On December 10, 2015 the technology was evidenced on a multifunctional prototype (see illustration above)
Dimensional problems were solved for all spheres: from micro-sized melting plants to giant-sized facilities
Iron and steel
In steelmaking, Dynamic Furnace can be used in both the complete value added chain and in individual process stages. In a furnace route, for example, the channel system (conveyor line of the melted mass) can be replaced by a dynamic channel system. In a route based on the melting of scrap, an electric arc furnace may be employed, whereas in the continuous casting procedure a dynamic distributor (tundish) may be used.
For the production of steel grades featuring lower quality requirements (e. g. construction steel), Dynamic Furnace provides the possibility of converting the hitherto discontinuous process (ladle technology) into a continuous, fully automated process. starting from the melting process in the electric arc furnace followed by secondary metallurgy up to the discharge of the melted mass.
Dynamic Furnace, however, offers even more possibilities of a high quality, material utilization of metal slag. By mixing it with sand and additives, metal slag can be used for the production of low-cost glass melt (black glass). Black glass, in turn, is the basic material for the production of foam glass used as mineral insulating material or lightweight construction material.
Waste disposal costs for the slag are completely avoided and the use of the hot metal slag reduces the energy required for the production of the foam glass.
- An additional source of income for the steel plant is generated -
The possibility of replacing refractory materials during the melting process offers the opportunity of a continuous melting operation as far as nonferrous metals are concerned. As nonferrous metals may be melted in the same nonferrous melted mass, the required energy consumption is much less than that of conventional melting plants. The floating upwards, different material cocktails (slags) can be continuously discharged. In cascading melting plants, a direct re-feeding of a considerable part of the produced nonferrous metals contained in the material cocktail (slags) is possible.
In glass making, Dynamic Furnace can substitute all conventional melting plants.
Thanks to the possibility of replacing the refractory material during the melting process, there is no longer any need of cooling it down within the critical zones. Now - as refractory material will not limit the furnace cycle any more - simpler, budget-priced refractory material manufactured in mass production can be used. Thus, the costs of acquisition are reduced significantly.
As a result of the round geometry, a directional flow is generated, dead water zones do not exist any more and the retention period is reduced radically. This means a considerable reduction of the tank volume required. Moreover, the round geometry will reduce the proportion of surface vs. volume and thus lead to a further reduction of the wetted surface of the refractory material. The possibility of replacing refractory material allows an optimum utilization.
The round geometry and the shortened retention period will result in a substantially decreased thermal surface. Complete insulation of all surfaces in combination with the absence of cooling operations will cause a significant drop in energy requirement.
The revolutionary substitution method of this new technology will even allow the use of unpurified biogas and thus permit a completely CO2 neutral production of glass. Users of this technology can forget about the inconveniences associated with CO2 certificates.
The refractory material removed from the plant will allow to directly and continuously determine the condition of the melting tank. Tank bursts will be avoided and the respective insurance risk is no longer existent. Drainages may be replaced by bag-shaped recessions.
By adding or removing elements the volume of the melting tank may at any time be adapted to the respective market and sales situation. Additionally, the system allows a further highly increased flexibility to fluctuations in demand, in that the melt temperature can be increased in response to market demand and a stirring unit can be included to accelerate the homogenization of the melt. In a conventional system these two measures would lead to higher wear and reduced furnace campaign length, i.e. not recommended for a conventional furnace.
In case of already existing plants, for which a replacement investment to date is uneconomical, DF provides the possibility of retrofitting individual, critical areas under the conditions of a cold repair. As far as flat glass production is concerned, Dynamic Furnace, for example, allows the replacement of the lip without any interruption of the manufacturing process.
The standardized modular design of the steel structure, the use of cost-efficient refractory material and the resulting from this modified cost structure, provide for the possibility of leasing melting plants. This new cost structure also allows the presentation of the melting tank prior to purchase.
Last but not least, the geometry can still be individually adapted and optimized during operation.
The best known product group of mineral melted masses is cement. They also comprise basaltic liquid for the production of mineral wool and a multitude of other derivatives.
Thanks to the possibility of replacing refractory material during the melting process, Dynamic Furnace offers the opportunity of multiplying the furnace cycle and thus provides for optimized operational procedures. When processing multi-layer melted masses or in the manufacturing process of mineral wool, the individual melted masses resp. the «Schmolz» (waste material to be disposed) may be discharged separately. The advantages of the dynamic melting process are strongly varying with the particular mineral melted mass. Therefore, they need to be looked at on an individual basis; the same goes for the achievable energy saving.
Electronic scrap is no waste material, but precious secondary material for the recovery of gold, silver and platinum and also of rare earth. In future, it will not be possible to cover the increasing demand for them without partial recycling. Reprocessing, however, will be complex and expensive. Upon presorting, grinding and enrichment of the individual metals, the remaining, highly aggressive material cocktail is melted in day tanks in a disacontinuous process and subsequently separated.
Thanks to the possibility of replacing the refractory material during the melting process, Dynamic Furnace offers the opportunity for a continuous recycling of electronic scrap without significant presorting. Thus, a cost-efficient raw material supply with expensive precious metals and rare earth is provided for.
The fields of application of the dynamic melting process, offering the possibility of replacing the refractory material surrounding the melted mass during the melting process, are manifold.
In addition to the described high temperature melted masses (steel, nonferrous metals, glass, scrap, and so on), significant advantages can be provided in a wide range of other application areas, such as the production of sodium silicate in the chemical industry or the production of