Copper Melting Shaft Furnace
1.Shaft furnace charging system
Application: put the cathode or other raw material into the melting furnace.
Instruction: Melting furnace charging system is putting the cathode or other raw material into the melting furnace, charging mechanism is lifting the raw material from the ground to the material inlet of melting furnace.
One set of Industry TV camera is installed upon the feeding inlet. Thus the melting furnace operator can observe the material height in the furnace from a distance.
An cathode copper distribution insert device will spread the bundled copper plate to improve the energy efficiency.
Characteristics and advantages:
1. Rigid steel framework, stable running of bucket.
2. Cable tension has the cushion device.
3. Feeding trolley accept wedge-shaped hopper, loading waste billet, Billet shavings or rolling mill copper scrap rod. It can transfer one bundle of cathode, packaged copper scrap and other several of raw material.
4. In order to improve the combustion rate, separate and spread the cathode.
5. Overload protection.
6. Wire rope buffer device.
2. Shaft melting furnace system
Usage: Melting cathode or other raw material
Instruction: Shaft is circular vertical melting furnace. The inner is carborundum brick, and during the middle of the brick and the steel shell adopts refractory bricks and insulating refractory. The furnace body is made by Steel structure. The up furnace body is charging inlet. Using natural gas or gasification of liquid as fuel, shaft furnace melting speed is 16T/h, equipped with two line of gas burner. This furnace design is used melting mixed certain percentage of 1#copper scrap, scrap wire and wire ingot mould.
Operation:
When the furnace is empty (new furnace or long time not working), the 1st charging should be done by the operators, they should enter the furnace and stack the material (cathode or packed scrap) until materials reach the lower edge of anti-collision section. All the burners are started when start the furnace until the furnace temperature reach technological requirements. Once the melting starts, then the heat rate will increase. It sinks with the bottom with supporting material heated, softens and melted. The surface of material should maintain the height range of 0-0.5 m under the charging inlet according melting rate and quantity of each batch of material.
Because there is no any of metal melting pool, the liquid copper flows fluently from the outlet, the liquid copper go through launder, after the heating of launder, burner flows into the holding furnace.
During the process of melting, the main tasks of operator are inspecting and making a little adjustment. In order to ensure the appropriate gas -air ratio and the liquid copper temperature meet the process, temperature and Oxygen content requirements.
The furnace can stop the metal flow out shortly, most it takes about 1minute. The method is cut off the supply of main gas and retains the air flow in the burner, until the furnace material and the refractory materials' temperature are lower than the furnace material melting point. It can stop the wind when you observed that the furnace material becomes black from the observe hole from the bottom burner. Temperature of copper outlet and launder has to maintain higher than the furnace material melting point always to prevent freeze up.
Characteristic and advantage:
1. Cover less of area
2. Simple design, simple operation, less operator
3. High heat efficiency, more than 60%.
Shaft furnace natural gas consumption: ~32m3/T:
4. Start and Stop furnace quickly.
5. Continuous melting.
6. No molten metal pool.
7. Excellent metallurgical control.
8. Limiting molten metal overheated.
9. Melting rate can be adjusted.
10. Safe, it will not store a large amount of molten metal, thus it will not cause copper run away because of the damage of refractory bricks or copper outlet.
11. Refractory material, Normal using time: 3-5 year, it is used for partial replace and furnace liner patching
12. There is no smoke pollution when produce.
13. It is convenient for charging, and it adopts mechanical charging to save the human resources and labor intensity. It is easy to realize automatic, at the same time it can reduce the energy consumption caused by when the furnace door open.
The way to achieve above characteristic is using high speed micro reductive combustion flue gas from high heat release burner touch the copper material tightly with large area, high heat efficient, short flame of burner. Coupled with the precise combustion control and combustion monitoring system, prevented unburned oxygen contact with the burden directly, so for this it can avoid the furnace material absorb oxygen.
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