A method of melting an aluminum charge having no more that 4% salt by mass, including during a melting phase, introducing fuel and oxidant via a burner operating at a first firing rate, the fuel and oxidant reacting to form a combustion zone above the aluminum charge, terminating the melting phase and commencing a transition phase when the aluminum charge is nearly completely molten, during the transition phase, reducing the firing rate of the burner to a second firing rate lower than the first firing rate, introducing a non-oxidizing gas at a first velocity to form a non-oxidizing zone between the combustion zone and the aluminum charge, and allowing the aluminum charge to become completely molten, and terminating the transition phase and commencing a tapping phase after the aluminum charge has become completely molten, and during the tapping phase, pouring the molten aluminum charge out of the furnace.

A method of melting an aluminum charge having no more that 4% salt by mass, including during a melting phase, introducing fuel and oxidant via a burner operating at a first firing rate, the fuel and oxidant reacting to form a combustion zone above the aluminum charge, terminating the melting phase and commencing a transition phase when the aluminum charge is nearly completely molten, during the transition phase, reducing the firing rate of the burner to a second firing rate lower than the first firing rate, introducing a non-oxidizing gas at a first velocity to form a non-oxidizing zone between the combustion zone and the aluminum charge, and allowing the aluminum charge to become completely molten, and terminating the transition phase and commencing a tapping phase after the aluminum charge has become completely molten, and during the tapping phase, pouring the molten aluminum charge out of the furnace.

A molten material apparatus can include a container including a wall at least partially defining a containment area and an opening extending through the wall. The molten material apparatus can include a protective sleeve mounted at least partially within the opening of the wall of the container. A thermocouple can be positioned within an internal bore of the protective sleeve. A method of processing molten material can include inserting a thermocouple into a protective sleeve fabricated from a refractory ceramic material, and measuring a temperature of material within a containment area of a container with the thermocouple.

A molten material apparatus can include a container including a wall at least partially defining a containment area and an opening extending through the wall. The molten material apparatus can include a protective sleeve mounted at least partially within the opening of the wall of the container. A thermocouple can be positioned within an internal bore of the protective sleeve. A method of processing molten material can include inserting a thermocouple into a protective sleeve fabricated from a refractory ceramic material, and measuring a temperature of material within a containment area of a container with the thermocouple.

The present invention preferably comprises a system and method for measuring and/or continuously monitoring the temperature and/or height of a molten metal bath in a vessel. Specifically, an ultrasonic transmitter and an ultrasonic receiver are disposed about sides of the vessel and are used to send and receive an ultrasonic signal in order to detect the temperature of the bath. More specifically, the ultrasonic transmitter is configured to send an ultrasonic signal through the vessel, and the ultrasonic receiver is configured to receive that ultrasonic signal after it has travelled through the vessel (comprising the molten metal bath). The ultrasonic receiver provides at least one signal to a processing unit (i.e., control center), which processes the at least one signal to determine the temperature and/or level of the molten metal bath. The invention may further comprise chillers to protect the transmitter and receiver from the heat of the bath.

The present invention preferably comprises a system and method for measuring and/or continuously monitoring the temperature and/or height of a molten metal bath in a vessel. Specifically, an ultrasonic transmitter and an ultrasonic receiver are disposed about sides of the vessel and are used to send and receive an ultrasonic signal in order to detect the temperature of the bath. More specifically, the ultrasonic transmitter is configured to send an ultrasonic signal through the vessel, and the ultrasonic receiver is configured to receive that ultrasonic signal after it has travelled through the vessel (comprising the molten metal bath). The ultrasonic receiver provides at least one signal to a processing unit (i.e., control center), which processes the at least one signal to determine the temperature and/or level of the molten metal bath. The invention may further comprise chillers to protect the transmitter and receiver from the heat of the bath.

A system measures parameters of the electricity drawn by an arc furnace and, based on an analysis of the parameters, provides indicators of whether arc coverage has been optimized. Factors related to optimization of arc coverage include electrode position, charge level, slag level and slag behaviour. More specifically, such indicators of whether arc coverage has been optimized may be used when determining a position for the electrode such that, to an extent possible, a stable arc cavity is maintained and an open arc condition is avoided. Conveniently, by avoiding open arc conditions, the internal linings of the furnace walls and roof may be protected from excessive wear and tear.

A cooling plate for a metallurgical furnace including a body with a front face and an opposite rear face, the body having at least one cooling channel therein having an opening in the rear face and a coolant feed pipe connected to the rear face of the cooling panel and is in fluid communication with the cooling channel where in use, the front face is turned towards a furnace interior, and at least one emergency cooling tube is arranged within the cooling channel, the emergency cooling tube having a cross-section smaller than a cross-section of the cooling channel, the emergency cooling tube has an end section with connection means for connecting an emergency feed pipe thereto, and in an emergency operation, the emergency cooling tube is physically connected to an emergency feed pipe via the connection means; while, in a normal operation, the connection means of the emergency cooling tube is physically disconnected from the emergency feed pipe. The invention also concerns the use of such a cooling plate.

A cooling plate for a metallurgical furnace including a body with a front face and an opposite rear face, the body having at least one cooling channel therein having an opening in the rear face and a coolant feed pipe connected to the rear face of the cooling panel and is in fluid communication with the cooling channel where in use, the front face is turned towards a furnace interior, and at least one emergency cooling tube is arranged within the cooling channel, the emergency cooling tube having a cross-section smaller than a cross-section of the cooling channel, the emergency cooling tube has an end section with connection means for connecting an emergency feed pipe thereto, and in an emergency operation, the emergency cooling tube is physically connected to an emergency feed pipe via the connection means; while, in a normal operation, the connection means of the emergency cooling tube is physically disconnected from the emergency feed pipe. The invention also concerns the use of such a cooling plate.

The present invention relates to damage detection systems for refractory linings for molten metal vessels, comprising an electrically conductive grid disposed underneath the surface of the refractory lining closest to a molten metal when in use, one or more electrically conductive electrodes disposed in contact with the molten metal when in use and an electrical power source, wherein the electrically conductive metallic grid and the one or more electrically conductive electrodes are electrically connected to each other, such as to form an open electrical circuit powered by the said electrical power source, and a detected closure of the said electrical circuit during normal use of the molten metal vessel indicates that the said refractory lining is damaged, or the presence of a molten metal during normal operation of the vessel closes the said electrical circuit in case the refractory lining is damaged. The present invention relates to a method for detecting damage in a refractory lining during use, and the use of a damage detection system according to the invention.