Molten Metal Transfer System and Method
20200360990 ยท 2020-11-19
Assignee
Inventors
Cpc classification
B22D41/00
PERFORMING OPERATIONS; TRANSPORTING
B22D35/04
PERFORMING OPERATIONS; TRANSPORTING
B22D39/02
PERFORMING OPERATIONS; TRANSPORTING
F04D7/065
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/026
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F27D3/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F27B3/045
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/426
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F27D2003/0054
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F27M2001/012
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B22D39/00
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A system according to aspects of the invention includes a pump and a refractory casing that houses the pump or is in fluid communication with the pump. As the pump operates it moves molten metal upward through an uptake section of the casing until it reaches a rectangular outlet wherein it exits the vessel. The rectangular outlet is configured to be connected to, or may be attached to, a launder. Another system uses a wall to divide a cavity of the chamber into two portions. The wall has an opening and a pump pumps molten metal from a first portion into a second portion until the level in the second portion reaches an outlet and exits the vessel.
Claims
1. A vessel used for transferring molten metal, the vessel comprising: (a) a refractory housing having a first side; (b) a cylindrical uptake section in the refractory housing, wherein the cylindrical uptake section is open and configured so molten metal can be moved up the uptake section; and (c) a rectangular opening in the first side of the refractory housing; the rectangular opening in fluid communication with the cylindrical uptake section.
2. The vessel of claim 1 that further includes a launder connected to the rectangular opening.
3. A device for transferring molten metal, the device comprising a transfer conduit in communication with a vessel cavity; the transfer conduit having a bottom that includes an opening in communication with the vessel cavity, a first section having a first cross-sectional area and a second section above the first section, the second section having a second cross-sectional area that is greater than the first cross-sectional area, and a rectangular outlet in fluid communication with the second section and leading out of the transfer conduit; wherein the first section is configured to receive a molten metal pump rotor, and the rectangular outlet is configured to mate with a launder.
4. The device of claim 3 that is comprised of refractory material.
5. The device of claim 3, wherein the cavity is cylindrical.
6. The device of claim 3 that a launder extending from the second section.
7. The device of claim 3, wherein the launder is between 6 and 6 in length.
8. The device of claim 7, wherein the launder is formed at a horizontal angle of one or more of the group selected from: 0, an angle tilting backwards towards the second section of between 1 and 3, an angle tilting backwards towards the second section of between 1 and 10.
9. The device of claim 3, wherein there is a wall that separates the vessel cavity from the transfer conduit and a channel is formed in the bottom of the wall and allows molten metal to pass from the vessel cavity to the opening.
10. The device of claim 3 that further includes a molten metal pump including a motor, a platform on which the motor rests, a shaft having a first end connected to the motor and a second end connected to a rotor, wherein at least part of the shaft is positioned in the second section and the rotor is positioned in the first section.
11. The device of claim 10, wherein the vessel has an upper perimeter, and the transfer conduit has an upper perimeter, and the platform of the molten metal pump is supported by at least the upper perimeter of the transfer conduit in order to support the pump.
12. The device of claim 11, wherein the platform of the molten metal pump also rests on at least the upper perimeter of the vessel.
13. The device of claim 3, wherein the transfer conduit includes a first wall having a first outer surface and a second wall having a second outer surface, and one side of the platform includes a first centering bracket and the opposite side of the platform includes a second centering bracket; the first centering bracket being juxtaposed the first outer surface and the second centering bracket being juxtaposed the second outer surface to help center the shaft and rotor in the transfer conduit.
14. A pumping device for pumping molten metal, the device including (a) a pump having a motor, a rotor and a drive shaft connecting the motor to the rotor, and (b) a refractory casing that includes an inlet, an uptake tube having a first section with a first cross-sectional area and a second section with a second cross-sectional area, wherein the second section is above the first section and the second cross-sectional area is larger than the first cross-sectional area, and a rectangular outlet in communication with the second section (c) the rotor being received in the first section, and (d) the pump being removable from the casing without removing the casing from a molten metal bath.
15. The pumping device of claim 1 that further includes a launder attached to the outlet.
16. The pumping device of claim 1 wherein the casing has a rectangular outer surface.
17. The device of claim 1, wherein the rectangular outlet is at least two feet above the opening.
18. The device of claim 1, wherein the rectangular outlet is at least two feet above an inner bottom surface of the vessel.
19. A device for use with a vessel including a cavity for containing molten metal, the device being in fluid communication with a vessel cavity and including: (a) an inlet in communication with the cavity to permit molten metal to enter the transfer chamber; (b) an enclosed inner section and an open section, the enclosed inner section having a first opening in communication with the open section; (c) a pump positioned in the transfer chamber, the pump having a motor, a drive shaft having a first end connected to the motor, and a second end, and a rotor connected to the second end, wherein the shaft is positioned at least partially in the enclosed inner section and the rotor is positioned at least partially in the enclosed inner section; (d) a rectangular outlet above the first opening and below the motor, wherein molten metal can exit the transfer chamber through the outlet; (e) wherein the rotor has a diameter, and the enclosed inner section has an interior diameter, and the interior diameter is between to 1 greater than the diameter of the rotor; wherein, as the pump operates the rotor is rotated and directs molten metal up into the enclosed inner section and out of the rectangular outlet.
20. The device of claim 19, wherein the pump does not include a pump base.
21. The device of claim 19, wherein the pump does not include a superstructure or support posts.
22. The device of claim 19, wherein the drive shaft comprises a motor shaft coupled to a rotor shaft and the rotor shaft is positioned at least partially in the enclosed inner section.
23. The device of claim 19, that has three walls and shares a fourth, common wall with the vessel.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0045] Turning now to the drawings, where the purpose is to describe a preferred embodiment of the invention and not to limit same, a system and insert according to the invention will be described.
[0046] System 10 comprises a molten metal pump 20 and an insert 100. Pump 20 is preferably a circulation pump and can be any type of circulation pump satisfactory to move molten metal into the insert as described herein. The structure of circulator pumps is know to those skilled in the art and one preferred pump for use with the invention is called The Mini, manufactured by Molten Metal Equipment Innovations, Inc. of Middlefield, Ohio 44062, although any suitable pump may be used. The pump 20 preferably has a superstructure 22, a drive source 24 (which is most preferably a pneumatic motor) mounted on the superstructure 22, support posts 26, a drive shaft 28, and a pump base 30. The support posts 26 connect the superstructure 22 to the base 30 in order to support the superstructure 22.
[0047] Drive shaft 28 preferably includes a motor drive shaft (not shown) that extends downward from the motor and that is preferably comprised of steel, a rotor drive shaft 32, that is preferably comprised of graphite, or graphite coated with a ceramic, and a coupling (not shown) that connects the motor drive shaft to end 32B of rotor drive shaft 32.
[0048] The pump base 30 includes an inlet (not shown) at the top and/or bottom of the pump base, wherein the inlet is an opening that leads to a pump chamber (not shown), which is a cavity formed in the pump base. The pump chamber is connected to a tangential discharge, which is known in art, that leads to an outlet, which is an opening in the side wall 33 of the pump base. In the preferred embodiment, the side wall 33 of the pump base including the outlet has an extension 34 formed therein and the outlet is at the end of the extension. This configuration is shown in
[0049] A rotor (not shown) is positioned in the pump chamber and is connected to an end of the rotor shaft 32A that is opposite the end of the rotor shaft 32B, which is connected to the coupling.
[0050] In operation, the motor rotates the drive shaft, which rotates the rotor. As the rotor (also called an impeller) rotates, it moves molten metal out of the pump chamber, through the discharge and through the outlet.
[0051] An insert 100 according to this aspect of the invention includes (a) an enclosed device 102 that can be placed into vessel well 2, and (b) a trough (or launder section) 200 positioned on top of device 102. Device 102 as shown (and best seen in
[0052] Device 102 as shown has four sides 102A, 102B, 102C and 102D, a bottom surface 102E, and an inner cavity 104. Bottom surface 102E may be substantially flat, as shown in
[0053] Side 102B has a first opening 106 formed in its lower half, and preferably no more than 24, or no more than 12, and most preferably no more than 6, from bottom surface 102E. First opening 106 can be of any suitable size and shape, and as shown has rounded sides 106A and 106B. First opening 106 functions to allow molten metal to pass through it and into cavity 104. Most preferably, opening 104 is configured to receive an extension 34 of base 30 of pump 10, as best seen in
[0054] Device 102 has a second opening 108 formed in its top. Second opening 108 can be of any suitable size and shape to permit molten metal that enters the cavity 104 to move through the second opening 108 once the level of molten metal in cavity 104 becomes high enough.
[0055] Trough 200 is positioned at the top of device 102. Trough 200 has a back wall 202, side walls 204 and 206, and a bottom surface 208. Trough 200 defines a passage 210 through which molten metal can flow once it escapes through second opening 108 in device 102. The bottom surface 208 of trough 200 is preferably angled backwards towards second opening 108, at a preferred angle of 2-5, even though any suitable angle could be used. In this manner, any molten metal left in trough 200, once the motor 20 is shut off, will flow backward into opening 108. The bottom surface 208 could, alternatively, be level or be angled forwards away from opening 108. Trough 200 may also have a top cover, which is not shown in this embodiment.
[0056] In the embodiment shown in
[0057] If trough 200 is a piece separate from device 102, it could be attached to device 102 by metal angle iron and/or brackets (which would preferably made of steel), although any suitable attachment mechanism may be used. Alternatively, or additionally, a separate trough 200 could be cemented to device 200.
[0058] An extension 250 is preferably attached to the end of trough 200. Extension 250 preferably has an outer, steel frame 252 about - thick and the same refractory cement of which insert 100 is comprised is cast into frame 252 and cured, at a thickness of preferably -2. Brackets 260 are preferably welded onto frame 252 and these align with bracket 254 on trough 200. When the holes in brackets 260 align with the holes in bracket 254, bolts or other fasteners can be used to connect the extension 250 to the trough 200. Any suitable fasteners or fastening method, however, may be used. In one embodiment the bracket 254 is formed of to thick angle iron, and brackets 260 are also to thick iron or steel. Preferably, the surfaces of the refractory cement that from the trough and extension that come into contact with the molten metal are coated with boron nitride.
[0059] It is preferred that if brackets or metal structures of any type are attached to a piece of refractory material used in any embodiment of the invention, that bosses be placed at the proper positions in the refractory when the refractory piece is cast. Fasteners, such as bolts, are then received in the bosses.
[0060] An upper bracket 256 is attached to trough 200. Eyelets 258, which have threaded shafts that are received through upper bracket 256 and into bosses in the refractory (not shown), are used to lift the insert 100 into and out of vessel 1.
[0061] Positioning brackets 270 position insert 100 against an inner wall of vessel 1. The size, shape and type of positioning brackets, or other positioning devices, depend on the size and shape of the vessel, and several types of positioning structures could be used for each vessel/insert configuration. The various ones shown here are exemplary only. The positioning structures are usually formed of thick steel.
[0062] It is also preferred that the pump 20 be positioned such that extension 34 of base 30 is received in the first opening 100. This can be accomplished by simply positioning the pump in the proper position. Further the pump may be head in position by a bracket or clamp that holds the pump against the insert, and any suitable device may be used. For example, a piece of angle iron with holes formed in it may be aligned with a piece of angle iron with holes in it on the insert 100, and bolts could be placed through the holes to maintain the position of the pump 20 relative the insert 100.
[0063] In operation, when the motor is activated, molten metal is pumped out of the outlet through first opening 106, and into cavity 104. Cavity 104 fills with molten metal until it reaches the second opening 108, and escapes into the passage 210 of trough 200, where it passes out of vessel 1, and preferably into another vessel, such as the pot P shown, or into ingot molds, or other devices for retaining molten metal. Installation of the insert into a furnace that contains molten metal is preferably accomplished by pre-heating the insert to 300-400 F. in an oven and then slowly lowering unit into the metal over a period of 1.5 to 2 hours.
[0064] In another embodiment of the invention shown in
[0065] Another embodiment of the invention is shown in
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[0067] In this embodiment, trough 200 has a top cover 220 held in place by members 222. Extension 250 has a top cover 290 held in place by members 292. The purpose of each top cover is to prevent heat from escaping and any suitable structure may be utilized. It is preferred that each top cover 220 and 290 be formed of heat-resistant material, such as refractory cement or graphite, and that members 222 and 292 are made of steel. As shown, a clamp 294 holds member 292 in place, although any suitable attachment mechanism may be used.
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[0069] The support brackets are preferably attached to a steel structure of the furnace to prevent the insert from moving once it is in place. A locating pin on the steel frame allows for alignment of the outlet of the pump with the inlet hole at the bottom.
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[0071] Pumping device 510 includes a motor 512 that rests on a platform 514. Motor 512 can be any suitable type, such as pneumatic or electric. Device 510 also includes a cast housing 516 that acts as a pump chamber and discharge. Cast housing 516 is made of any suitable refractory material and the compositions and methods of making cast housing 516 are known. An advantage of housing 516 is that it can permit system 500 to be placed essentially anywhere in a vessel, and if repairs are required to the pump shaft, rotor or other components, the platform 514 with the motor, shaft and rotor can be disconnected from housing 516 and lifted out vertically. Housing 16 remains in cavity 502, or wherever it has been placed. When the repairs are completed, the pump, rotor shaft and rotor and vertically lowered back into the housing 16 and reconnected to it. Housing 16 is still portable and can be easily moved if desired.
[0072] Alternatively, the coupling between the rotor shaft and motor shaft can be disconnected and the rotor shaft and rotor can be removed for repair.
[0073] Cast housing 16 as shown has a square or rectangular outer surface. As best seen in
[0074] When molten metal is pushed up the uptake tube 524 it exits through rectangular outlet 528 and into launder 550. Launder 550 may be of any suitable design, but is preferably between 1 and 10 deep and may either have an open or closed top, and as shown herein it has a top 552. The launder is preferably formed at a 0 horizontal angle, or at a horizontal angle wherein it tilts back towards outlet 528. Such an angle back towards outlet 528 is preferably 1-10, 1-5 or 1-3, or a backward slope of for every 10 of launder length.
[0075] Motor 510 is retained on housing 16 by metal brackets and any suitable structure will suffice. Launder 550 is fastened into place on housing 16 by metal brackets and fasteners, which are also known in the art, and its weight is preferably supported at least in part by support structure 580 and by the top surface of vessel 501.
[0076] As shown support structure 580 is a metal bracket and I-beam structure that fastens to the upper surface of vessel 1 and to brackets 515 extending from motor device 510 and to launder 500 in order to secure system 500 in the proper position.
[0077] Turning to
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[0082] Having thus described some embodiments of the invention, other variations and embodiments that do not depart from the spirit of the invention will become apparent to those skilled in the art. The scope of the present invention is thus not limited to any particular embodiment, but is instead set forth in the appended claims and the legal equivalents thereof Unless expressly stated in the written description or claims, the steps of any method recited in the claims may be performed in any order capable of yielding the desired result.