Step-by-step Electrode Insertion for Low-impurity Regenerated Brass
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Solution Overview
Problem
Existing methods for producing regenerated brass alloys face challenges such as high energy consumption, high production costs, and the introduction of new impurities during impurity removal through slag formation, which hinder efficient purification and meet industrial green development requirements.
Innovation Solution
A device and method utilizing an electric field-assisted melt purification technology with a graphite electrode that is step-by-step inserted into a brass melt under a pulse current, creating a current density gradient to drive impurity elements vertically, thereby enhancing purification efficiency and reducing impurity content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrolytic tank with DC electric field is used for copper powder production, then waste copper material can be electrolyzed into electrolytic copper powder meeting national standards, but energy consumption is high and production cost is high
Solution Approach 1:
The patent employs periodic pulse current instead of continuous DC current. The pulse current parameters include frequency of 50-1000 Hz, duty cycle of 10-90%, and pulse width of 0.1-10 ms. This periodic action reduces energy consumption while maintaining effective impurity removal through intermittent electromagnetic stirring and electromigration effects.
Solution Approach 2:
The patent changes the electrical parameters from continuous DC to pulsed current with variable frequency, duty cycle, and pulse width. Additionally, the electrode insertion depth is dynamically adjusted (0-500mm) to optimize the current density distribution in the melt, thereby reducing energy consumption while maintaining purification effectiveness.
2Manufacturing precision
If refining agent is used for impurity removal through slag formation, then iron content in copper alloy can be reduced to 0.1% or lower, but new impurity elements are introduced and matrix metals Cu and Zn are oxidized
Solution Approach 1:
The patent replaces the chemical refining method (using refining agents) with a physical method based on electromagnetic field. The pulse current generates electromagnetic stirring and electromigration effects that separate impurities from the melt without chemical reactions, thus avoiding introduction of new impurities and oxidation of matrix metals.
Solution Approach 2:
The patent introduces a graphite electrode as an intermediary that generates electromagnetic fields in the melt. This electromagnetic field acts as a mediator to drive impurity removal through electromigration and electromagnetic stirring, replacing the need for chemical refining agents.
3Manufacturing precision
If electrode is directly inserted at bottom for pulse current treatment, then impurity elements can migrate in vertical direction, but current density gradient is insufficient due to large-volume melt size effect
Solution Approach 1:
The patent segments the electrode insertion process into multiple stages with different insertion depths (0-500mm). By progressively inserting the electrode to different depths and holding at each stage, the current density gradient is optimized at different locations in the melt, enhancing overall impurity removal efficiency despite large melt volume.
Solution Approach 2:
The patent employs dynamic electrode insertion and withdrawal during pulse current treatment. The electrode position is adjusted in real-time (0-500mm depth control) to maintain optimal current density distribution as the melt responds to electromagnetic stirring, thereby enhancing impurity migration 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
This approach enables a short, cost-effective, and energy-efficient process for producing low-impurity regenerated brass alloys, suitable for large-scale continuous production, with high impurity removal rates and compliance with industrial green development standards.
Implementation Method 1
utilizing an electric field-assisted melt purification technology with a graphite electrode that is step-by-step inserted into a brass melt under a pulse current, creating a current density gradient to drive impurity elements vertically
Implementation Method 2
the melt heating apparatus includes a heating source, a metal melt, and a melting pool
Data Source
AI summary
A device and method for preparing a low-impurity regenerated brass alloy through step-by-step insertion of an electrode are provided. The device includes a melt heating apparatus, an electrode displacement apparatus, and a pulse current generation apparatus. The automatic electrode lifting apparatus is controlled to adjust an insertion depth of the graphite electrode plate in the metal melt, and the pulse current generation apparatus is controlled to adjust the parameters of pulse current to achieve the impurity reduction on the metal melt. The preparation of a low-impurity regenerated brass alloy involves a short production process, simple operations, low energy consumption, and high impurity removal efficiency, and is suitable for regeneration and large-scale continuous production of non-ferrous metal alloys.