Vortexing Chamber Layout for Submerging Floating Lead Scrap
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Solution Overview
Problem
Existing methods struggle to efficiently melt and separate pure lead from thin-walled lead scrap pieces in lead acid batteries due to their tendency to float on molten metal, leading to contamination and inefficiencies in the recycling process.
Innovation Solution
A system and process utilizing a vortexing chamber with a dross dam and circulation pump to introduce lead scrap into a molten lead bath, separating contaminants through a dross well and ensuring rapid submergence and melting of lead pieces, followed by removal of clean molten lead for further processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If lead scrap pieces are introduced into a molten lead bath, then the lead can be melted and recycled, but thin-walled scrap pieces float on the molten metal causing contamination and inefficiency
Solution Approach 1:
A vortexing chamber acts as an intermediary device between the lead scrap input and the molten lead bath. The chamber creates a controlled vortex flow that forces scrap pieces to submerge properly before entering the bath, mediating the interaction between floating scrap and molten metal to eliminate contamination while maintaining recycling efficiency
Solution Approach 2:
The system changes the flow parameters of molten lead by creating a vortex pattern with controlled velocity and direction. This parameter change transforms the stagnant or simple flow into a dynamic vortex that actively pushes scrap pieces underwater, resolving the floating issue without compromising the melting process
2Productivity
If a vortexing chamber is added to force scrap submergence, then lead recycling efficiency improves, but system complexity increases
Solution Approach 1:
The vortexing chamber is merged with the existing molten lead bath system, combining the submergence function and melting function into a single integrated apparatus. This reduces overall system complexity compared to having separate submergence and melting devices, while still achieving improved recycling efficiency
Solution Approach 2:
The vortexing chamber serves multiple functions: it forces scrap submergence, creates controlled flow patterns, and facilitates the transition from solid scrap to molten state. This multi-functionality reduces the need for additional separate devices, offsetting the added complexity with functional consolidation
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
Enhances the efficiency of lead recycling by effectively melting thin-walled scrap pieces and separating contaminants, reducing costs and improving the overall recycling process efficiency.
Implementation Method 1
A vortexing chamber with a dross dam and circulation pump to introduce lead scrap into a molten lead bath
Implementation Method 2
separating contaminants through a dross well
Implementation Method 3
ensuring rapid submergence and melting of lead pieces
Data Source
AI summary
A system for melting lead scrap pieces. The system includes a vessel. A vortexing chamber is disposed in the vessel. The vortexing chamber includes an inlet, an outlet and an open top configured to receive lead pieces. A pump is disposed in the vessel and directs molten lead to the inlet of the vortexing chamber. A dross dam divides the vessel into a first region and a second region. The vortexing chamber is disposed in the second region and a conduit extends between the vortexing chamber outlet and the first region. A transfer pump is disposed in the second region and is configured for removal of molten lead from the vessel. The system allows dross to be skimmed from a surface of the molten lead bath in the first region.