MOLTEN METAL TRANSFER SYSTEM AND ROTOR

• US 20130299524A1
• Filed: 03/13/2013
• Published: 11/14/2013
• Est. Priority Date: 06/21/2007
• Status: Active Grant

• Current Assignee: Molten Metal Equipment Innovations Incorporated (Molten)
• Original Assignee: Molten Metal Equipment Innovations Incorporated (Molten)
• Inventors: Cooper, Paul V., Fontana, Vincent D.
• Granted Patent: US 9,156,087 B2
• Time in Patent Office: Days
• US Class Current: 222/590
• CPC Class Codes: B22D 37/00 Controlling or regulating the pouring of molten metal from a casting melt-holding vessel B22D11/18, B22D39/00, B22D41/00 take precedence
• CPC Class Codes: B22D 39/00 Equipment for supplying molten metal in rations
• CPC Class Codes: B22D 41/00 Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like B22D39/00, B22D43/00 take precedence
• CPC Class Codes: B22D 41/02 Linings
• CPC Class Codes: B22D 7/00 Casting ingots, e.g. from ferrous metalsequipment for conveying molten metal B22D35/00
• CPC Class Codes: C22B 21/0084 melting and handling molten aluminium C22B21/02, C22B21/04 and C22B21/06 take precedence
• CPC Class Codes: C22B 21/064 using inert or reactive gases C22B21/066 and C22B21/068 take precedence
• CPC Class Codes: F27D 27/005 Pumps
• CPC Class Codes: F27D 3/14 Charging or discharging liquid or molten material
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture

Abstract

The invention relates to systems for transferring molten metal from one structure to another. Aspects of the invention include a transfer chamber constructed inside of or next to a vessel used to retain molten metal. The transfer chamber is in fluid communication with the vessel so molten metal from the vessel can enter the transfer chamber. A powered device, which may be inside of the transfer chamber, moves molten metal upward and out of the transfer chamber and preferably into a structure outside of the vessel, such as another vessel or a launder.

Claims

1. A rotor for use in a tube for directing molten metal upward, the rotor comprising one or more rotor blades, wherein each rotor blade comprises:

(a) a first portion having (i) a leading edge with a thickness of ⅛

″

or greater, (ii) a first upper surface angled to direct molten metal upwards, and (iii) a first bottom surface with an angle equal to or less than the angle of the first upper surface as measured from a vertical axis; and

(b) a second portion integrally formed with the first portion, the second portion having (i) a second upper surface angled to direct molten metal upwards, the angle of the second upper surface being greater than the angle of the first upper surface as measured from the vertical axis, and (ii) a second bottom surface, the second bottom surface having an angle greater than the angle of the first bottom surface as measured from the vertical axis.

2. The rotor of claim 1 that further includes a connective portion for connecting to a rotor shaft.

3. The rotor of claim 2 wherein the connective portion includes a threaded bore.

4. The rotor of claim 1 wherein the first upper surface has an angle of between 15°

and 45°

.

5. The rotor of claim 1 wherein the second upper surface has an angle of between 45°

and 70°

.

6. The rotor of claim 1 wherein the first bottom surface has an angle of between +5% and −

5%.

7. The rotor of claim 1 wherein the second bottom surface has an angle of between 45°

and 70°

.

8. The rotor of claim 1 wherein the angle of the second upper surface is within 10°

of the angle of the second bottom surface.

9. The rotor of claim 1 that includes a top surface having a leading part and a trailing part.

10. The rotor of claim 1 wherein the second bottom surface has a leading part that is vertically aligned with the leading part of the top surface.

11. The rotor of claim 10 wherein the leading part of the second bottom surface is advanced from the trailing part of the top surface.

12. The rotor of claim 1 that has three, equally-radially-spaced blades.

64. The vessel of claim 4 that further includes a molten metal pump including a pump base having a discharge in the pump base, with a riser tube connected to the discharge, the riser tube in fluid communication with the opening, so that as the pump operates molten metal is pumped through the opening, into the uptake section and out of the outlet.

13. A system for transferring molten metal out of a vessel, the system comprising:

(a) a vessel, the vessel having a cavity and including a transfer chamber having an opening in communication with the cavity, the transfer chamber including, an uptake section above the opening;

(b) an outlet in communication with the uptake section and above the opening; and

(c) a molten metal pump having a motor, a drive shaft connected to the pump and extending into the uptake section, the drive shaft connected to a rotor, wherein the rotor is configured to move molten metal upward into the uptake section, where it exits the outlet.

14. The system of claim 13 wherein the molten metal pump does not include a pump housing connected to a superstructure.

15. The system of claim 13 wherein the pump does not include support posts.

16. The system of claim 13 wherein the rotor comprises one or more rotor blades, and each blade includes:

(a) a first portion having (i) a leading edge with a thickness of ⅛

″

or greater, (ii) a first upper surface angled to direct molten metal upwards, and (iii) a first bottom surface with an angle equal to or less than the angle of the first upper surface as measured from a vertical axis; and

(b) a second portion integrally formed with the first portion, the second portion having (i) a second upper surface angled to direct molten metal upwards, the angle of the second upper surface being greater than the angle of the first upper surface as measured from the vertical axis, and (ii) a second bottom surface, the second bottom surface having an angle greater than the angle of the first bottom surface as measured from the vertical axis.

17. The system of claim 13 wherein the rotor comprises one or more blades and each blade is vertically oriented and straight.

18. The system of claim 13 wherein the vessel is comprised of refractory material.

19. The system of claim 13 wherein the vessel has an inner bottom surface and the inner bottom surface is angled downwards towards the opening.

20. The system of claim 13 wherein the rotor has a diameter and is positioned in the transfer chamber and the portion of the transfer chamber in which the rotor is positioned in is circular and has a diameter of ¼

″

or less than the diameter of the rotor.

21. The system of claim 20 wherein the opening has a diameter of 1/32″

-1⅛

″

of the diameter of the rotor.

22. The system of claim 13 wherein the transfer chamber has a first section having a first cross-sectional area and a second section having a second cross-sectional area, the second section adjacent the opening and for reviewing the rotor, and the second cross-sectional area being smaller than the first cross-sectional area.

23. The system of claim 22 that has a third section having a third cross-sectional area, the third section being between the first section and the second section, and the third cross-sectional area being smaller than the first cross-sectional area, but larger than the second cross-sectional area.

24. The system of claim 22 wherein the rotor is positioned at least partially in the second section.

25. The system of claim 22 wherein the rotor is positioned at least partially in the second section.

26. The system of claim 13 that further includes a superstructure for supporting the motor.

27. The system of claim 13 that includes one or more brackets for supporting the pump above the vessel.

28. The system of claim 27 wherein the vessel has a first side wall and a second side wall opposite the first side wall and the bracket comprises two metal beams that extend from the first side wall to the second side wall, and each bracket is connected to the first side wall, the second side wall and the superstructure.

29. The system of claim 28 wherein each bracket is a flat metal bar.

30. The system of claim 28 wherein each bracket is a metal L-bar.

31. The system of claim 13 wherein the rotor has a bottom and the outlet is 2 feet or more above the bottom of the rotor.

32. The system of claim 13 wherein the outlet is at least 2 feet above the inner bottom surface of the vessel.

33. The system of claim 13 wherein the outlet is two feet or more above the transfer chamber opening.

34. The system of claim 13 wherein the rotor has a bottom surface and the bottom surface is three inches or more above the inner bottom surface of the vessel.

35. The system of claim 13 that further includes a tap-out opening in communication with the vessel cavity, the tap-out opening being positioned lower than the rotor.

36. The system of claim 13 that further includes a circulation pump in the vessel and outside of the transfer chamber.

37. The system of claim 36 wherein the circulation pump has (a) a pump base including a pump chamber and a tangential discharge, (b) a superstructure on which a motor is mounted, (c) support posts connecting the pump base to the superstructure, (d) a rotor positioned in the pump chamber, and (e) a drive shaft connecting the motor to the rotor.

38. The system of claim 37 wherein the drive shaft comprises a motor shaft having a first end connected to the motor and a second end connected to a coupling, and a rotor shaft having a first end connected to the coupling and a second end connected to the rotor.

39. The system of claim 36 wherein the circulation pump has a discharge open to a portion of the vessel in which the transfer chamber is positioned.

40. The system of claim 39 that further includes a wall dividing the vessel into a first section that retains the transfer chamber and a second section that retains the circulation pump, the wall having an opening in fluid communication with the circulation pump discharge.

47. The system of claim 13 wherein a launder is connected to the outlet and the launder has a horizontal angle of between 0°

and 10°

tilting back towards the outlet.

48. The system of claim 47 wherein the launder has a horizontal angle of between 0°

and 5°

tilting back towards the outlet.

49. The system of claim 47 wherein the launder has a horizontal angle of between 0°

and 3°

tilting back towards the outlet.

50. The system of claim 47 wherein the launder has a horizontal angle of between 1°

and 3°

.

51. The system of claim 13 wherein a launder is connected to the outlet and the launder is angled backwards towards the outlet at a downward slope of ⅛

″

for every 10″

of launder length.

52. The system of claim 13 that further includes a circulation pump in the vessel upstream of the transfer chamber, the circulation pump having an outlet that discharges molten metal towards the transfer chamber.

54. The transfer well of claim 47 that has a bottom surface two feet or less beneath the first opening.

55. The transfer well system of claim 47 wherein the pump does not include a pump base housing the rotor.

56. The transfer well system of claim 47 wherein the pump does not include a superstructure or support posts.

57. The transfer well system of claim 47 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.

58. The transfer well system of claim 51 wherein the rotor shaft is comprised of one or more of the group consisting of graphite and ceramic.

59. The transfer well system of claim 47 that has three walls and shares a fourth, common wall with the vessel.

60. The transfer well system of claim 47 wherein the pump is supported by a carriage connected to the transfer well.

62. The transfer well system of claim 55 that has a third section having a third cross-sectional area, the third section being between the first section and the second section, and the third cross-sectional area being smaller than the first cross-sectional area, but larger than the second cross-sectional area.

63. The transfer well system of claim 47 that further includes a circulation pump in the vessel upstream of the transfer chamber, the circulation pump having an outlet that discharges molten metal towards the transfer chamber.

65. The vessel of claim 59 wherein the pump has (a) a pump base including a pump chamber and a tangential discharge, (b) a superstructure on which a motor is mounted, (c) support posts connecting the pump base to the superstructure, (d) a rotor positioned in the pump chamber, and (e) a drive shaft connecting the motor to the rotor.

66. The vessel of claim 60 wherein the drive shaft comprises a motor shaft having a first end connected to the motor and a second end connected to a coupling, and a rotor shaft having a first end connected to the coupling and a second end connected to the rotor.

41. A vessel for use in a system for transferring molten metal, the vessel including a cavity, a transfer chamber with an opening in communication with the cavity, the transfer chamber having an uptake section above the opening, and an outlet above the opening, the outlet in communication with the uptake section.

42. The vessel of claim 41 that also includes an inner bottom surface that slopes downward towards the opening.

43. The vessel of claim 41 that further includes a tap-out opening positioned lower than the opening.

44. The vessel of claim 41 wherein the outlet is at least two feet above the opening.

45. The vessel of claim 42 wherein the outlet is at least two feet above the inner bottom surface.

61. The transfer well system of claim 44 wherein the transfer chamber has a first section having a first cross-sectional area and a second section having a second cross-sectional area, the second section adjacent the opening and the second cross-sectional area being smaller than the first cross-sectional area.

46. A method of forming a transfer well to a vessel for containing molten metal, the method comprising the steps of:

(a) creating a form adjacent a side of the vessel, the form defining a transfer well having an outer wall, a top surface, a bottom surface, and a an opening in the top surface, and an internal cavity, the internal cavity having a chamber for holding molten metal, a restricted area above the chamber, an uptake section above the restricted area and in communication with the opening in the top surface, an outlet in communication with the uptake section;

(b) placing refractory material in the form to create the transfer well, wherein the side other vessel adjacent the transfer well forms part of the outer wall of the transfer well; and

(c) forming an opening near the bottom surface in the side of the vessel adjacent the transfer well.

53. A transfer well system for use with a vessel including a cavity for containing molten metal, the transfer chamber system being in fluid communication with the 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) an 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 ⅛

″

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 outlet.

67. A method of forming a first structure for the transfer of molten metal from the first structure to a second structure, the method comprising the steps of:

forming a transfer chamber in the first structure, the transfer chamber having an opening, an uptake section above the opening, and an outlet in communication with the uptake section and above the opening and leading out of the first structure;

wherein the transfer chamber includes a section at or above the opening, but below the outlet, configured to receive a molten metal pump rotor with between 1/32″ and

¼

″

of clearance along the entire circumference.

68. A method of transferring molten metal from a first structure to a second structure, the method comprising the steps of:

(a) providing a first structure having a transfer chamber in the first structure, the transfer chamber having an opening, an uptake section above the opening, and an outlet in communication with the uptake section and above the opening and leading out of the first structure;

wherein the transfer chamber includes a section at or above the opening, but below the outlet, configured to receive a molten metal pump rotor with between 1/32″ and

¼

″

of clearance along the entire circumference;

(b) positioning a molten metal pump in the first structure, such that the rotor is positioned in the section; and

(c) activating the pump to rotate the rotor, which moves molten metal up the uptake section and out of the outlet.