DESC:FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules, 2005

COMPLETE SPECIFICATION
(SEE SECTION 10 AND RULE 13)

TITLE OF THE INVENTION

“Thermite system and method for providing automatic thermiting of dross”

APPLICANT:

Name : Runaya Refining LLP
Nationality : Indian
Address : Runaya Refining LLP, Burkhamunda, Jharsuguda, Odisha, India - 768201

The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed:-

FIELD OF INVENTION
[0001] The present disclosure relates to aluminium dross processing, and more particularly to method and thermite system for providing automatic thermiting of dross. The present application is based on and claims priority from an Indian Provisional Application Number 202131033494 filed on 26th July 2021, the disclosure of which is hereby incorporated by reference herein.
BACKGROUND
[0002] Aluminium is a common metal which is abundantly available in environment. The aluminium is various sectors such as for example but not limited to aviation, manufacturing, power, industrial appliances, real-estate, household, etc. During production of the aluminium, re-melting and recycling of the aluminium, molten aluminium comes in contact with air leading to formation of dross due to a reaction of the molten aluminium with furnace atmosphere. The dross obtained from the furnace is hot and is transferred to dross pans for further processing which includes recover of the aluminium from the dross.
[0003] Further, pokers are used to manually poke holes into upper surface of the dross in the dross pan. Due to the holes created on the upper surface of the dross, air enters the dross leading to ignition of the aluminium. Also, the dross in the dross pan needs to be constantly stirred to ensure uniform heating of the dross to recover the aluminium and the poking and stirring are done manually by workers. Since the entire reaction is exothermic a large amount of heat is released along with smoke particles which in turn impacts health of workers involved in the process and also contributes to environmental pollution at large. Thus, it is desired to address the above mentioned disadvantages or other shortcomings or at least provide a useful alternative.
OBJECT OF INVENTION
[0004] The principal object of the embodiments herein is to provide a method and thermite system for providing automatic thermiting of dross without any human intervention. The proposed method and thermite system includes automatic poking and stirring of the dross periodically which enhances the yield in reclamation of aluminium from the dross. Also, the proposed method and system is environmental friendly as smoke released during mixing is treated in the thermite system before sending out of exhaust.

SUMMARY
[0005] Accordingly the embodiments herein disclose a thermite system for providing automatic thermiting of dross. The thermite system includes a dog house room structure including a right dross pan and a left dross pan of a 2-3 of dross pans including the dross and at least one automated stirring rod associated with each of the right dross pan and the left dross pan of the 2-3 of dross pans to stir the dross periodically. The thermite system also includes a right burner trolley corresponding to the right dross pan and entering the dog house room structure through a right window of the dog house room structure. The right burner trolley corresponding to the right dross pan automatically enters and exits the right window of the dog house room structure horizontally to heat the dross in the right dross pan periodically and a left burner trolley corresponding to the left dross pan and entering the dog house room structure through a left window of the dog house room structure. The left burner trolley corresponding to the left dross pan automatically enters and exits the left window of the dog house room structure horizontally to heat the dross in the left dross pan periodically. Further, the thermite system also includes a 2-4 of imaging sensors in the dog house room structure to monitor the thermiting of the dross and a right cover plate to cover the right window of the dog house room structure upon the entry and the exit of the right burner trolley into the dog house room structure. The thermite system includes a left cover plate to cover the left window of the dog house room structure upon the entry and exit of the left burner trolley into the dog house room structure and a switch box located out of the dog house room structure for controlling the thermiting of the dross.
[0006] In an embodiment, the thermite system also includes a DC motor for the automatic entry and exit of the right burner trolley and the left burner trolley into and from the dog house room structure correspondingly and an electric motor to move the at least one automated stirring rod along a vertical axis and a horizontal axis. The thermite system also includes a burner trolley chain sprocket assembly for providing motion to each of the right burner trolley and the left burner trolley at a constant speed and a smoke duct which includes a filter for emitting of filtered fumes produced during the thermiting of the dross. The thermite system includes coupling for stirrer and a hydraulic thermite system for the movement of the at least one automated stirring rod. Further, the thermite system includes a supporting plate for the hydraulic unit attached with the roof of the dog house room structure to support the hydraulic thermite system for up and down movement and stairs provided at a back portion of the dog house room structure for manually cleaning of the dog house room structure; and a sliding door assembly with a rack pinion arrangement for the sliding door assembly. The sliding door assembly is connected to a DC motor for movement.
[0007] In an embodiment, each of the right burner trolley and the left burner trolley includes a 3-6 of burners.
[0008] In an embodiment, the dog house room structure is made of steel and where three side walls of the dog house room structure are shielded with Ceramic wool and structural steel (SS) wire and a roof of the dog house room structure is shielded by SS sheet of 1.5 mm.
[0009] In an embodiment, the dog house room structure includes a right chamber including the right dross pan and a left chamber including the left dross pan, where each of the right chamber and the left chamber includes dimensions of 2.5 m x 2.2 m x 2.0 m and a common partition wall with dimensions 6.0 m length x 3.0 m width x 2.5 m height and where each of the right chamber and the left chamber includes a door on a front side which can be opened and closed automatically based on the thermiting of the dross, where each of the doors includes a Heat Resistant Glass Window to provide a view of the thermiting of the dross inside the dog house room structure.
[0010] In an embodiment, the burner unit heats the dross in each of the right dross pan and the left dross pan to a temperature of 600ºC by releasing a flame with gross calorific value of furnace oil IS 10,500.
[0011] In an embodiment, the at least one automated stirring rod comprise sharp cutting and pusher blades at an end and made of heat resistance plate alloy steel.
[0012] In an embodiment, the switch box includes switch gears for operating the 3-6 of burners of each of the right burner trolley and the left burner trolley, movement of each of the stirrers and movements of the right cover plate and the left cover plate.
[0013] In an embodiment, the electric motor is an induction motor with a rated power - 5HP, 3 phase speed – 720 RPM.
[0014] In an embodiment, the coupling for stirrer connects the stirrer rod and the motor / gear box.
[0015] In an embodiment, the supporting plate for hydraulic unit is made of alloy steel.
[0016] In an embodiment, the hydraulic thermite system includes a RAM size diameter of about 80 mm, stroke of 1000 mm, load caring capacity of 750 kg and includes a double acting cylinder.
[0017] In an embodiment, the sliding gate assembly is made of structural steel and is covered with heat resistant furnace blanket.
[0018] In an embodiment, the direct current (DC) motor is a 1 horse power (HP) 3 phase motor with voltage-220-240 and rotations per minute (RPM)-1500 which can move the gate at a speed of 0.3m/sec.
[0019] Accordingly the embodiments herein disclose a method for automatic thermiting of dross using a thermite system. The method includes receiving, by the thermite system, a right dross pan and a left dross pan of a 2-3 of dross pans including the dross into a dog house room structure and automatically introducing, by the thermite system, a right burner trolley to heat the dross in the right dross pan and a left burner trolley to heat the dross in the left dross pan periodically, into the dog house room structure. Each of the right burner trolley and the left burner trolley includes a 3-6 of burners. The method also includes determining, by the thermite system, a temperature of the heated dross in the right dross pan and the left dross pan meets a temperature threshold and switching-off, by the thermite system, the 3-6 of burners in each of the right burner trolley and the left burner trolley. Further, the method includes automatically exiting, by the thermite system, the right burner trolley and the left burner trolley from the dog house room structure and stirring, by the thermite system, the heated dross in the right dross pan and the left dross pan with at least one automated stirring rod associated with each of the right dross pan and the left dross pan. The method also includes removing, by the thermite system, the right dross pan and the left dross pan including the heated dross out of the dog house room structure.
[0020] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF FIGURES
[0021] This invention is illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0022] FIG. 1 illustrates a system for providing automatic thermiting of dross, according to the embodiments as disclosed herein;
[0023] FIG. 2 illustrates a side-view of the system for providing automatic thermiting of dross, according to the embodiments as disclosed herein;
[0024] FIG. 3 illustrates a top-view of the system for providing automatic thermiting of dross, according to the embodiments as disclosed herein;
[0025] FIG. 4 illustrates a isometric-view of the system for providing automatic thermiting of dross, according to the embodiments as disclosed herein;
[0026] FIG. 5 illustrates a diametric-view of the system for providing automatic thermiting of dross, according to the embodiments as disclosed herein.
[0027] FIG. 6 illustrates a triamatric-view of the system for providing automatic thermiting of dross, according to the embodiments as disclosed herein;
[0028] FIG. 7 illustrates a custom-view of the system for providing automatic thermiting of dross, according to the embodiments as disclosed herein;
[0029] FIG. 8A illustrates a scenario of the stirrer within the dross pan and the burner out of the heating chamber, according to the embodiments as disclosed herein;
[0030] FIG. 8B illustrates a scenario of the stirrer raised from the dross pan and the burner introduced into the heating chamber, according to the embodiments as disclosed herein;
[0031] FIG. 8C illustrates a front-view of the system when the burner is introduced into the heating chamber, according to the embodiments as disclosed herein; and
[0032] FIG. 9 is a flow chart illustrating a method for automatic thermiting of dross using a thermite system, according to the embodiments as disclosed herein.

DETAILED DESCRIPTION OF INVENTION
[0033] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. Also, the various embodiments described herein are not necessarily mutually exclusive, as some embodiments can be combined with one or more other embodiments to form new embodiments. The term “or” as used herein, refers to a non-exclusive or, unless otherwise indicated. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein can be practiced and to further enable those skilled in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0034] The accompanying drawings are used to help easily understand various technical features and it should be understood that the embodiments presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any alterations, equivalents and substitutes in addition to those which are particularly set out in the accompanying drawings. Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are generally only used to distinguish one element from another.
[0035] Accordingly the embodiments herein disclose a thermite system for providing automatic thermiting of dross. The thermite system includes a dog house room structure including a right dross pan and a left dross pan of a 2-3 of dross pans including the dross and at least one automated stirring rod associated with each of the right dross pan and the left dross pan of the 2-3 of dross pans to stir the dross periodically. The thermite system also includes a right burner trolley corresponding to the right dross pan and entering the dog house room structure through a right window of the dog house room structure. The right burner trolley corresponding to the right dross pan automatically enters and exits the right window of the dog house room structure horizontally to heat the dross in the right dross pan periodically and a left burner trolley corresponding to the left dross pan and entering the dog house room structure through a left window of the dog house room structure. The left burner trolley corresponding to the left dross pan automatically enters and exits the left window of the dog house room structure horizontally to heat the dross in the left dross pan periodically. Further, the thermite system also includes a 3-6 of imaging sensors in the dog house room structure to monitor the thermiting of the dross and a right cover plate to cover the right window of the dog house room structure upon the entry and the exit of the right burner trolley into the dog house room structure. The thermite system includes a left cover plate to cover the left window of the dog house room structure upon the entry and exit of the left burner trolley into the dog house room structure and a switch box located out of the dog house room structure for controlling the thermiting of the dross.
[0036] Accordingly the embodiments herein disclose a method for automatic thermiting of dross using a thermite system. The method includes receiving, by the thermite system, a right dross pan and a left dross pan of a 2-3 of dross pans including the dross into a dog house room structure and automatically introducing, by the thermite system, a right burner trolley to heat the dross in the right dross pan and a left burner trolley to heat the dross in the left dross pan periodically, into the dog house room structure. Each of the right burner trolley and the left burner trolley includes a 3-6 of burners. The method also includes determining, by the thermite system, a temperature of the heated dross in the right dross pan and the left dross pan meets a temperature threshold and switching-off, by the thermite system, the 3-6 of burners in each of the right burner trolley and the left burner trolley. Further, the method includes automatically exiting, by the thermite system, the right burner trolley and the left burner trolley from the dog house room structure and stirring, by the thermite system, the heated dross in the right dross pan and the left dross pan with at least one automated stirring rod associated with each of the right dross pan and the left dross pan. The method also includes removing, by the thermite system, the right dross pan and the left dross pan including the heated dross out of the dog house room structure.
[0037] In the conventional methods and systems, the dross in the dross pans are manually punched to make holes for the circulation of air into the dross during the thermiting process to let the aluminium get released from the dross. When the holes are punched into the dross a lot of heat, fumes and toxic smoke is released which drastically impacts both workers and environment. Unlike to the conventional methods and systems, the proposed method automates the entire thermiting process of the dross for the recovery of aluminium.
[0038] Unlike to the conventional methods and systems, the proposed method filters the smoke generated during the thermite process which reduces environmental pollution caused due to the release of untreated smoke.
[0039] Unlike to the conventional methods and systems, the proposed system includes a switch box for controlling the thermiting of the dross which automates the entire thermiting process.
[0040] Referring now to the drawings and more particularly to FIGS. 1 through 9, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[0041] FIG. 1 illustrates a thermite system (1000) for providing automatic thermiting of dross, according to the embodiments as disclosed herein.
[0042] The system includes a dog house room structure (POS-1), a stirring rod (POS-2a-b), burner trolleys (POS-3a-b) including 3-6 of burners (POS-14) on each side of the dog house room structure (POS-1), a switch box (POS-4), rail for burner trolley (POS-5), DC motor for the burner trolley (POS-6), 2-3 of dross pans (POS-7a-N), cover plates (POS-8a-b), 3-4 of cameras (POS-9), 2-3 of stirrer bodies (POS-10), electric motor for stirrer (POS-11), coupling for stirrer (POS-12), burner trolley chain sprocket (POS-13), supporting plate for hydraulic unit (POS-15), smoke duct (POS-16), hydraulic system (POS-17), stairs (POS-18), rack pinion arrangement for sliding door (POS-19), sliding gate assembly (POS-20) and DC motor for sliding doors (POS-21).
[0043] In an embodiment, the dog house room structure (POS-1) is a mother structure for the thermite system (1000), the various parts and the component. The dog house room structure (POS-1) is made of MS STEEL IS: 2062 2011 and the whole inside portion of the dog house room structure (POS-1) is covered with heat resistance furnace blanket. The steel of MS STEEL IS: 2062 20112 standard covers the requirements of steel including micro-alloyed steel plates, strips, shapes and sections (angles, tees, beams, channels, etc.), flats, bars, etc., for use in structural work.. The steels are suitable for welded, bolted and riveted structures and for general engineering purposes. The steel of MS STEEL IS: 2062 20112 is used specifically where welding is employed for fabrication and guaranteed-weldability is required, welding procedure should be as specified in IS 9595 : 1996 ‘Metal arc welding of carbon and carbon manganese steels.
[0044] The dog house room structure (POS-1) may include two chambers having common partition wall measuring overall dimensions as 6.0 m length x 3.0 m width x 2.5 m height. The three side walls of the dog house room structure (POS-1) are shielded with Ceramic wool and SS wire. The roof is shielded by SS sheet of 1.5 mm. Each Chamber size will be 2.5 m x 2.2 m x 2.0 m. Each Chamber has a door in the front side which can be opened or closed as required. The door is provided with a Glass (Heat Resistant Glass) Window for the operator to view the activities inside the dog house room structure (POS-1). The dog house room structure (POS-1) includes a right dross pan (POS-7a) and a left dross pan (POS-7a) of a plurality of dross pans where each of the dross pans is the casting part in which the dross is poured.
[0045] In an embodiment, the thermite system (1000) includes automated stirring rod (POS-2a and POS-2b) associated with each of a right dross pan (POS-7a) and a left dross pan (POS-7a) to stir the dross periodically. The automated stirring rod (POS-2a and POS-2b) holds the stirrer toothed body which will stir the whole dross inside the 2-3 of dross pans (POS-7a-N). A sliding door is provided at a back wall for entry and exit of the stirring rod (POS-2a-b). This door is operated using a pneumatic Cylinder.
[0046] In an embodiment, the thermite system (1000) includes a right burner trolley (POS-3a) corresponding to the right dross pan (POS-7a) and enter the dog house room structure (POS-1) through a right window of the dog house room structure (POS-1) and a left burner trolley (POS-3b) corresponding to the left dross pan (POS-7b) and entering the dog house room structure (POS-1) through a left window of the dog house room structure (POS-1). The right burner trolley (POS-3a) corresponding to the right dross pan automatically enters and exits the right window of the dog house room structure (POS-1) horizontally to heat the dross in the right dross pan (POS-7a) periodically and the left burner trolley (POS-3b) corresponding to the left dross pan (POS-7b) automatically enters and exits the left window of the dog house room structure (POS-1) horizontally to heat the dross in the left dross pan (POS-7b) periodically. The whole burner unit (POS-3) which includes burner vehicles, burner housing, burner housing support which will roll over a rail with the help of which the 3-6 of burners (POS-14) will move inside the room and heat up the dross up to 600 degree C. The 3-6 of burners (POS-14) will heat the dross up to the temperature by releasing the flame with the gross calorific value of furnace oil IS 10,500. For the burning, the burner unit (POS-3) requires LPG burners with nozzle orifice of diameter 6mm, LPG flow rate of 7.81 kg/hour, pressure of 2738 Pascal, with 85% efficiency from the height 125 mm with the help of such 6 burners with approx. 45 kg/hr. of LPG required.
[0047] In an embodiment, the thermite system (1000) includes the rail for burner trolley (POS-5) on which the burner trolley will move inside the room. The DC motor for burner trolley (POS-6) will move the trolley back and forth.
[0048] In an embodiment, the thermite system (1000) includes a right cover plate (POS-8a) to cover the right window of the dog house room structure (POS-1) upon the entry and the exit of the right burner trolley (POS-3a) into the dog house room structure (POS-1) and a left cover plate (POS-8b) to cover the left window of the dog house room structure (POS-1) upon the entry and exit of the left burner trolley (POS-3b) into the dog house room structure (POS-1). The cover plate (POS-8a-b) is made of any heat resistance plate HARDOX-400. The burner unit (POS-3a-b) for entering the chamber can swing the cover plate (POS-8a-b) and the cover plate (POS-8a-b) will automatically close when the burner unit (POS-3a-b) is retracted out. The mechanism is by a counter weight principle.
[0049] In an embodiment, the thermite system (1000) includes the 3-4 of imaging sensors (POS-9) provided within the dog house room structure (POS-1) to observe the process of thermiting of the dross. The 3-4 of imaging sensors (POS-9) can be for example any high temperature resistant camera. For example, ProTIR® – infrared thermal imaging system for continuous temperature monitoring inside furnaces.
[0050] In an embodiment, the thermite system (1000) includes the 2-3 of stirrer bodies (POS-10) for stirring the dross while penetrating inside the dross with a constant speed. The 2-3 of stirrer bodies (POS-10) is made of heat resistance plate HARDOX-400. The stirrer includes sharp cutting and pusher blades at the end. The stirrer with electric motor for stirrer (POS-11) will be mounted on a moving frame for the up and down movement as well as side wise movement to cover the entire area of the pan for uniform heating of the dross. The up and down movement will be controlled by a Pneumatic Cylinder which can adjust the extent of Stirrer getting into Dross. The total stroke will be completed in two or three installments depending upon process requirement. The side wise movement will also be controlled by the motorized Lead Screw arrangement. This movement will also be variable considering the process requirement. The entire operation of the Stirrer will be Controlled from the switch box (POS-4) placed in the front side of the chamber for burner Operation. As such the switch box (POS-4) will house the switch gears for burner and stirrer and gate movements. The switch box (POS-4) will be made compartmentalized for each chamber for ease of operation.
[0051] In an embodiment, the thermite system (1000) includes the electric motor for stirrer (POS-11) is mounted upside on the stirrer rod to rotate the stirrer at a constant speed. Proper gearing system will be provided for @ 30 rpm / min. The electric motor for stirrer (POS-11) is any induction motor with a rated power - 5HP, 3 phase speed – 720 RPM. These are the most frequently used motors because electrical power is normally supplied as alternating current. The most common types are synchronous motors which are three-phase AC motors which run at fixed speed, without slip, and are generally applied for large outputs (due to their relatively high costs in smaller frame sizes). Another type includes induction motors which generally run at a constant speed which changes slightly when mechanical loads are applied to the motor shaft. Due to its simplicity, robustness and low cost, this type of motor is the most widely used and, in practical terms, is quite suitable for almost all types of machines. Currently it is possible to control the speed of induction motors by frequency inverters.
[0052] In an embodiment, the thermite system (1000) includes the coupling for stirrer (POS-12) is provided to connect the stirrer rod and the motor / gear box.
[0053] In an embodiment, the thermite system (1000) includes the burner trolley chain sprocket (POS-13) assembly provides the required motion to the burner trolley at a constant speed of 0.3 m/sec.
[0054] FIG. 2 illustrates a side-view of the thermite system (1000) for providing automatic thermiting of the dross, according to the embodiments as disclosed herein.
[0055] Referring to the FIG. 2, in conjunction with the FIG. 1, various parts of the thermite system (1000) are clearly articulated using the side-view of the thermite system (1000).
[0056] In an embodiment, the supporting plate for the hydraulic unit (POS-15) is made of MS STEEL IS: 2062 2011. The supporting plate for hydraulic unit (POS-15) supports the entire hydraulic system (POS-17) for the up and the down movement attached with the roof of the dog house room structure (POS-1).
[0057] In an embodiment, the smoke duct (POS-16) is made of MS STEEL IS: 2062 2011. The smoke duct (POS -16) is provided for the escape of the dust, gas and fume which rise during the reaction of the dross inside the dog house room structure (POS-1) especially while mixing the dross to achieve uniform heating.
[0058] In an embodiment, the hydraulic system (POS-17) through the smoke duct (POS-16) is attached to each of the stirrer bodies (POS-10). The hydraulic system (POS-17) is provided for the up and down movement of the 2-3 of stirrer bodies (POS-10). Further, the RAM size diameter is about 80 mm, stroke of 1000 mm, load caring capacity of 750 kg and includes a double acting cylinder.
[0059] In an embodiment, the stairs (POS-18) is provided at a back portion of the dog house (POS-1) for maintenance of the entire thermite system (1000) and entire the thermite system (1000) is approachable with the help of the stairs (POS-18).
[0060] In an embodiment, the rack pinion arrangement for sliding door (POS-19) is provided for enabling sliding of the doors.
[0061] In an embodiment, the sliding gate assembly (POS-20) is made of structural steel of MS STEEL IS: 2062 2011 and is covered with heat resistant furnace blanket. The sliding gate assembly (POS-20) ensures that the doors slide properly and with ease.
[0062] In an embodiment, the DC motor for the sliding doors (POS-21) is a 1 HP 3 phase motor with voltage-220-240 and RPM-1500. The DC motors use a constant strength, permanent magnet field which yields a motor with a more linear speed-torque curve, higher starting torque and much lower no-load speeds. Because it runs only on DC voltage, the DC motor requires the use of a rectifier or a control to be operated in a system with AC line voltage. The main characteristics of the DC motor for the sliding doors (POS-21) includes but are not limited to Straight line speed-torque curve, medium speed operation 1,000-5,000 rpm, efficiency 60%-75% (small to large), high starting torque (8-10 times rated torque), operation on the DC voltage, life of 2,000+ hours, totally enclosed construction. The DC motor for the sliding doors (POS-21) will be attached to the proper gearing system to move the gate @ 0.3m/sec.
[0063] In an embodiment, the switch box (POS-4) is provided to completely automate and control the operation of the system by a user from outside. Further, the complete system arrangement is provided in FIGS. 3-8C.
[0064] The operation of the system includes taking about 700 kg of dross at 200°C (minimum) in the 2-3 of dross pans (POS-7a-b)and is introduced into the dog house room structure (POS-1) with the help of a fork lift. After the closing of the entry door the LPG burner mounted at an inclined position enters into the dog house room structure (POS-1) and lights up with the help of specially designed ignite. The positioning of the burner units (POS-3a-b) inside the dog house room structure (POS-1) will be carried out by Pneumatic Cylinder. The Flame of the Burner will reach to the upper layer of the Dross in the 2-3 of dross pans (POS-7a-b). The dross in the pan will be heating up and liberate hot gases and fumes which will be evacuated by the suction condition at the exhaust opening of the dog house room structure (POS-1), which will be connected to the exhaust system of the shop.
[0065] The firing will continue for about 10 minutes. Thereafter the burner units (POS-3a-b) is switched off and withdrawn out the dog house room structure (POS-1) by the reverse operation of the Pneumatic Cylinder. Immediately, the stirrer which was ready for operation outside the dog house room structure (POS-1) will come down vertically and cut through the dross in the pan up to one third depth of the dross material. The material within the rotating area of the stirrer will get loosened. After a couple of minutes, the running stirrer will move sidewise in a to and fro motion to cover more area of the pan for better heating.
[0066] After completion of this operation the stirrer will retract back to its original parking position outside the dog house room structure (POS-1). Further, the burner will come down to repeat the operation for the second time. Since the top layer of Dross is loose, the Burner flame will penetrate into Dross to heat up the material at lower levels. The heating and stirring operation will be repeated twice more to ensure homogeneous heating of the entire mass of the dross material in the pan. The total process time is envisaged as 30 minutes or so.
[0067] Considering huge generation of heat and fumes during heating (due exothermic reactions), the duration of process for Heating and Stirring as envisaged above is indicative. During the initial trials the duration of heating and stirring will be manually adjusted for performance. Subsequently the set timers will control the functions automatically and in sequence. However, an operator over ride facility will be provided to make changes depending upon the quality, quantity and related properties, if required. On completion of the process, the dog house room structure (POS-1) door will be opened by Pneumatic Cylinders and the Fork Lift will take out the Pan for further processing. For parallel operation two dog house room structure (POS-1), having common partition wall and with identical facilities will be provided. Each Chamber can be operated independently as required.
[0068] FIG. 3 illustrates a top-view of the thermite system (1000) for providing automatic thermiting of dross, according to the embodiments as disclosed herein.
[0069] FIG. 4 illustrates an isometric-view of the thermite system (1000) for providing automatic thermiting of dross, according to the embodiments as disclosed herein.
[0070] FIG. 5 illustrates a diametric-view of the thermite system (1000) for providing automatic thermiting of dross, according to the embodiments as disclosed herein.
[0071] FIG. 6 illustrates a triamatric-view of the thermite system (1000) for providing automatic thermiting of dross, according to the embodiments as disclosed herein.
[0072] FIG. 7 illustrates a custom-view of the thermite system (1000) for providing automatic thermiting of dross, according to the embodiments as disclosed herein.
[0073] FIG. 8A illustrates a scenario of the stirrer within the dross pan and the burner out of the heating chamber, according to the embodiments as disclosed herein.
[0074] FIG. 8B illustrates a scenario of the stirrer raised from the dross pan and the burner introduced into the heating chamber, according to the embodiments as disclosed herein.
[0075] FIG. 8C illustrates a front-view of the thermite system (1000) when the burner is introduced into the heating chamber, according to the embodiments as disclosed herein.
[0076] The heating of the dross will be carried out by LPG burner one each for heating and stirring chamber. The LPG is recommended considering the advantages of the LPG over other Liquid Fuel like HSD/LDO, Furnace Oil etc. For quick heating requirement O.3 MKCAL capacity burner is used. Since there will be many process and operational variations, the LPG Burner will have split Gas supply arrangement to half of the rated capacity. Two Gas feed line to burner equal in size will have Solenoid Valves to allow or stop gas supply to the burner. The location of the burner inside the chamber is such that the Gas Flame and the products of combustion directly hit the dross in the pan. For Light up from cold condition a commercial Spark igniter is used with each burner. With hot condition in the chamber, the operation of igniter may not be necessary.
[0077] Combustion air from a centrifugal fan common for both the chambers will supply the necessary combustion air to the burner. A manually adjustable butterfly type damper is provided on the air pipe line connecting to the burner. The combustion air fan directly driven by an electric motor will be located at a place such that the air piping can be made conveniently taking into consideration of maintenance and other equipment operating nearby.
[0078] The burner is mounted on a sliding support and will be moved in and out of the heating chamber with the help of a pneumatic cylinder. Since the burner will have different location for operation and parking, the air and LPG gas supply to the burner will be through flexible hoses. All other pipe lines for air and gas will be mounted on a stationary frame little away from the chamber in the back side to protect the same from heat that may cause damage the pipe work. The entire operation of the Burner will be controlled / monitored from the switch box (POS-4) placed in the front side of the chamber. The location of the switch box (POS-4) is decided considering the full view of the burner and stirrer movement as well as keeping away for fork lift movement with hot and burning dross.
[0079] The LPG supply shall be made from a LPG GAS Bank made with 6 to 8 Industrial LPG Gas Cylinders complying with all safety norms. This can be located on the back side of the chamber sufficiently away for replacing empty cylinders by filled cylinders.
[0080] The heating and stirring process as per tec of the drosshnical requirement will generate huge hot gas and fumes. As such there will be burning of liberated combustible elements. For safe operation and pollution control these gases are to be connected to the plant dedusting and exhaust System. An exhaust hood will be mounted on the chamber which will be connected to the plant dedusting system. Process designers must confirm that the fumes generated will not contain any combustible matter and safe to connect the exhaust hood to the dedusting system. Otherwise, a combustion chamber may be required to burn out the residual combustible to avoid any explosion hazard at a later date. The details of the combustion chamber can be work out upon receipt of specific feedback.
[0081] FIG. 9 is a flow chart illustrating a method for automatic thermiting of dross using the thermite system (1000), according to the embodiments as disclosed herein. Referring to the FIG. 9, at step 902, the method includes receiving, by the thermite system (1000), a right dross pan (POS-7a) and a left dross pan (POS-7a) of a 2-3 of dross pans including the dross into a dog house room structure (POS-1)
[0082] At step 904, the method includes automatically introducing a right burner trolley (POS-3a) to heat the dross in the right dross pan (POS-7a) and a left burner trolley (POS-3b) to heat the dross in the left dross pan (POS-7a) periodically, into the dog house room structure (POS-1). Each of the right burner trolley (POS-3a) and the left burner trolley (POS-3b) includes the 3-6 of burners (POS-14).
[0083] At step 906, the method includes determining a temperature of the heated dross in the right dross pan (POS-7a) and the left dross pan (POS-7a) meets a temperature threshold.
[0084] At step 908, the method includes switching-off the 3-6 of burners (POS-14) in each of the right burner trolley (POS-3a) and the left burner trolley (POS-3b).
[0085] At step 910, the method includes automatically exiting the right burner trolley (POS-3a) and the left burner trolley (POS-3b) from the dog house room structure (POS-1).
[0086] At step 912, the method includes stirring the heated dross in the right dross pan (POS-7a) and the left dross pan (POS-7a) with the automated stirring rod (POS-2a and POS-2b) associated with each of the right dross pan (POS-7a) and the left dross pan (POS-7a).
[0087] At step 914, the method includes removing the right dross pan (POS-7a) and the left dross pan (POS-7a) with the heated dross out of the dog house room structure (POS-1).
[0088] Therefore, the proposed method completely automates the existing method using the thermite system (1000) which enhances the recovery of the aluminium metal from the dross. Additionally, the thermite system (1000) enhances the safety of the process since no poking of holes needs to be performed manually. The thermite system (1000) also reduces or eliminates fugitive emissions during the thermiting process. The fumes that are generated during the process will be treated at baghouse filter without any direct emission to the atmosphere. The thermite system (1000) provides a homogenisation in temperature of the dross through the automated burner system and stirring system. Further, the thermite system (1000) optimizes or reduces thermiting time when compared to the manual thermiting process.
[0089] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the scope of the embodiments as described herein.
,CLAIMS:CLAIMS
We Claim:
1. A thermite system (1000) for providing automatic thermiting of dross, wherein the thermite system (1000) comprising:
a dog house room structure (POS-1) comprising a right dross pan (POS-7a) and a left dross pan (POS-7a) of a plurality of dross pans comprising the dross;
at least one automated stirring rod (POS-2a and POS-2b) associated with each of the right dross pan (POS-7a) and the left dross pan (POS-7a) of the plurality of dross pans to stir the dross periodically;
a right burner trolley (POS-3a) corresponding to the right dross pan (POS-7a) and entering the dog house room structure (POS-1) through a right window of the dog house room structure (POS-1), wherein the right burner trolley (POS-3a) corresponding to the right dross pan (POS-7a) automatically enters and exits the right window of the dog house room structure (POS-1) horizontally to heat the dross in the right dross pan (POS-7a) periodically;
a left burner trolley (POS-3b) corresponding to the left dross pan (POS-7b) and entering the dog house room structure (POS-1) through a left window of the dog house room structure (POS-1), wherein the left burner trolley (POS-3b) corresponding to the left dross pan (POS-7b) automatically enters and exits the left window of the dog house room structure (POS-1) horizontally to heat the dross in the left dross pan (POS-7b) periodically;
a plurality of imaging sensors (POS-9) in the dog house room structure (POS-1) to monitor the thermiting of the dross;
a right cover plate (POS-8a) to cover the right window of the dog house room structure (POS-1) upon the entry and the exit of the right burner trolley (POS-3a) into the dog house room structure (POS-1);
a left cover plate (POS-8b) to cover the left window of the dog house room structure (POS-1) upon the entry and exit of the left burner trolley (POS-3b) into the dog house room structure (POS-1); and
a switch box (POS-4) located out of the dog house room structure (POS-1) for controlling the thermiting of the dross.
2. The thermite system (1000) as claimed in claim 1, further comprises:
a DC motor (POS-6) for the automatic entry and exit of the right burner trolley (POS-3a) and the left burner trolley (POS-3b) into and from the dog house room structure (POS-1) correspondingly;
an electric motor (POS-11) to move the at least one automated stirring rod (POS-2a and POS-2b) along a vertical axis and a horizontal axis;
a burner trolley chain sprocket (POS-13) assembly for providing motion to each of the right burner trolley (POS-3a) and the left burner trolley (POS-3b) at a constant speed; and
at least one smoke duct (POS-16) comprising a filter for emitting of filtered fumes produced during the thermiting of the dross;
coupling for stirrer (POS-12);
a hydraulic thermite system (1000) (POS-17) for the movement of the at least one automated stirring rod (POS-2a and POS-2b);
a supporting plate for the hydraulic unit (POS-15) attached with the roof of the dog house room structure (POS-1) to support the hydraulic thermite system (1000) (POS-17) for up and down movement;
stairs (POS-18) provided at a back portion of the dog house room structure (POS-1) for manually cleaning of the dog house room structure (POS-1);
a sliding door assembly (POS-20) with a rack pinion arrangement (POS-19) for the sliding door assembly (POS-20), wherein the sliding door assembly (POS-20) is connected to a DC motor (POS-21) for movement.
3. The thermite system (1000) as claimed in claim 1, wherein each of the right burner trolley (POS-3a) and the left burner trolley (POS-3b) comprises a plurality of burners (POS-14).
4. The thermite system (1000) as claimed in claim 1, wherein the dog house room structure (POS-1) is made of steel and wherein three side walls of the dog house room structure (POS-1) are shielded with Ceramic wool and structural steel (SS) wire and a roof of the dog house room structure (POS-1) is shielded by SS sheet of 1.5 mm.
5. The thermite system (1000) as claimed in claim 1, wherein the dog house room structure (POS-1) comprises a right chamber comprising the right dross pan (POS-7a) and a left chamber comprising the left dross pan (POS-7b), wherein each of the right chamber and the left chamber comprises dimensions of 2.5 m x 2.2 m x 2.0 m and a common partition wall with dimensions 6.0 m length x 3.0 m width x 2.5 m height and wherein each of the right chamber and the left chamber comprises a door on a front side which can be opened and closed automatically based on the thermiting of the dross, wherein each of the doors comprises a Heat Resistant Glass Window to provide a view of the thermiting of the dross inside the dog house room structure.
6. The thermite system (1000) as claimed in claim 1 wherein, the burner unit (POS-3) heats the dross in each of the right dross pan (POS-7a) and the left dross pan (POS-7a) to a temperature of 600ºC by releasing a flame with gross calorific value of furnace oil IS 10,500.
7. The thermite system (1000) as claimed in claim 2, wherein the at least one automated stirring rod (POS-2a and POS-2b) comprise sharp cutting and pusher blades at an end and made of heat resistance plate alloy steel.
8. The thermite system (1000) as claimed in claim 1 wherein, the switch box (POS-4) comprises switch gears for operating the plurality of burners (POS-14) of each of the right burner trolley (POS-3a) and the left burner trolley (POS-3b), movement of each of the stirrers and movements of the right cover plate (POS-8) and the left cover plate (POS-8).
9. The thermite system (1000) as claimed in claim 2 wherein, the electric motor (POS-11) is an induction motor with a rated power - 5HP, 3 phase speed – 720 RPM.
10. The thermite system (1000) as claimed in claim 2 wherein, the coupling for stirrer (POS-12) connects the stirrer rod and the motor / gear box.
11. The thermite system (1000) as claimed in claim 2 wherein, the supporting plate for hydraulic unit (POS-15) is made of alloy steel.
12. The thermite system (1000) as claimed in claim 2 wherein, the hydraulic thermite system (1000) (POS-17) comprises a RAM size diameter of about 80 mm, stroke of 1000 mm, load caring capacity of 750 kg and includes a double acting cylinder.
13. The thermite system (1000) as claimed in claim 2, wherein the sliding gate assembly (POS-20) is made of structural steel and is covered with heat resistant furnace blanket.
14. The thermite system (1000) as claimed in claim 2, wherein the DC motor (POS-21) is a 1 HP 3 phase motor with voltage-220-240 and RPM-1500 which can move the gate at a speed of 0.3m/sec.
15. A method for automatic thermiting of dross using a thermite system (1000), wherein the method comprising:
receiving, by the thermite system (1000), a right dross pan (POS-7a) and a left dross pan (POS-7a) of a plurality of dross pans comprising the dross into a dog house room structure (POS-1);
automatically introducing, by the thermite system (1000), a right burner trolley (POS-3a) to heat the dross in the right dross pan (POS-7a) and a left burner trolley (POS-3b) to heat the dross in the left dross pan (POS-7a) periodically, into the dog house room structure (POS-1), wherein each of the right burner trolley (POS-3a) and the left burner trolley (POS-3b) comprises a plurality of burners (POS-14);
determining, by the thermite system (1000), a temperature of the heated dross in the right dross pan (POS-7a) and the left dross pan (POS-7a) meets a temperature threshold;
switching-off, by the thermite system (1000), the plurality of burners (POS-14) in each of the right burner trolley (POS-3a) and the left burner trolley (POS-3b);
automatically exiting, by the thermite system (1000), the right burner trolley (POS-3a) and the left burner trolley (POS-3b) from the dog house room structure (POS-1);
stirring, by the thermite system (1000), the heated dross in the right dross pan (POS-7a) and the left dross pan (POS-7a) with at least one automated stirring rod (POS-2a and POS-2b) associated with each of the right dross pan (POS-7a) and the left dross pan (POS-7a); and
removing, by the thermite system (1000), the right dross pan (POS-7a) and the left dross pan (POS-7a) comprising the heated dross out of the dog house room structure (POS-1).
16. The method as claimed in claim 15, wherein the temperature of the heated dross in the right dross pan (POS-7a) and the left dross pan (POS-7a) meets the temperature threshold is determined by a plurality of imaging sensors (POS-9) in the dog house room structure (POS-1).
17. The method as claimed in claim 15, wherein the dross in each of the right dross pan (POS-7a) and the left dross pan (POS-7a) is heated by switching-on the plurality of burners (POS-14) for a period of at least 10 minutes.
18. The method as claimed in claim 15, wherein the temperature threshold is 900°C held for a period of 1 hour.