The disclosure relates to apparatuses melting batch materials, the apparatuses comprising a vessel; an electrode assembly comprising an electrode and at least one detection component coupled to the electrode; and at least one device configured to measure an electrical or optical property of the electrode assembly. Also disclosed herein are electrode assemblies for the optical or electrical detection of electrode length, and apparatuses comprising such electrode assemblies.

The disclosure relates to apparatuses melting batch materials, the apparatuses comprising a vessel; an electrode assembly comprising an electrode and at least one detection component coupled to the electrode; and at least one device configured to measure an electrical or optical property of the electrode assembly. Also disclosed herein are electrode assemblies for the optical or electrical detection of electrode length, and apparatuses comprising such electrode assemblies.

A refill system includes a tempering furnace, a refill furnace which stores the molten potassium nitrate obtained by melting powdered potassium nitrate, a supply unit which supplies the molten potassium nitrate to the tempering furnace, a tempering furnace side load measuring unit which measures a load amount of the molten potassium nitrate in the tempering furnace, a refill furnace side load measuring unit which measures a load amount of the molten potassium nitrate in the refill furnace, and a central control unit which checks the load amount of the molten potassium nitrate in the tempering furnace and the refill furnace in real time, and controls the supply unit to stop supplying the molten potassium nitrate to the tempering furnace when the load amount of the molten potassium nitrate in the tempering furnace is greater than or equal to a predetermined load amount.

A refill system includes a tempering furnace, a refill furnace which stores the molten potassium nitrate obtained by melting powdered potassium nitrate, a supply unit which supplies the molten potassium nitrate to the tempering furnace, a tempering furnace side load measuring unit which measures a load amount of the molten potassium nitrate in the tempering furnace, a refill furnace side load measuring unit which measures a load amount of the molten potassium nitrate in the refill furnace, and a central control unit which checks the load amount of the molten potassium nitrate in the tempering furnace and the refill furnace in real time, and controls the supply unit to stop supplying the molten potassium nitrate to the tempering furnace when the load amount of the molten potassium nitrate in the tempering furnace is greater than or equal to a predetermined load amount.

Multiple magnetic field sensors are arranged around a current-containing volume at multiple longitudinal and circumferential positions. Each sensor measures multiple magnetic field components and is characterized by one or more calibration parameters. A longitudinal primary current flows through two end-to-end electrical conductors that are separated by an arc gap, and flows as at least one longitudinal primary electric arc that spans the arc gap and that moves transversely within the arc gap. Estimated transverse position of the primary electric arc is calculated, based on the longitudinal position of the arc gap, and two or more of the measured magnetic field components along with one or more corresponding sensor positions or calibration parameters. In addition, estimated occurrence, position, and magnitude of a transverse secondary current (i.e., a side arc) can be calculated based on those quantities.

Multiple magnetic field sensors are arranged around a current-containing volume at multiple longitudinal and circumferential positions. Each sensor measures multiple magnetic field components and is characterized by one or more calibration parameters. A longitudinal primary current flows through two end-to-end electrical conductors that are separated by an arc gap, and flows as at least one longitudinal primary electric arc that spans the arc gap and that moves transversely within the arc gap. Estimated transverse position of the primary electric arc is calculated, based on the longitudinal position of the arc gap, and two or more of the measured magnetic field components along with one or more corresponding sensor positions or calibration parameters. In addition, estimated occurrence, position, and magnitude of a transverse secondary current (i.e., a side arc) can be calculated based on those quantities.

A method includes firing a first burner into a furnace process chamber in a first initial condition, firing a second burner into the process chamber in a second initial condition, and measuring temperature at each of an array of locations in the process chamber. The first burner is adjusted to a first adjusted condition while the second burner is being fired at the second initial condition, and a resulting first temperature change is measured at each of the locations. The second burner is adjusted to a second adjusted condition while the first burner is being fired at the first initial condition, and a resulting second temperature change is measured at each of the locations. The measured first and second temperature changes are recorded as reference data for adjusting burner conditions to adjust temperatures at each of the locations. The method can thus be used to improve temperature uniformity throughout the array of locations.

A melting method including a step of loading solid metal material into an electric furnace, a step of generating an electric arc between at least one electrode and the metal material, a step of perforating the metal material during which the electrode is moved through the metal material, a step of melting the solid metal material in order to obtain a molten material, and a step of refining the molten material by adding reaction compounds. At least one of the steps includes regulating the electric parameters of the electric arc.

A melting method including a step of loading solid metal material into an electric furnace, a step of generating an electric arc between at least one electrode and the metal material, a step of perforating the metal material during which the electrode is moved through the metal material, a step of melting the solid metal material in order to obtain a molten material, and a step of refining the molten material by adding reaction compounds. At least one of the steps includes regulating the electric parameters of the electric arc.

A control scheme for a furnace can use real-time and historical data to model performance and determine relationships between different data and performance parameters for use in correcting suboptimal performance of the furnace in real-time. Operational parameters can be logged throughout the cycle for all cycles for a period of time in order to establish a baseline. This data can then be used to calculate the performance of the process. A regression analysis can be carried out in order to determine which parameters affect different aspects of performance. These relationships can then be used to predict performance during a single cycle in real-time and provide closed or open loop feedback to control furnace operation to result in enhanced performance.