Al Furnace
Al Furnace
Al Furnace
com
ISSN: 2394-2630
Research Article CODEN(USA): JSERBR
Engineering Materials Research Department, Nigerian Building and Road Research Institute, Km 10
Idiroko Road, Ota, Ogun State, Nigeria.
Abstract The increasing demand for aluminium scrap (as waste constituent) in our environment cannot be over
emphasized. Hence, an improved system of continuous aluminium recycling as a secondary aluminium
production is designed and constructed. A gas-fired crucible furnace is designed and fabricated for melting scrap
aluminium. This furnace is a modified model suitable for laboratories and workshops. This furnace is designed
and fabricated using locally available materials and butane gas as the thermal energy source in heating up the
system to the melting point of aluminium (660.4 °C). The molten aluminium is casted to a desired shape and
size either as ingot or end product.
1. Introduction
Secondary aluminium production (recycling) saves 95% energy needed to produce aluminium from its ore [1].
Hence, it is more of economic importance that aluminium recycling becomes a major source of aluminium
production [2]. Aluminium is primarily used to produce pistons, engine and body parts for cars. Beverages cans,
doors, sliding door and aluminium foil. It may also be used as sheet metal, aluminium plate and foil, Rods, bars
and wire, aircraft components, windows and door frames. The leading users of aluminium include the container
and packaging industry, the transportation industry, building and construction industry [3]. Aluminium can
either be produced from bauxite ore (primary aluminium refining) or from aluminium scrap (secondary
aluminium refining). Refinement of aluminium ore is sufficiently expensive that the secondary production
industry commands much of the market. It is recorded that about 40% of aluminium of aluminium in the US is
recovered from secondary refining [4]. Hence, the interest of this project lies on the secondary aluminium
production.
Furnace is a space surrounded on all sides by walls and a roof for heating metal or glass to very high
temperatures [5]. The earliest furnace was excavated at Balakot, a site of the Indus valley civilization. Then,
furnace was most used for the manufacturing of ceramics objects [6]. Furnaces operate in aggressive
environment, where several components-molten metal, furnace lining, atmospheric gases, and products from
combustion of fuels-coexist at extreme high temperature. Aluminium melting furnace derives its heat from solid
fuel (coke and breeze), natural gas, electricity, or other source of energy. Furnaces vary in design, geometry,
production capacity (melting rate), materials of construction, and mode of operation [7]. Other factors related to
the energy source also affect the furnace design which includes how the energy is transferred to the molten
material, how combustion gases are removed, and what refining and treating equipment must enter the furnace,
how long the holding periods are, and how the molten metal will be tapped. Several factors come into play
besides the core ingredient of heat and metal as illustrated in figure 1 below:
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Babatunde YS et al Journal of Scientific and Engineering Research, 2015, 2(3):36-43
Chimney
Melting Chamber
The operating temperature required in the furnace depends on the melting and pouring temperature of the
materials being melted. They can range from about 350 °C (650 F) for zinc alloy to 1700 °C (3100F) for alloy
steels. But for aluminium, the operating temperature is from 650 °C and above. There are various types of
furnace. They are mainly classified according to their energy source, and application – in this case melting, or
holding purpose. Different furnaces types are: Crucible Furnace, Induction Furnace, Dosing Furnace, Immersion
Furnace, Reverberatory Furnace, Stack Furnace, etc. The furnaces of interest in this research work are the
crucible furnace and reverberatory furnace [8-10].
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Babatunde YS et al Journal of Scientific and Engineering Research, 2015, 2(3):36-43
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Babatunde YS et al Journal of Scientific and Engineering Research, 2015, 2(3):36-43
v. Vent/chimney: a controlled vent of 5 mm diameter pipe is attached to the cover, for reduction of
internal furnace pressure gradient built across the ceiling, and waste gas exit.
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Babatunde YS et al Journal of Scientific and Engineering Research, 2015, 2(3):36-43
𝑞 𝑑
1 ln 𝑑 1
2
𝑇𝑎 − 𝑇𝑏 = . (4)
2𝜋𝑘 1
K, is the thermal conductivity for different wall materials.
Substituting the values
750 - Tb = 5203.9 ln(306/238) ÷ 2 × 3.142 × 1.4 = 9
Hence,
Tb = 750 – 9 = 7410C
For Tc;
𝑑
𝑞 1 ln 𝑑 3
2
𝑇𝑏 − 𝑇𝑐 = . (5)
2𝜋𝑘 2
741 - Tc = 5203.9 ln (318/306) ÷ 2 × 3.142 × 0.040
Tc = 550C
For Td;
𝑑
𝑞 1 ln 𝑑 4
3
55 − 𝑇𝑑 =
2𝜋𝑘 3
Td = 1140C
Steady-state, one dimensional heat flow through insulation systems is governed by Fourier’s law
𝑑𝑇
𝑄 = 𝐾. 𝐴. . (6)
𝑡
Where,
Q = rate of heat flow, w
A = cross sectional area normal to heat flow, m2
T = thickness of insulating materials
dT = temperature difference in material, oC
From equation 6;
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Babatunde YS et al Journal of Scientific and Engineering Research, 2015, 2(3):36-43
𝑑𝑇
𝑡 = 𝐾. 𝐴. . (7)
𝑄
Applying equation (7) for each wall;
For ta;
𝑇𝑎 − 𝑇𝑏
𝑡𝑎 = 𝑘1 . 𝐴. = 1.4 x 0.6133 x (750 – 741)/927.5 = 0.008m
𝑄
For tb
𝑇𝑏 − 𝑇𝑐
𝑡𝑏 = 𝑘2 . 𝐴. = 0.040 x 0.6133 x (741 – 55)/927.5 = 0.018m
𝑄
For tc
𝑇𝐶 −𝑇𝑑
𝑡𝑐 = 𝑘3 . 𝐴. = 11.5 x 0.6133 x (55 – 114)/927.5 = 0.448m
𝑄
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Babatunde YS et al Journal of Scientific and Engineering Research, 2015, 2(3):36-43
It was observed that the temperature of the melting furnace was maintained at 720 °C over a period exceeding
300 seconds and this shows that the furnace was designed to attain a maximum temperature of 720 °C.
700
Temperature (Degree) 600
500
400
300
200
100
0
0 30 120 260 300
Time (Seconds)
4. Conclusion
This research work was undertaken to design and fabricate an aluminum melting furnace for laboratory and
workshop use. The furnace was constructed putting into consideration; its temperature attainment, capacity of
metals it can hold, operators safety, space to be occupied in the workshop floor/laboratory, cost restrictions,
availability of the materials used, its maintainability and portability. This research has revealed that the locally
fabricated aluminum melting furnace for laboratory and workshop operations have an efficiency of 28%, low
energy consumption and shorter time of operation. Hence, a more effective and performing furnace were
developed. The developed Aluminum melting furnace will not only melt Aluminium but also ant metal that have
a melting temperature below 720 °C. The actualization and realization of this research work is a boost to the
development of local manpower capacity in Nigeria and also to advance the reliability of engineering materials
in service.
References
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6. http://www.wikipedia.com/furnace.html, August 20, 2014.
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Babatunde YS et al Journal of Scientific and Engineering Research, 2015, 2(3):36-43
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