Furnaces and methods of melting

Abstract

The invention provides an improved furnace structure and methods of melting material in furnaces, particularly aimed at reducing the start up time for such furnaces. The furnace ( 2 ) defines a container for the molten metal having a maximum depth of molten metal in that container during use. A flow generator ( 30 ) for the molten metal within the furnace is fed through a first conduit ( 32 ) and supplies maternal back to the furnace through a second conduit ( 36 ). The first conduit entrance is provided in the upper 60% of the maximum depth of the molten metal in the container and/or the second conduit exit is provided in the lower 25% of the maximum depth of the molten metal in the container. The flow generator may receive material preferentially from around the periphery of the container and/or direct material towards the centre of the container. The inlet and outlet to the flow generator my be angled downwards towards the container. All of these features improve heat transfer and material circulation within the furnace.

1 . A furnace, the furnace including a container for molten metal, the container providing a maximum depth for molten metal within the container, and further including a first conduit connected to the container by an entrance and a second conduit connected to the container by an exit, the first conduit providing an inlet to a flow generator, the second conduit providing an outlet from the flow generator, wherein the first conduit entrance is provided in the, upper 60% of the maximum depth of the molten metal in the container and/or wherein the second conduit exit is provided in the lower 25% of the maximum depth of the molten metal in the container.  
   
   
       2 . A furnace according to  claim 1  in which the container has a periphery adjacent to the walls forming the container and a centre, wherein the first conduit receives molten metal from along the periphery of the container and/or wherein the second conduit directs molten metal towards the centre of the container.  
   
   
       3 . A furnace according to  claim 1  in which the container has a centre with the first conduit connected to the container by an entrance portion and the, second conduit connected to the container by an exit portion, wherein at least the entrance portion of the first conduit is angled relative to the adjoining part of the container by an angle of less than 30° and/or is angled relative to the centre of the container by an angle of at least 30° and/or wherein at least the exit portion of the second conduit is angled relative to the adjoining part of the container by an angle of at least  60 ° and/or is angled relative to the centre of the container by an angle of less than 30°.  
   
   
       4 . A furnace according to any preceding claim in which the molten metal surface is defined a plane in use, the furnace including a second conduit connected to the container by an exit portion, wherein at least the exit portion of the second conduit is angled downward by an angle of at least 2° relative to the plane of the molten metal surface.  
   
   
       5 . A furnace, preferably according to any preceding claim, the furnace including a container for molten metal, the container having a periphery adjacent to the walls forming the container and a centre, the furnace further including a first conduit connected to the container and a second conduit connected to the container, the first conduit providing an inlet to a flow generator, the second conduit providing an outlet from the flow generator, wherein the first conduit receives molten metal from along the periphery of the container and/or wherein the second conduit directs molten metal towards the centre of the container.  
   
   
       6 . A furnace, preferably according to any preceding claim, the furnace including a container for molten metal, the container having a centre, the furnace further including a first conduit connected to the container by an entrance portion and a second conduit connected to the container by an exit portion, the first conduit providing an inlet to a flow generator, the second conduit providing an outlet from the flow generator, wherein at least the entrance portion of the first conduit is angled relative to the adjoining part of the container by an angle of less than 30° and/or is angled relative to the centre of the container by an angle of at least 30° and/or wherein at least the exit portion of the second conduit is angled relative to the adjoining part of the container by an angle of at least 60° and/or is angled relative to the centre of the container by an angle of less than 30°.  
   
   
       7 . A furnace, preferably according to any preceding claim, the furnace including a container for molten metal the molten metal surface defining a plane in use, the furnace further including a first conduit connected to the container and a second conduit connected to the container by an exit portion, the first conduit providing an inlet to a flow generator, the second conduit providing an outlet form the flow generator, wherein at least the exit portion of the second conduit is angled downward by an angle of at least  2 ° relative to the plane of the molten metal surface.  
   
   
       8 . A furnace according to any preceding claim in which the flow generator is an electromagnetic pump.  
   
   
       9 . A furnace according to any preceding claim in which the first conduit entrance is provided within the upper 40% to 60% of the maximum depth.  
   
   
       10 . A furnace according to any preceding claim in which the second conduit exit is provided within lower 10% to 25% of the maximum depth.  
   
   
       11 . A furnace according to any preceding claim in which the first conduit receives molten metal preferentially from the periphery relative to other parts of the container, the periphery being the outer 15% of the container volume.  
   
   
       12 . A furnace according to any preceding claim in which the first conduit receives molten metal from the periphery from one side of the entrance to the first conduit preferentially to molten metal from the other side of the entrance to the first conduit.  
   
   
       13 . A furnace according to any preceding claim in which the second conduit directs molten metal towards the centre of the container preferentially relative to other parts of the container, the centre being the 20% of the container volume furthest from a wall of the container other than the floor of the container.  
   
   
       14 . A furnace according to any preceding claim in which the second conduit directs molten metal towards one side of the centre in preference to the other side.  
   
   
       15 . A furnace according to any preceding claim in which the first conduit entrance portion and adjoining container part define an angle of between 15° and 30°.  
   
   
       16 . A furnace according to any preceding claim in which the first conduit entrance portion and centre of the container define an angle of between 30° and 45°.  
   
   
       17 . A furnace according to any preceding claim in which the second conduit exit portion and adjoining container part define an angle of between 60° and 120°.  
   
   
       18 . A furnace according to any preceding claim in which the second conduit exit portion and centre of the container define an angle of between 5° and 25°.  
   
   
       19 . A circulation system for molten metal preferably according to any preceding claim the system including a flow generator, a first conduit connected to the flow generator and a second conduit connected to the flow generator, the end portion of the first conduit distal to the flow generator having an end face defined by a surface which is non-perpendicular relative to the axis of the end part of the first conduit and/or the end portion of the second conduit distal to the flow generator having an end face defined by a surface which is non-perpendicular relative to the axis of the end part of the second conduit, the first and second conduit end portions being different front one another.  
   
   
       20 . A furnace according to  claim 19  in which the end portion of the first conduit and I or second conduit is defined in part the radius or curve, in particular the radius or curve of the peripheral wall of the furnace with which the end face of the first conduit is to form a flush surface.  
   
   
       21 . A method of melting metal, the method including introducing a mass of solid metal to a furnace and introducing heat to the furnace to at least partially melt the metal, the furnace including a container for molten metal, the container providing a maximum depth for molten metal within the container, the furnace farther including a first conduit connected to the container by an entrance from the first conduit and a second conduit connected to the container by an exit from the second conduits the first conduit providing an inlet to a flow generator, the second conduit providing an outlet form the flow generator, the first conduit entrance being provided in the upper 60% of the maximum depth of the molten metal in the container and/or the second conduit exit being provided in the lower 25% of the maximum depth of the molten metal in the container, the flow generator moving molten metal through itself via the inlet and outlet conduits.  
   
   
       22 . A method of melting metal, preferably according to  claim 21 , the method including introducing a mass of solid metal to a furnace and introducing heat to the furnace to at least partially melt the metal, the furnace including a container for molten metal, the container having a periphery adjacent to the walls forming the container and a centre, the furnace farther including a first conduit connected to the container and a second conduit connected to the container, the first conduit providing an inlet to a flow generator, the second conduit providing an outlet form the flow generator, the flow generator moving molten metal through itself via the inlet and outlet conduits, the first conduit receiving molten metal from along the periphery of the container and/or the second conduit directing molten metal towards the centre of the container.  
   
   
       23 . A method of melting metal, preferably according to  claim 21  or  claim 22 , the method including introducing a mass of solid metal to a furnace and introducing heat to the furnace to at least partially melt the metal, the furnace including a container for molten metal, the container having a centre, the furnace further including a first conduit connected to the container by an entrance portion and a second conduit connected to the container by an exit portion, the first conduit providing an inlet to a flow generator, the second conduit providing an outlet form the flow generator, at least the entrance portion of the first conduit being angled relative to the adjoining part of the container by an angle of less than 30° and/or being angled relative to the centre of the container by a angle of at least 30° and/or at least the exit portion of the second conduit being angled relative to the adjoining part of the container by an angle of at least 60° and/or being angled relative to the centre of the container by an angle of less than 30°, the flow generator moving molten metal through itself via the inlet and outlet conduits.  
   
   
       24 . A method of melting metal, preferably according to  claim 21 ,  claim 22  or  claim 23 , the method including introducing a mass of solid metal to a furnace and introducing heat to the furnace to at least partially melt the metal, the flurnace including a container for molten metal, the molten metal- surface defining a plane, the furnace further including a first conduit connected to the container and a second conduit connected to the container by an exit portion, the first conduit providing an inlet to a flow generator, the second conduit providing an outlet form the flow generator, at least the exit portion of the second conduit being angled downward by an angle of at least 2° relative to the plane of the molten metal surface, the flow generator moving molten metal through itself via the inlet and outlet conduits.  
   
   
       25 . A method according to any of  claims 21  to  24  in which the methods cause molten metal to be withdrawn from the furnace from its periphery.  
   
   
       26 . A method according to any of  claims 21  to  25  in which the methods cause molten metal to be introduced to the furnace towards its centre.  
   
   
       27 . A method according to any of  claims 21  to  26  in which the method causes flow of molten metal from the inlet, across the floor of the container, up the walls of the container and along the periphery of the container in the upper part of the melt to the inlet.