U.S. patent application number 13/176077 was filed with the patent office on 2013-01-10 for separation type metallurgical reduction method and apparatus thereof.
Invention is credited to WEN YUAN CHANG.
Application Number | 20130009349 13/176077 |
Document ID | / |
Family ID | 47438181 |
Filed Date | 2013-01-10 |
United States Patent
Application |
20130009349 |
Kind Code |
A1 |
CHANG; WEN YUAN |
January 10, 2013 |
SEPARATION TYPE METALLURGICAL REDUCTION METHOD AND APPARATUS
THEREOF
Abstract
A separation type metallurgical reduction method and an
apparatus thereof. The separation type metallurgical reduction
apparatus includes a reduction furnace and a multistage cooling
device. By means of the separation type metallurgical reduction
apparatus, the metallurgical reduction/smelting process and the
cooling process are separately performed in different spaces at the
same time to improve the operation of the conventional
metallurgical reduction furnace within which the smelting process
and the cooling process are totally limitedly performed.
Accordingly, the shortcomings of too long waiting time, waste of
great amount of energy and low yield rate that exist in the
conventional metallurgical reduction furnace can be eliminated.
Inventors: |
CHANG; WEN YUAN; (MIAOLI
COUNTY, TW) |
Family ID: |
47438181 |
Appl. No.: |
13/176077 |
Filed: |
July 5, 2011 |
Current U.S.
Class: |
266/44 ; 266/175;
266/195 |
Current CPC
Class: |
C22B 5/02 20130101; F27B
19/00 20130101; F27D 15/0206 20130101 |
Class at
Publication: |
266/44 ; 266/195;
266/175 |
International
Class: |
C22B 1/02 20060101
C22B001/02; C22B 1/26 20060101 C22B001/26 |
Claims
1. A separation type metallurgical reduction apparatus comprising:
a reduction furnace having an internal space, a material dropping
passage extending from outer side of the reduction furnace into the
internal space and a material release passage extending from the
internal space to outer side of the reduction furnace, the internal
space serving to receive a material to be reduced and provide a
high temperature, for reducing the material to be reduced; and a
cooling device disposed on one side of the reduction furnace and
connected with the material release passage that extends into an
internal space of the cooling device, the material release passage
being provided with a material release gate for controlling
unblocking/blocking of the material release passage.
2. The separation type metallurgical reduction apparatus as claimed
in claim 1, wherein the cooling device at least includes a load
chamber in which at least one carrier device can be positioned in
alignment with the material release passage for accepting a
reduction product released from the material release passage, the
load chamber being at least provided with a load gate through which
the carrier device can be conveyed into the load chamber.
3. The separation type metallurgical reduction apparatus as claimed
in claim 2, wherein the cooling device further includes a
preheating chamber in connection with one of the load gates of the
load chamber and in communication with the load chamber through the
load gate, whereby the carrier device can pass through the load
gate between the load chamber and the preheating chamber.
4. The separation type metallurgical reduction apparatus as claimed
in claim 2, wherein the cooling device further includes a cooling
chamber in connection with one of the load gates of the load
chamber and in communication with the load chamber through the load
gate, whereby the carrier device can pass through the load gate
between the load chamber and the cooling chamber.
5. The separation type metallurgical reduction apparatus as claimed
in claim 3, wherein the cooling device further includes a cooling
chamber in connection with one of the load gates of the load
chamber and in communication with the load chamber through the load
gate, whereby the carrier device can pass through the load gate
between the load chamber and the cooling chamber.
6. The separation type metallurgical reduction apparatus as claimed
in claim 1, wherein a material dropping device is disposed above
the reduction furnace for receiving the material to be dropped into
the reduction furnace and reduced, the material dropping passage
being arranged between the material dropping device and the
reduction furnace, the material dropping device having an internal
space in communication with the internal space of the reduction
furnace through the material dropping passage, a material dropping
gate being disposed in the material dropping passage for
controlling unblocking/blocking of the material dropping
passage.
7. The separation type metallurgical reduction apparatus as claimed
in claim 2, wherein a material dropping device is disposed above
the reduction furnace for receiving the material to be dropped into
the reduction furnace and reduced, the material dropping passage
being arranged between the material dropping device and the
reduction furnace, the material dropping device having an internal
space in communication with the internal space of the reduction
furnace through the material dropping passage, material dropping
gate being disposed in the material dropping passage for
controlling unblocking/blocking of the material dropping
passage.
8. The separation type metallurgical reduction apparatus as claimed
in claim 1, wherein a reduction pot is disposed in the reduction
furnace for receiving the material to be reduced.
9. The separation type metallurgical reduction apparatus as claimed
in claim 2, wherein a reduction pot is disposed in the reduction
furnace for receiving the material to be reduced.
10. The separation type metallurgical reduction apparatus as
claimed in claim 6, wherein a reduction pot is disposed in the
reduction furnace for receiving the material to be reduced.
11. The separation type metallurgical reduction apparatus as
claimed in claim 1, wherein at least one heating device is disposed
in the reduction furnace for heating the internal space of the
reduction furnace.
12. The separation type metallurgical reduction apparatus as
claimed in claim 2, wherein at least one heating device is disposed
in the reduction furnace for heating the internal space of the
reduction furnace.
13. The separation type metallurgical reduction apparatus as
claimed in claim 1, wherein a conveying device is disposed in the
cooling device for conveying at least one carrier device.
14. The separation type metallurgical reduction apparatus as
claimed in claim 2, wherein a conveying device is disposed in the
cooling device for conveying at least one carrier device.
15. The separation type metallurgical reduction apparatus as
claimed in claim 6, wherein a conveying device is disposed in the
cooling device for conveying at least one carrier device.
16. The separation type metallurgical reduction apparatus as
claimed in claim 1, wherein the reduction furnace has an inner wall
and an outer wall, a heat insulation device being disposed between
the inner and outer walls of the reduction furnace.
17. The separation type metallurgical reduction apparatus as
claimed in claim 2, wherein the reduction furnace has an inner wall
and an outer wall, a heat insulation device being disposed between
the inner and outer walls of the reduction furnace.
18. The separation type metallurgical reduction apparatus as
claimed in claim 6, wherein the reduction furnace has an inner wall
and an outer wall, a heat insulation device being disposed between
the inner and outer walls of the reduction furnace.
19. The separation type metallurgical reduction apparatus as
claimed in claim 13, wherein the reduction furnace has an inner
wall and an outer wall, a heat insulation device being disposed
between the inner and outer walls of the reduction furnace.
20. The separation type metallurgical reduction apparatus as
claimed in claim 1, wherein a cooling fan or a circulation cooling
device is disposed in the cooling device for speeding cooling
process.
21. The separation type metallurgical reduction apparatus as
claimed in claim 2, wherein a cooling fan or a circulation cooling
device is disposed in the cooling device for speeding cooling
process.
22. The separation type metallurgical reduction apparatus as
claimed in claim 6, wherein a cooling fan or a circulation cooling
device is disposed in the cooling device for speeding cooling
process.
23. The separation type metallurgical reduction apparatus as
claimed in claim 13, wherein a cooling fan or a circulation cooling
device is disposed in the cooling device for speeding cooling
process.
24. The separation type metallurgical reduction apparatus as
claimed in claim 1, wherein the cooling device has an inner wall
and an outer wall a heat insulation device being disposed between
the inner and outer walls of the cooling device.
25. The separation type metallurgical reduction apparatus as
claimed in claim 2, wherein the cooling device has an inner wall
and an outer wall, a heat insulation device being disposed between
the inner and outer walls of the cooling device.
26. The separation type metallurgical reduction apparatus as
claimed in claim 6, wherein the cooling device has an inner wall
and an outer wall, a heat insulation device being disposed between
the inner and outer walls of the cooling device.
27. The separation type metallurgical reduction apparatus as
claimed in claim 13, wherein the cooling device has an inner wall
and an outer wall, a heat insulation device being disposed between
the inner and outer walls of the cooling device.
28. A separation type metallurgical reduction method comprising
steps of: (1) dropping a material to be reduced into a reduction
furnace for reduction; (2) moving a reduction product from the
reduction furnace into a closed cooling device, which is separable
from the reduction furnace and isolated from outer side; (3)
separating the reduction furnace from the cooling device; (4)
dropping another crop of material to be reduced into the reduction
furnace for reduction and simultaneously cooling the reduction
product in the cooling device; and (5) moving the cooled reduction
product out of the cooling device.
29. The separation type metallurgical reduction method as claimed
in claim 28, wherein in step (1), when reduced, the material in the
reduction furnace is blended to speed reduction process.
30. The separation type metallurgical reduction method as claimed
in claim 28, wherein in step (2), the reduction product is first
moved from the reduction furnace into a load chamber and after the
reduction furnace is separated from the cooling device, the
reduction product is moved from the load chamber into a cooling
chamber for cooling.
31. The separation type metallurgical reduction method as claimed
in claim 28, wherein in step (2), the cooling device includes a
preheating chamber, a carrier device being conveyed from the
preheating chamber into the load chamber, after the load chamber is
closed and isolated from outer side, the reduction product being
moved into the carrier device in the closed load chamber.
32. The separation type metallurgical reduction method as claimed
in claim 30, wherein in step (2), the cooling device includes a
preheating chamber, a carrier device being conveyed from the
preheating chamber into the load chamber, after the load chamber is
closed and isolated from outer side, the reduction product being
moved into the carrier device in the closed load chamber.
33. The separation type metallurgical reduction method as claimed
in claim 28, wherein in step (4), a cooling fan or a circulation
cooling device is disposed in the cooling device for speeding
cooling process.
34. The separation type metallurgical reduction method as claimed
in claim 30, wherein in step (4), a cooling fan or a circulation
cooling device is disposed in the cooling device for speeding
cooling process.
35. The separation type metallurgical reduction method as claimed
in claim 28, wherein in step (4), an inert gas is released into the
cooling device to keep the reduction product in a stable state.
36. The separation type metallurgical reduction method as claimed
in claim 30, wherein in step (4), an inert gas is released into the
cooling device to keep the reduction product in a stable state.
37. The separation type metallurgical reduction method as claimed
in claim 31, wherein in step (4), an inert gas is released into the
cooling device to keep the reduction product in a stable state.
38. The separation type metallurgical reduction method as claimed
in claim 28, wherein at least one of steps (1) to (4) is performed
in a clean or vacuum condition.
39. The separation type metallurgical reduction method as claimed
in claim 31, wherein the step of moving the reduction product from
the reduction furnace into the carrier device in the closed load
chamber is performed in a clean or vacuum condition.
40. The separation type metallurgical reduction method as claimed
in claim 35, wherein the steps are performed in a clean or vacuum
condition.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to a separation type
metallurgical reduction method and an apparatus thereof. By means
of the separation type metallurgical reduction apparatus, the
metallurgical reduction/smelting process and the cooling process
are separately performed in different spaces at the same time. In
contrast, in a convent ional metallurgical reduction furnace, the
smelting process and the cooling process must be performed in the
same space and it is necessary to repeatedly raise and lower the
temperature of the reduction furnace. Accordingly, by means of the
separation type metallurgical reduction apparatus of the present
invention, the operation time of the metallurgical process is
greatly shortened to overcome the shortcoming of too long waiting
time that exists in the conventional metallurgical reduction
furnace. Moreover, by means of the separation type metallurgical
reduction apparatus of the present invention, the energy
consumption is greatly reduced and the yield rate is greatly
increased.
[0003] 2. Description of the Related Art
[0004] It is known that the developments of all kinds of industries
have relied on sufficient supply and full application of specific
materials for so long, especially some metal materials. Therefore,
the metallurgical technique plays an important role in the advance
of human society. The most important material used in the current
electronic industries is silicon (Si). The sale of silicon-made
components is about 95% of the sale of the semiconductor components
in the world. In natural field, all silicon materials exist not in
element state. Instead, the silicon materials exist in form of
silica (impure SiO.sub.2) and silicate. Therefore, it is an
important tropic in science and technology how to effectively and
economically smelt silicon material from the natural raw material
for manufacturing all kinds of silicon-made products.
[0005] In the above materials, metallurgical-grade Si (MG-Si) is a
material of solar cell. The metallurgical-grade Si can be divided
into three major varieties, that is, monocrystalline silicon,
multicrystalline silicon and non-crystalline silicon. The raw
material from which multicrystalline silicon or monocrystalline
silicon is smelted is mainly high-purity (>97%) quartz sand,
which is also a crystal of SiO.sub.2. The first step of
manufacturing high-purity multicrystalline silicon is reducing
silicon from silica. In a common manufacturing process, the
materials of silica, coke, coal and woods are mixed and placed in a
graphite electrical arc heating reduction furnace and heated at a
high temperature of 1500.degree. C..about.2000.degree. C. to reduce
SiO.sub.2 into silicon. The chemical reaction formulas are
follows:
SiO.sub.2+C.fwdarw.Si+CO.sub.2
SiO.sub.2+2C.fwdarw.Si+2CO
[0006] In the conventional reduction technique, after the silica is
placed into the reduction furnace, it is necessary to gradually
raise the temperature of the reduction furnace from an ambient
temperature to the high temperature of 1500.degree.
C..about.2000.degree. C. for melting and reducing the material to
be reduced. After the reduction process is completed, it is
necessary to gradually lower the temperature of the reduction
furnace to about 250.degree. C. (approximate to the ambient
temperature) for taking out the reduction product and avoiding
abrupt temperature change, which may ill affect the equipment, the
quality of the reduction product and the operation environment.
After the reduction product is taken out from the reduction
furnace, another crop of material to be reduced is placed into the
reduction furnace. Then, it is necessary to gradually re-raise the
temperature of the reduction furnace from the ambient temperature
to the high temperature of 1500.degree. C..about.2000.degree. C.
for melting and reducing the material. In the above process, it is
necessary to repeatedly raise and lower the temperature of the
reduction furnace. This is because in the case that the reduction
furnace is opened under the high temperature of 1500.degree.
C..about.2000.degree. C., there is a danger of explosion of the
furnace body due to excessively great difference between the
temperature of the furnace body and the temperature of the
environment. Moreover, a great amount of high-temperature fluid
will enter the operation environment to cause thermal contamination
of the operation environment and injury to site workers. What is
more, the abrupt temperature drop may lead to structural damage to
the high-temperature smelted silicon product. Also, the silicon
product will be inevitably contaminated with impurities in the
environment and become useless.
[0007] According to practical estimation, one single cycle of the
conventional metallurgical reduction of the silicon material
(filling material.fwdarw.heating.fwdarw.reducing.fwdarw.lowering
temperature.fwdarw.releasing product) will cost a quite long time
of about 32 hours.
[0008] Moreover, after the temperature of the reduction furnace is
continuously raised from about 250.degree. C. to 1500.degree.
C..about.2000.degree. C. for smelting the material and then
gradually lowered to about 250.degree. C. for taking out the
reduction product, a great amount of thermal energy is lost and
wasted. Furthermore, when re-raising the temperature of the
reduction furnace from 250.degree. C. to 1500.degree.
C..about.2000.degree. C. for reduction, a great amount of
electrical energy is consumed. Therefore, in the conventional
metallurgical reduction method, a very long waiting time is wasted
and the environment is contaminated. Also, a great amount of energy
is wasted. This is not economic and fails to meet the requirement
of environmental protection.
[0009] It is therefore tried by the applicant to provide a novel
metallurgical reduction method and an apparatus thereof. By means
of the separation type metallurgical reduction apparatus, the
operation time of the metallurgical process is greatly shortened
and the energy consumption is greatly reduced and the yield rate is
greatly increased.
SUMMARY OF THE INVENTION
[0010] It is therefore a primary object of the present invention to
provide a separation type metallurgical reduction method and an
apparatus thereof. The separation type metallurgical reduction
apparatus includes a reduction furnace and a multistage cooling
device in cooperation with the reduction furnace. By means of the
separation type metallurgical reduction apparatus, the
reduction/smelting process of the material and the cooling process
of the reduction product are separately performed in different
spaces at the same time. Accordingly, the waiting time for re-rise
of the temperature of the reduction furnace is greatly shortened so
that the operation time of the metallurgical process is greatly
shortened. Also, the energy consumption in each operation is
greatly reduced in accordance with the requirement of environmental
protect ion. Therefore, the production efficiency is greatly
promoted and the yield rate is greatly increased.
[0011] To achieve the above and other objects, the separation type
metallurgical reduction apparatus of the present invention includes
a reduction furnace and a multistage cooling device. The reduction
furnace serves to provide a high temperature for melting and
reducing a material placed in the reduction furnace. The cooling
device is connected with the reduction furnace in alignment with a
material release passage thereof. The reduction product is released
from the material release passage into the cooling device for
cooling. Accordingly, the reduction/smelting process of the
material and the cooling process of the reduction product are
separately performed in different spaces at the same time. The
cooling device includes a load chamber arranged under the reduction
furnace. The material release passage is positioned between the
load chamber and the reduction furnace. The internal space of the
load chamber communicates with the internal space of the reduction
furnace through the material release passage. A material release
gate is disposed in the material release passage for controlling
unblocking/blocking of the material release passage. In addition, a
preheating chamber is arranged on one side of the load chamber in
communication with the load chamber. A first load gate is disposed
between the load chamber and the preheating chamber to control
communication/non-communication between the preheating chamber and
the load chamber. The preheating chamber is provided with a carrier
input gate through which the carrier device can be input from outer
side. A cooling chamber is installed on the other side of the load
chamber in communication with the load chamber. A second load gate
is disposed between the cooling chamber and the load chamber to
control communication/non-communication between the cooling chamber
and the load chamber. The cooling chamber is provided with a
carrier output gate through which the carrier device can be moved
out of the cooling chamber. In addition, a continuous conveying
device is arranged in a path extending from outer side of the
carrier input gate through the carrier input gate, the preheating
chamber, the first load gate, the load chamber, the second load
gate, the cooling chamber and the carrier output gate to the outer
side of the cooling chamber. The conveying device serves to convey
the carrier device through the path to carry the reduction product
for the preheating and cooling processes stage by stage.
[0012] A material dropping device is disposed above the reduction
furnace. A material dropping passage is positioned between the
material dropping device and the reduction furnace, whereby the
internal space of the material dropping device communicates with
the internal space of the reduction furnace through the material
dropping passage. A material dropping gate is arranged in the
material dropping passage for controlling unblocking/blocking of
the material dropping passage. The material to be reduced is filled
in the internal space of the material dropping device. When the
material dropping gate of the material dropping passage is opened
to unblock the material dropping passage, the material to be
reduced is allowed to drop into the reduction furnace through the
material dropping passage.
[0013] According to the above arrangement, the reduction/smelting
process of the material and the cooling process of the reduction
product are separately performed in different spaces at the same
time. Accordingly, the metallurgical reduction process and cooling
process can be overlapped and performed at the same time crop by
crop to shorten time interval between reduction processes of two
crops of material to be reduced. Therefore, the production
efficiency is promoted and the yield rate is increased. Moreover,
the cooling device is separated from the reduction furnace and the
carrier device is separately conveyed through the cooling device
section by section so that the quality of the reduction product can
be ensured. Also, the energy consumption is greatly reduced in
accordance with the requirement of environmental protection.
[0014] The present invention can be best understood through the
following description and accompanying drawings, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a front view of a preferred embodiment of the
separation type metallurgical reduction apparatus of the present
invention:
[0016] FIG. 2 is a side view of the preferred embodiment of the
separation type metallurgical reduction apparatus of the present
invention;
[0017] FIG. 3 is a front view according to FIG. 1, showing that the
material to be reduced is filled into the material dropping
device:
[0018] FIG. 4 is a front view according to FIG. 1, showing that the
material to be reduced is dropped from the material dropping device
into the reduction furnace:
[0019] FIG. 5 is a front view according to FIG. 1, showing that the
material is heated, molten and reduced in the reduction
furnace;
[0020] FIG. 6 is a front view according to FIG. 1, showing that the
preheated carrier device is conveyed to the load chamber;
[0021] FIG. 7A is a front view according to FIG. 1, showing that
the reduction product is dropped from the reduction furnace into
the load chamber;
[0022] FIG. 7B is a side view according to FIG. 7A, showing that
the reduction product is dropped from the reduction furnace into
the load chamber;
[0023] FIG. 8 is a front view according to FIG. 1, showing that the
reduction product is completely released from the reduction furnace
and the reduction furnace is re-filled with another crop of
material to be reduced and the carrier device with the reduction
product is ready to be conveyed into the cooling chamber;
[0024] FIG. 9 is a front view according to FIG. 1, showing that the
carrier device with the reduction product is conveyed into the
cooling chamber for cooling and a vacant carrier device is conveyed
into the preheating chamber for preheating; and
[0025] FIG. 10 is a front view according to FIG. 1, showing that
the cooled carrier device with the cooled reduction product is
conveyed out of the cooling chamber.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Please refer to FIGS. 1 and 2. According to a preferred
embodiment, the separation type metallurgical reduction apparatus
of the present invention includes at least one reduction furnace 10
and a cooling device 20.
[0027] The reduction furnace 10 has an internal space in which the
material to be reduced is placed (as shown in FIG. 3). In practice,
a reduction pot 11 is disposed in the reduction furnace 10 for
containing the material 30 to be reduced. The material 30 to be
reduced is molten and reduced in the reduction furnace 10 at a high
temperature of 1500.degree. C..about.2000.degree. C. The material
to be reduced can be silicon material such as silica or silica
sand, chrome material, tungsten material, magnesium material, iron
material, copper material or any other smeltable metal material.
The present invention can be used to reduce and smelt any material
that can be molten and reduced at high temperature. A heating
device 13 is arranged in the reduction furnace 10 to uniformly heat
the internal space of the reduction furnace 10. The heating device
13 can heat the internal space in an electrical arc heating manner,
high-frequency heating manner or any other suitable heating manner.
A blending device 14 is installed in the reduction furnace 10 to
extend into the reduction pot 11 and continuously blend the
material for the heating device 13 to more uniformly heat and melt
the material 30. In addition, a heat insulation device 15
(preferably a liquid-cooled or water-cooled heat insulation device)
is disposed between inner wall 101 and outer wall 102 of the
reduction furnace to prevent the high heat in the reduction furnace
10 from being conducted to outer side of the reduction furnace 10.
In this case, the ambient environment of the reduction furnace 10
is protected from being thermally contaminated. Also, the thermal
energy can be recycled for reuse.
[0028] A material dropping device 17 is disposed above the
reduction furnace 10. A material dropping passage 171 is positioned
between the material dropping device 17 and the reduction furnace
10, whereby the internal space of the material dropping device 17
communicates with the internal space of the reduction furnace 10
through the material dropping passage 171. A material dropping gate
172 is arranged in the material dropping passage 171 for
controlling unblocking/blocking of the material dropping passage
171. The material to be reduced is filled in the internal space of
the material dropping device 17. When the material dropping gate
172 of the material dropping passage 171 is opened to unblock the
material dropping passage 171, the material 30 to be reduced is
allowed to drop into the reduction furnace 10 (or the reduction pot
11). A material filling port 173 is disposed on an upper side of
the material dropping device 17. An upper cover 174 is disposed at
the material filling port 173 for blocking/unblocking the material
filling port 173 so as to prevent the material 30 from being
contaminated by ambient impurities. The material 30 to be reduced
can be automatically regularly and quantitatively filled into the
material dropping device 17 by means of a conveying belt to save
labor and avoid inconvenience.
[0029] The cooling device 20 is arranged under a material release
passage 16 of the reduction furnace 10. The cooling device 20 is
provided with a load chamber 21. The internal space of the
reduction furnace and the internal space of the load chamber 21
communicate with each other through the material release passage
16. A material release gate 161 is disposed in the material release
passage 16 for controlling unblocking/blocking of the material
release passage 16. The material can be previously input to at
least one carrier device 40 in the internal space of the load
chamber 21. The carrier device 40 is aligned with an exit of the
material release passage 16 to accept the material output from the
material release passage 16.
[0030] A preheating chamber 22 is installed on one side of the load
chamber 21. A first load gate 221 is disposed between the load
chamber 21 and the preheating chamber 22 to control
communication/non-communication between the preheating chamber 22
and the load chamber 21. When the first load gate 221 is opened,
the carrier device 40 can pass through the first load gate 221 into
the load chamber 21. The preheating chamber 22 is further provided
with a carrier input gate 222 through which the carrier device 40
can be input from outer side. In addition, a heating device 223 is
further disposed in the preheating chamber 22 for heating the
internal space thereof. The preheating chamber 22 mainly serves to
preheat the input carrier device 40 and then input the carrier
device to the load chamber 21 before the reduction product is input
to the load chamber 21. This can avoid too large difference between
the temperature of the carrier device 40 and the temperature of the
reduction product so as to avoid ill affection on the reduction
product or accident in the loading process.
[0031] A cooling chamber 23 is installed on the other side of the
load chamber 21. A second load gate 231 is disposed between the
cooling chamber 23 and the load chamber 21 to control
communication/non-communication between the cooling chamber 23 and
the load chamber 21. When the second load gate 231 is opened, the
carrier device 40 can pass through the second load gate 231. A
cooling fan 232 or the like circulation cooling device can be
disposed in the cooling chamber 23 to speed the cooling operation.
In addition, the cooling chamber 23 is provided with a carrier
output gate 233 through which the cooled reduction product and the
carrier device 40 are conveyed to outer side of the cooling chamber
23.
[0032] A continuous or multisection conveying device 24 is disposed
in the preheating chamber 22, the load chamber 21 and the cooling
chamber 23 between the gates thereof for conveying the carrier
device 40. By means of the conveying device 24, the carrier device
40 can be input from outer side through the carrier input gate 222
to the preheating chamber 22. The carrier device 40 then is
conveyed through the first load gate 221 into the load chamber 21
and then conveyed through the second load gate 231 into the cooling
chamber 23. Finally, the carrier device 40 is conveyed through the
carrier output gate 233 to the outer side. Accordingly, the carrier
device (or the reduction product) can be conveniently and
continuously conveyed. In addition, two carrier transportation
trolleys 50 are respectively disposed behind the carrier input gate
222 of the preheating chamber 22 and in front of the carrier output
gate 233 of the cooling chamber 23 for inputting the carrier device
40 to the conveying device 25 and outputting the carrier device 40
from the conveying device 25. Accordingly, the preheating chamber
22, the load chamber 21, the cooling chamber 23 and the conveying
device cooperate with each other to form a separation type
multistage cooling device, which can continuously convey the
carrier device 40.
[0033] In addition, heat insulation devices 25 (preferably
liquid-cooled or water-cooled heat insulation devices) are
respectively disposed between inner walls and outer walls of the
separated spaces of the cooling device 20 to prevent the high heat
in the spaces from being conducted to outer side and protect the
ambient environment from being thermally contaminated. Moreover,
the internal spaces of the reduction furnace 10 and the cooling
device 20 are all clean rooms (or vacuum rooms) to avoid
contamination of the material or the product and ensure stable
quality of operation.
[0034] Please now refer to FIGS. 3 to 10. The separation type
metallurgical reduction method of the present invention
includes:
[0035] step 201 of filling the material 30 to be reduced into the
material dropping device 17 and preparing the material 30;
[0036] step 202 of opening the material dropping gate 172 to
quantitatively drop the material 30 to be reduced through the
material dropping passage 171 into the internal space of the
reduction furnace 10 (or the reduction pot 11);
[0037] step 203 of closing the material dropping gate 172 and the
material release gate 161 to form a closed space in the reduction
furnace 10;
[0038] step 204 of using the heating device 13 of the reduction
furnace 10 to heat the material 30 to a high temperature so as to
melt and reduce the material 30, in this step, the material 30 in
the reduction furnace 10 being heated to a high temperature of
1500.degree. C..about.2000.degree. C. and molten, when heated and
molten, a blending device 14 being used to uniformly blend the
material 30 for reducing the material 30 into a reduction product
301;
[0039] step 205 of using the conveying device 24 to convey the
preheated carrier device 40 from the preheating chamber 22 into the
load chamber 21 in a position under the material release passage
16, then the first and second load gates 221, 231 being closed and
then the material release gate 161 being opened to drop the
reduction product 301 through the material release passage 16 into
the carrier device in the load chamber 21;
[0040] step 206 of closing the material release gate 161 and
further dropping another crop of material 30 to be reduced from the
material dropping device 17 into the reduction furnace 10 for
heating and reduction process, in the meantime, the second load
gate 231 of the cooling device 20 being opened to convey the
carrier device 40 with the reduction product 301 from the load
chamber 21 into the cooling chamber 23 for cooling;
[0041] step 207 of closing the carrier output gate 233 and
simultaneously (later) opening the carrier input gate 222 to convey
the carrier device 40 from the outer side (the trolley 50) into the
preheating chamber 22 for preheating:
[0042] step 208 of previously conveying the carrier device 40 into
the load chamber 21 before step 205 is performed again; and
[0043] step 209 of cooling the reduction product 301 in the cooling
chamber 23 to a set temperature relatively approximate to ambient
temperature and then opening the carrier output gate 233 to convey
the cooled reduction product 301 and the carrier device 40 out of
the cooling chamber 23. The set temperature can be under
150.degree. C..about.100.degree. C. according to the current normal
operation. In steps 206 to 208, a cooling fan 232 or the like
cooling device can be used to speed the cooling process of the
reduction product 301 and the carrier device 40 carrying the
reduction product 301. The operation is performed in a clean or
vacuum room. In addition, an inert gas can be released during the
cooling process to keep the reduction product 301 in a stable state
to complete the reduction process of one crop of material.
[0044] According to the aforesaid, the heating/reduction operation
of the material 30 in the reduction furnace 10 and the cooling
operation of the reduction product 301 are performed in different
spaces at the same time. The blocking/unblocking of the material
release passage 16 and the opening/closing of the respective gates
are effectively controlled to keep the reduction furnace 10 at a
high temperature. It is unnecessary to repeatedly raise/lower the
temperature of the reduction furnace as in the conventional
reduction furnace. Therefore, the energy consumption can be greatly
reduced. Moreover, the time for each re-rise of the temperature of
the internal space of the reduction furnace to a high temperature
necessary for the reduction operation is greatly shortened.
Therefore, the product ion efficiency is greatly promoted.
Furthermore, the reduction stage of operation and cooling stage of
operation are performed in separated environments and thus can be
independently more flexibly and conveniently controlled as
necessary to ensure high quality of the reduction product 301.
[0045] According to the above arrangement, the present invention
has the following advantages: [0046] 1. By means of the separation
type metallurgical reduction method and the apparatus thereof, the
heating/reduction operation of the material and the cooling
operation of the reduction product are performed in different
spaces at the same time. Therefore, the waiting time for each
re-rise of the temperature of the reduction furnace to the
reduction temperature is greatly shortened and the energy
consumption is greatly reduced. Therefore, the product ion
efficiency is greatly promoted and a great amount of energy is
saved. [0047] 2. By means of the separation type metallurgical
reduction method and the apparatus thereof, the steps of dropping
material, reduction, cooling and achieving reduction product can be
integratedly and continuously performed to save the time for
closedown of the furnace, lowering of the temperature, release of
the material, preparation of the material, holdup for lack of
material, restart of the furnace and reheating. Therefore, the
yield rate can be greatly increased. [0048] 3. The present
invention includes a unique cooling device connected with the
reduction furnace to independently cool the reduction product.
Therefore, it is unnecessary to repeatedly cool the reduction
furnace for cooling the reduction product. This can reduce loss of
thermal energy in the reduction furnace and save electrical energy
for repeatedly raising the temperature of the reduction furnace in
accordance with the environmental protection requirements of
energy-saving and carbon reduction, [0049] 4. By means of the
separation type metallurgical reduction method and the apparatus
thereof, the heating/reduction operation of the material and the
cooling operation of the reduction product are performed in
different spaces at the same time. Therefore, the reduction product
is provided with a better and more stable cooling environment to
minimize the possibility of contamination of the reduction product
by ambient impurities during the cooling process. Therefore, the
reduction stage of operation and the cooling stage of operation are
performed in separated environments and thus can be independently
and more flexibly controlled to ensure high quality of the
reduction product.
[0050] The above embodiments are only used to illustrate the
present invention, not intended to limit the scope thereof. Many
modifications of the above embodiments can be made without
departing from the spirit of the present invention.
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