple ingots are present at the tank bottom to maintain bath level, then the bath level is maintained, but ingot pile formation occurs leading to quality issues
Solution Approach 1:
The notch modification changes the melting kinetics parameter, enabling single ingots to melt faster and more completely. This eliminates the need to maintain multiple ingots at the tank bottom, preventing pile formation and associated quality problems while maintaining bath level
4Productivity
If the ingot surface area to volume ratio is increased to improve melting rate, then productivity increases, but the ingot structure becomes more complex
Solution Approach 1:
The notch introduces a segmentation feature into the ingot structure, dividing the surface into different zones with varying heat exposure. This simple geometric modification effectively increases the surface area to volume ratio and improves melting rate without requiring complex multi-component structures
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 notch configuration in the ingot significantly reduces dross formation and increases coating line productivity by improving the melting rate and preventing ingot pile formation at the tank bottom.
Implementation Method 1
the notch configuration in the ingot significantly reduces dross formation and increases coating line productivity by improving the melting rate
Implementation Method 2
the ingot is introduced little by little into the bath 2 until the ingot portion 8 where the ingot is hold melts
Data Source
Figure 1~2
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AI summary
A rectangular parallelepiped ingot defined by a height H, a width W and a length L, having longitudinal faces extending between two end faces, having a volume between 0.15 m3 and 0.80 m3 and a surface area to volume ratio between 10 m-1 and 18 m-1, made of at least one metal, comprising at least one notch and a notch tip along said ingot length, wherein said at least one notch is configured such that : - MaxD < H/2, - MaxD < W/2 and - MaxD being the maximum distance between any point of said ingot and the closest surface of said ingot.