Abstract:
An electric induction furnace for heating and melting electrically conductive materials is provided with a lining wear detection system that can detect replaceable furnace lining wear when the furnace is properly operated and maintained. In some embodiments of the invention the lining wear detection system utilizes an electrically conductive wire assemblage embedded in a wire assemblage refractory disposed between the replaceable lining and the furnace&#39;s induction coil.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of U.S. application Ser. No. 13/478,690 filed May 23, 2012, which claims the benefit of U.S. Provisional Application No. 61/488,866 filed May 23, 2011 and U.S. Provisional Application No. 61/497,787 filed Jun. 16, 2011, all of which are hereby incorporated by reference in their entireties. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to electric induction furnaces, and in particular, to detecting the wear of furnace linings in induction furnaces. 
       BACKGROUND OF THE INVENTION 
       [0003]      FIG. 1  illustrates components of a typical electric induction furnace relevant to a replaceable refractory lining used in the furnace. Replaceable lining  12  (shown stippled in the figure) consists of a material with a high melting point that is used to line the inside walls of the furnace and form interior furnace volume  14 . A metal or other electrically conductive material is placed within volume  14  and is heated and melted by electric induction. Induction coil  16  surrounds at least a portion of the exterior height of the furnace and an alternating current flowing through the coil creates a magnetic flux that couples with the material placed in volume  14  to inductively heat and melt the material. Furnace foundation  18  is formed from a suitable material such as refractory bricks or cast blocks. Coil  16  can be embedded in a trowelable refractory (grout) material  20  that serves as thermal insulation and protective material for the coil. A typical furnace ground leak detector system includes probe wires  22   a  protruding into melt volume  14  through the bottom of lining  12  as illustrated by wire end  22   a ′ protruding into the melt volume. Wires  22   a  are connected to electrical ground lead  22   b , which is connected to a furnace electrical ground (GND). Wires  22   a , or other arrangements used in a furnace ground leak detector system may be generally referred to herein as a ground probe. 
         [0004]    As the furnace is used for repeated melts within volume  14 , lining  12  is gradually consumed. Lining  12  is replenished in a furnace relining process after a point in the service life of the furnace. Although it is contrary to safe furnace operation and disregards the recommendation of the refractory manufacturer and installer, an operator of the furnace may independently decide to delay relining until refractory lining  12  between the molten metal inside furnace volume  14  and coil  16  has deteriorated to the state that furnace coil  16  is damaged and requires repair, and/or foundation  18  has been damaged and requires repair. In such event, the furnace relining process becomes extensive. 
         [0005]    U.S. Pat. No. 7,090,801 discloses a monitoring device for melting furnaces that includes a closed circuit consisting of several conductor sections with at least a partially conducting surface and a measuring/displaying device. A comb-shaped first conductor section is series connected through an ohmic resistor R to a second conductor section. The comb-shaped first conductor section is mounted on the refractory lining and arranged directly adjacent, however, electrically isolated from the second conductor section. 
         [0006]    U.S. Pat. No. 6,148,018 discloses an induction melting furnace that includes a detection system for sensing metal penetration into a wall of the furnace depending upon detecting heat flow from the hearth to the furnace. An electrode system is interposed between the induction coil and a slip plane material that serves as a backing to the refractory lining. The electrode system comprises a sensing mat housing conductors receiving a test signal from the power supply, wherein the sensing mat includes a temperature sensitive binder that varies conductivity between the conductors in response to heat penetration through the lining. 
         [0007]    U.S. Pat. No. 5,319,671 discloses a device that has electrodes arranged on the furnace lining. The electrodes are divided into two groups of different polarity and are spaced apart from each other. The electrode groups can be connected to a device that determines the electrical temperature-dependent resistance of the furnace lining. At least one of the electrodes is arranged as an electrode network on a first side on a ceramic foil. Either the first side of the ceramic foil or the opposite side is arranged on the furnace lining. The foil in the former case has a lower thermal conductivity and a lower electrical conductivity than the ceramic material of the furnace lining, and in the latter case an approximately identical or higher thermal conductivity and an approximately identical or higher electrical conductivity. 
         [0008]    U.S. Pat. No. 1,922,029 discloses a shield that is inserted in the furnace lining to form one contact of a control circuit. The shield is made of sheet metal and is bent to form a cylinder. When metal leaks out from the interior of furnace it makes contact with the shield, and the signal circuit is closed. 
         [0009]    U.S. Pat. No. 1,823,873 discloses a ground shield that is located within the furnace lining and spaced apart from the induction coil. An upper metallic conduit of substantially open annular shape is provided, as is also a similar lower metal conduit also of open annular shape. A plurality of relatively smaller metallic pipes or conduits extend between the two larger conduits and are secured thereto in a fluid-tight manner. A ground is provided which is connected to the protecting shield. 
         [0010]    One object of the present invention is to provide an electric induction furnace with a lining wear detection system that can assist in avoiding furnace coil damage and/or bottom foundation damage due to lining wear when the furnace is properly operated and maintained. 
       BRIEF SUMMARY OF THE INVENTION 
       [0011]    In one aspect, the present invention is an apparatus for, and method of providing a lining wear detection system for an electric induction furnace. 
         [0012]    In another aspect the present invention is an electric induction furnace with a lining wear detection system. A replaceable furnace lining has an inner boundary surface and an outer boundary surface, with the inner boundary surface forming the interior volume of the electric induction furnace in which electrically conductive material can be deposited for induction heating and melting. At least one induction coil surrounds the exterior height of the replaceable lining. A furnace ground circuit has a first end at a ground probe, or probes, protruding into the interior volume of the electric induction furnace and a second end at an electrical ground connection external to the electric induction furnace. At least one electrically conductive wire assemblage is embedded in a refractory disposed between the outer boundary surface of the wall of the replaceable lining and the induction coil. Each electrically conductive wire assemblage forms an electrically discontinuous boundary between the refractory in which it is embedded and the replaceable lining. A direct current voltage source has a positive electric potential connected to the electrically conductive wire assemblage, and a negative electric potential connected to the electrical ground connection. A lining wear detection circuit is formed from the positive electric potential connected to the electrically conductive wire assemblage to the negative electric potential connected to the electrical ground connection so that the level of DC leakage current in the lining wear detection circuit changes as the wall of the replaceable lining is consumed. A detector can be connected to each one of the lining wear detection circuits for each electrically conductive wire assemblage to detect the change in the level of DC leakage current, or alternatively a single detector can be switchably connected to multiple lining wear detection circuits. 
         [0013]    In another aspect the present invention is a method of fabricating an electric induction furnace with a lining wear detection system. A wound induction coil is located above a foundation and a refractory can be installed around the wound induction coil to form a refractory embedded induction coil. A flowable refractory mold is positioned within the wound induction coil to provide a cast flowable refractory volume between the outer wall of the flowable refractory mold and the inner wall of the refractory embedded induction coil. At least one electrically conductive wire assemblage is fitted around the outer wall of the flowable refractory mold. A wire assemblage refractory is placed into the refractory volume to embed the at least one electrically conductive wire assemblage in the cast flowable refractory to form an embedded wire assemblage refractory. The refractory mold is removed, and a replaceable lining mold is positioned within the volume of the embedded wire assemblage refractory to establish a replaceable lining wall volume between the outer wall of the replaceable lining mold and the inner wall of the embedded wire assemblage refractory, and a replaceable lining bottom volume above the foundation. A replaceable lining refractory is fed into the replaceable lining wall volume and the replaceable lining bottom volume, and the replaceable lining mold is removed. 
         [0014]    In another aspect, the invention is an electric induction heating or melting furnace with a lining wear detection system that can detect furnace lining wear when the furnace is properly operated and maintained. 
         [0015]    These and other aspects of the invention are set forth in the specification and the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The figures, in conjunction with the specification and claims, illustrate one or more non-limiting modes of practicing the invention. The invention is not limited to the illustrated layout and content of the drawings. 
           [0017]      FIG. 1  is a simplified cross sectional diagram of one example of an electric induction furnace. 
           [0018]      FIG. 2  is a cross sectional diagram of one example of an electric induction furnace with a lining wear detection system of the present invention. 
           [0019]      FIG. 3( a )  illustrates in flat planar view one example of an electrically conductive mesh, a lining wear detection circuit, and a control and/or indicating (detector) circuit used in the electric induction furnace shown in  FIG. 2   
           [0020]      FIG. 3( b )  illustrates in top plan view the electrically conductive mesh shown in  FIG. 3( a )  in the shape as installed around the circumference of the electric induction furnace shown in  FIG. 2 . 
           [0021]      FIG. 4  is a cross sectional diagram of another example of an electric induction furnace with a lining wear detection system of the present invention that includes a bottom electrically conductive mesh. 
           [0022]      FIGS. 5( a ) and 5( b )  illustrate in top plan view alternative bottom electrically conductive mesh, bottom lining wear detection circuit, and control and/or indicating (detector) circuit used for bottom lining wear detection in one example of the present invention. 
           [0023]      FIG. 6( a )  through  FIG. 6( g )  illustrate fabrication of one example of an electric induction furnace with a lining wear detection system of the present invention. 
           [0024]      FIG. 7  is a detail of one example of the electrically conductive mesh embedded in a cast flowable refractory used in an electric induction furnace with a lining wear detection system of the present invention. 
           [0025]      FIG. 8  is a cross sectional diagram of another example of an electric induction furnace with a lining wear detection system of the present invention. 
           [0026]      FIG. 9( a )  through  FIG. 9( d )  illustrate alternative arrangements of electrically conductive mesh, lining wear detection circuits and detectors used in the electric induction furnace with a lining wear detection system of the present invention. 
           [0027]      FIG. 10  is a cross sectional diagram of another example of an electric induction furnace with a lining wear detection system of the present invention that uses an electrically conductive wire assemblage embedded in a wire assemblage embedded refractory. 
           [0028]      FIG. 11( a )  illustrates in flat planar view one example of an electrically conductive wire assemblage, a lining wear detection circuit, and a control and/or indicating (detector) circuit used in the electric induction furnace shown in  FIG. 10 . 
           [0029]      FIG. 11( b )  illustrates in top plan view the electrically conductive wire assemblage shown in  FIG. 11( a )  embedded in the wire assemblage refractory in the shape as installed around the circumference of the electric induction furnace shown in  FIG. 10 . 
           [0030]      FIG. 12( a )  illustrates in flat planar view another example of an electrically conductive wire assemblage, a lining wear detection circuit, and a control and/or indicating (detector) circuit that can be used in the furnace volume shown in  FIG. 10 . 
           [0031]      FIG. 12( b )  illustrates in top plan view one example of a fixture that is used to install the electrically conductive wire assemblage shown in  FIG. 12( a )  around the top circumference of the electric induction furnace shown in  FIG. 10 . 
           [0032]      FIG. 12( c )  illustrates in partial elevation view one example of the fixture shown in  FIG. 12( b ) . 
           [0033]      FIG. 12( d )  illustrates in partial elevation view one example of weaving a continuous electrically conductive wire assemblage around the fixture shown in  FIG. 12( b ) . 
           [0034]      FIG. 12( e )  illustrates in top plan view one example of a fixture that is used to install the electrically conductive wire assemblage shown in  FIG. 12( a )  around the bottom circumference of the electric induction furnace shown in  FIG. 10 . 
           [0035]      FIG. 13  is a cross sectional diagram of another example of an electric induction furnace with a lining wear detection system of the present invention that includes a bottom electrically conductive mesh. 
           [0036]      FIGS. 14( a ), 14( b ) and 14( c )  illustrate in top plan view alternative bottom electrically conductive discontinuous mesh; continuous mesh; and wire assemblage, with bottom lining wear detection circuit, and control and/or indicating (detector) circuit used for bottom lining wear detection in one example of the present invention. 
           [0037]      FIG. 15( a )  through  FIG. 15( h )  illustrate fabrication of alternative examples of an electric induction furnace with a lining wear detection system of the present invention that use an electrically conductive wire assemblage embedded in a wire assemblage embedded refractory. 
           [0038]      FIG. 16  is a detail of one example of the electrically conductive wire assemblage embedded in a refractory used in an electric induction furnace with a lining wear detection system of the present invention. 
           [0039]      FIG. 17  is a cross sectional diagram of another example of an electric induction furnace with a lining wear detection system of the present invention that uses an electrically conductive wire assemblage embedded in a wire assemblage embedded refractory. 
           [0040]      FIG. 18( a )  through  FIG. 18( c )  illustrate alternative arrangements of electrically conductive wire assemblage, lining wear detection circuits and detectors used in the electric induction furnace with a lining wear detection system of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0041]    There is shown in  FIG. 2  one example of an electric induction furnace  10  with a lining wear detection system of the present invention. A cast flowable refractory  24  is disposed between coil  16  and replaceable furnace lining  12 . In this example of the invention, electrically conductive mesh  26 , (for example, a stainless steel mesh) is embedded within the inner boundary of castable refractory  24  that is adjacent to the outer boundary of lining  12 . One non-limiting example of a suitable mesh is formed from type 304 stainless steel welded wire cloth with mesh size 4×4; wire diameter between 0.028-0.032-inch; and opening width of 0.222-0.218-inch. As shown in  FIGS. 3( a ) and 3( b ) , for this example of the invention, mesh  26  forms a discontinuous cylindrical mesh boundary between castable refractory  24  and lining  12  from the top ( 26   TOP ) to the bottom ( 26   BOT ) of the outer boundary of the lining wall. One vertical side  26   a  of mesh  26  is suitably connected to a positive electric potential that can be established by a suitable voltage source, such as direct current (DC) voltage source V dc  that has its other terminal connected to furnace electrical ground (GND). A lining wear detection circuit is formed between the positive electric potential connected to the electrically conductive mesh and the negative electric potential connected to the furnace electrical ground. Vertical discontinuity  26   c  (along the height of the lining in this example) in mesh  26  is sized to prevent short circuiting between opposing vertical sides  26   a  and  26   b  of mesh  26 . Alternatively the mesh may be fabricated in a manner so that the mesh is electrically isolated from itself; for example, a layer of electrical insulation can be provided between two overlapping ends (sides  26   a  and  26   b  in this example) of the mesh. As shown in  FIG. 3( a )  the voltage source circuit can be connected to control and/or indicating circuits via suitable circuit elements such as a current transformer. The control and/or indicating circuits are referred to collectively as a detector. As lining  12  is gradually consumed during the service life of the furnace, DC leakage current will rise, which can be sensed in the control/indicating circuits. For a particular furnace design, a leakage current rise level set point can be established for indication of lining replacement when the furnace is properly operated and maintained. 
         [0042]    In some examples of the invention, a bottom lining wear detection system may be provided as shown, for example in  FIG. 4 , in addition to the wall lining wear detection system shown in  FIG. 2 . In  FIG. 4  electrically conductive bottom mesh  30  is disposed within cast flowable refractory  28  with bottom mesh  30  adjacent to the lower boundary of lining  12  at the bottom of the furnace. As shown in  FIG. 5( a )  in this example of the invention, bottom mesh  30  forms a discontinuous circular mesh boundary between bottom cast flowable refractory  28  and the bottom of lining  12 . In other examples of the invention, the bottom mesh boundary may be formed from a continuous circular mesh  30 ′ as shown in  FIG. 5( b )  between bottom cast flowable refractory  28  and the bottom of lining  12 . In the discontinuous examples, discontinuous radial side  30   a  of bottom mesh  30  is suitably connected to a positive electric potential established by a suitable voltage source V′ dc  that has its other terminal connected to furnace electrical ground (GND). A bottom lining wear detection circuit is formed between the positive electric potential connected to the electrically conductive bottom mesh and the negative electric potential connected to the furnace electrical ground. If use, radial discontinuity  30   c  in mesh  30  is sized to prevent short circuiting between opposing radial sides  30   a  and  30   b  of mesh  30 . Alternatively the mesh may be fabricated in a manner so that the mesh is electrically isolated from itself; for example, a layer of electrical insulation can be provided between two overlapping ends (radial sides  30   a  and  30   b  in this example) of the mesh. As shown in  FIG. 5( a ) , the bottom lining wear detection circuit can be connected to a bottom lining wear control and/or indicating circuits, which are collectively referred to as a detector. As the bottom of lining  12  is gradually consumed during the service life of the furnace, DC leakage current will rise, which can be sensed in the bottom lining wear control and/or indicating circuits. For a particular furnace design, a leakage current rise level set point can be established for indication of lining replacement, based on bottom lining wear, when the furnace is properly operated and maintained. 
         [0043]    The particular arrangements of the discontinuous side wall and bottom meshes shown in the figures are one example of discontinuous mesh arrangements of the present invention. The purpose for the discontinuity is to prevent eddy current heating of the mesh from inductive coupling with the magnetic flux generated when alternating current is flowing through induction coil  16  when the coil is connected to a suitable alternating current power source during operation of the furnace. Therefore other arrangements of side wall and bottom meshes are within the scope of the invention as long as the mesh arrangement prevents such inductive heating of the mesh. Similarly arrangement of the electrical connection(s) of the mesh to the lining wear detection circuit, and the control and/or indicating circuits can vary depending upon a particular furnace design. Depending upon the physical arrangement of a particular electric induction furnace continuous bottom and/or side wall meshes may be satisfactory without excessive eddy current heating. 
         [0044]    In some examples of the invention refractory embedded wall mesh  26  may extend for the entire vertical height of lining  12 , that is, from the bottom ( 12   BOT ) of the furnace lining to the very top ( 12   TOP ) of the furnace lining that is above the nominal design melt line  25  for a particular furnace as shown, for example, in  FIG. 8 . 
         [0045]    In other applications, wall mesh  26  may be provided in one or more selected discrete regions along the vertical height of lining  12 . For example in  FIG. 9( a )  and  FIG. 9( b )  wall mesh comprises two vertical electrically conductive meshes  36   a  and  36   b  that are electrically isolated from each other and connected to separate lining wear detection circuits so that lining wear can be diagnosed as being on either one half side of the furnace lining. In this example there are two electrical discontinuities  38   a  (formed between vertical sides  37   a  and  37   d ) and  38   b  (formed between vertical sides  37   b  and  37   c ) along the vertical height of the two meshes  36   a  and  36   b . Further any multiple of separate, vertically oriented and electrically isolated wall mesh regions may be provided along the vertical height of lining  12  with each separate wall mesh region being connected to a separate lining wear detection circuit so that lining wear could be localized to one of the wall mesh regions. Alternatively as shown in  FIG. 9( c )  the multiple electrically conductive meshes  46   a  through  46   d  can be horizontally oriented with each electrically isolated mesh connected to a separate lining wear detection circuit and control and/or indicating circuits (D) so that lining wear can be localized to one of the isolated mesh regions. Most generally as shown in  FIG. 9( d )  the multiple electrically conductive meshes  56   a  through  56   p  can be arrayed around the height of the replaceable lining wall with each electrically conductive mesh connected to a separate lining wear detection circuit, and control and/or indicating circuits (not shown in the figure) so that lining wear can be localized to one of the isolated mesh regions that can be defined by a two-dimensional X-Y coordinate system around the circumference of the replaceable lining wall with the X coordinate defining a position around the circumference of the lining and the Y coordinate defining a position along the height of the lining. 
         [0046]    In similar fashion bottom mesh  30  may cover less than the entire bottom of replaceable lining  12  in some examples of the invention, or comprise a number of electrically isolated bottom meshes with each of the electrically isolated bottom meshes connected to a separate lining wear detection circuit so that lining wear could be localized to one of the bottom mesh regions. 
         [0047]    Alternatively to a separate detector (control and/or indicating circuits) used with each lining wear detection circuit in the above examples, a single detector can be switchably connected to the lining wear detection circuits associated with two or more of the electrically isolated meshes in all examples of the invention. 
         [0048]    While the figures illustrate separate wall and bottom lining wear detection systems, in some examples of the invention, a combined wall and bottom lining wear detection system may be provided either by (1) providing a continuous side and bottom mesh embedded in an integrally cast flowable refractory with a single lining wear detection circuit and detector or (2) providing separate side and bottom meshes embedded in a cast flowable refractory with a common lining wear detection circuit and detector. 
         [0049]      FIG. 6( a )  through  FIG. 6( f )  illustrate one example of fabrication of an electric induction furnace with a lining wear detection system of the present invention. Induction coil  16  can be fabricated (typically wound) and positioned over suitable foundation  18 . As shown in  FIG. 6( a )  trowelable refractory (grout) material  20  can be installed around the coil as in the prior art. One suitable proprietary trowelable refractory material  20  is INDUCTOCOAT™ 35AF (available from Inductotherm Corp., Rancocas, N.J.). If a bottom lining wear detection system is used, bottom mesh  30  can be fitted at the top of foundation  18  and embedded in cast flowable refractory by pouring the cast flowable refractory around bottom mesh  30  so that the mesh is embedded within the refractory after it sets as shown in  FIG. 6( b ) . Alternatively the bottom mesh can be cast in a cast flowable refractory  28  in a separate mold and then the cast refractory embedded bottom mesh can be installed in the bottom of the furnace after the cast flowable refractory sets. 
         [0050]    A suitable temporary cast flowable refractory mold  90  (or molds forming a formwork) for example, in the shape of an open right cylinder, is positioned within the volume formed by coil  16  and refractory material  20  to form a cast flowable refractory annular volume between refractory material  20  and the outer wall perimeter of the mold as shown in  FIG. 6( c ) . Mesh  26  is fitted around the outer perimeter of temporary mold  90  and the cast flowable refractory  24 , such as INDUCTOCOAT™ 35AF-FLOW (available from Inductotherm Corp., Rancocas, N.J.), can be poured into the cast flowable refractory annular volume to set and form hardened castable refractory  24  as shown in  FIG. 6( d ) . Vibrating compactors can be used to release trapped air and excess water from the cast flowable refractory so that the refractory settles firmly in place in the formwork before setting. Mesh  26  will be at least partially embedded in cast flowable refractory  24  when it sets inside of the cast flowable refractory annular volume. In other examples of the invention mesh  26  can be embedded anywhere within the thickness, t, of cast flowable refractory  24 . For example as shown in  FIG. 7 , mesh  26  is offset by distance, t 1 , from the inner wall perimeter of cast flowable refractory  24 . Offset embedment can be achieved by installing suitable standoffs  91  around the outer perimeter of mold  90  as shown in  FIG. 6( d )  and then fitting mesh  26  around the standoffs before pouring the cast flowable refractory. In the broadest sense as used herein, the terminology mesh “embedded” in a cast flowable refractory means the mesh is either fixed within the refractory; at a surface boundary of the refractory, or sufficiently, but not completely, embedded at a surface boundary of the refractory so that the mesh is retained in place in the refractory after the refractory sets. 
         [0051]    After cast flowable refractory  24  sets, temporary mold  90  is removed, and a replaceable lining mold  92  that is shaped to conform to the boundary wall and bottom of interior furnace volume  14  can be positioned within the volume formed by set cast flowable refractory  24  (with embedded mesh  26 ) to form a replaceable lining annular volume between set cast flowable refractory  24  and the outer wall perimeter of the lining mold  92  as shown in  FIG. 6( e ) . A conventional powdered refractory can then be fed into the lining volume according to conventional procedures. If lining mold  92  is formed from an electrically conductive mold material, lining mold  92  can be heated and melted in place according to conventional procedures to sinter the lining refractory layer that forms the boundary of furnace volume  14 . Alternatively the lining mold may be removed and sintering of the lining refractory layer may be accomplished by direct heat application. 
         [0052]    Distinction is made between the replaceable lining refractory, which is typically a powdered refractory and the cast flowable refractory in which the electrically conductive mesh is embedded. The cast flowable refractory is used so that the electrically conductive mesh can be embedded in the refractory. The cast flowable refractory is also referred to herein as castable refractory and flowable refractory. 
         [0053]      FIG. 6( g )  illustrates an electric induction furnace with one example of a lining wear detection system of the present invention with addition of typical furnace ground leak detector system probe wires  22   a  and electrical ground lead  22   b  that is connected to a furnace electrical ground (GND). 
         [0054]    The fabrication process described above and as shown in  FIG. 6( a )  through  FIG. 6( g )  illustrates one example of fabrication steps exemplary to the present invention. Additional conventional fabrication steps may be required to complete furnace construction. 
         [0055]    There is shown in  FIG. 10  one example of an electric induction furnace  11  with a lining wear detection system of the present invention. A wall refractory  23  is disposed between coil  16  and replaceable furnace lining  12 . The refractory may be a castable or trowelable refractory. In this example of the invention, electrically conductive wire assemblage  27  is embedded within the inner boundary of wall refractory  23  that is adjacent to the outer boundary of lining  12 . One non-limiting example of a suitable electrically conductive wire assemblage is formed from an assemblage of stainless or copper nickel stranded wire in a range from 18 to 10 AWG depending upon the particular configuration of the induction furnace. In other arrangements of the invention other types of electrically conductive wire may be used as suitable for a particular application. The wire may be bare or insulated if arcing is an issue in a particular application. Stranded wire is preferred although solid wire may be used in some applications. As shown in  FIGS. 11( a ) and 11( b ) , for this example of the invention, electrically conductive wire assemblage  27  forms a vertical wire cage between refractory  23  and consumable lining  12  from the top ( 26   TOP ) to the bottom ( 26   BOT ) of the outer boundary of the lining wall. In this example of the invention twenty-six vertical wires  27   1  to  27   26  are vertically spaced apart from each other around the circumference of wire assemblage refractory  23 . In this example of the invention the twenty-six vertically oriented wires are electrically connected together by suitable electrically connecting means such as multiple tap connectors or wire lugs  31  to bottom collector wire  29  of electrically conductive wire assemblage  27 . 
         [0056]    More generally the number of vertical wires used depends upon the configuration of a particular induction furnace and are referred to as riser protection wires. While vertically-oriented riser protection wires are shown in the above example of the invention, in other examples the arrangement of riser protection wires around the circumference of refractory  23  may be of other configurations such as a spiral configuration. While a bottom collector wire is used in the above example of the invention the collector wire may be located anywhere between the top and bottom ends of the riser protection wires and there may be more than one collector wire depending upon a particular application. 
         [0057]    In the above example of the invention, collector wire  29  is connected at a single terminal point T 1  to a positive electric potential that can be established by a suitable voltage source, such as direct current (DC) voltage source V dc  that has its other (negative) terminal connected to furnace electrical ground (GND). A lining wear detection circuit is formed between the positive electric potential connected to electrically conductive wire assemblage  27  and the negative electric potential connected to the furnace electrical ground. As shown in  FIG. 11( a )  the voltage source circuit can be connected to control circuits and/or indicating circuits via suitable circuit elements such as a current transformer. Alternatively a direct measurement of leakage current can be provided with suitable direct measurement device such as, but not limited to, a current shunt resistor. The control and/or indicating circuits are referred to collectively as a detector. As consumable lining  12  is gradually consumed during the service life of the furnace, DC leakage current will rise, which can be sensed in the control/indicating circuits. For a particular furnace design, a leakage current rise level set point can be established for indication of lining replacement when the furnace is properly operated and maintained. 
         [0058]      FIG. 12( a )  illustrates an alternative to the protective riser wires shown in  FIG. 11( a ) . In  FIG. 12( a )  a single continuous protective riser wire  35  is provided by weaving the riser wire around the top and bottom circumferences of the induction furnace. Top fitting  51  as shown in  FIG. 12( b )  and  FIG. 12( c )  is used to facilitate weaving the single continuous protective wire  35 . Fitting  51  is generally cylindrical in shape and has top wire turn notches  51 ′ that facilitate turn of the continuous wire at the top of the furnace during installation. Each notch  51 ′ comprises a generally semicircular volume as seen in cross section in  FIG. 12( c )  and  FIG. 12( d )  that is larger in cross section than the cross sectional diameter of wire  35  to allow rapid insert into the wire seating sub-notch  51 ″ at the bottom of each wire turn notch  51 ′ that has a cross sectional diameter slightly larger than the cross sectional diameter of wire  35 . Off-centering of wire seating sub-notch  51 ″ in the direction of the top-to-bottom weave (illustrated by the arrow in  FIG. 12( c )  assists in making the turn of the protective riser wire 180 degrees from the upward to downward direction at the top of the furnace. A bottom fitting  52  as shown in  FIG. 12( e )  is provided to facilitate weaving of the single protective wire  35  at the bottom of the furnace being assembled. Bottom fitting  52  is similar to top fitting  51  with complementary arranged bottom wire turn notches  52 ′ and wire seating sub-notches  52 ″. 
         [0059]    In some examples of the invention, a bottom lining wear detection system may be provided as alternatively shown, for example in  FIG. 14( a ), 14( b )  or  14 ( c ), in addition to one of the wall lining wear detection systems shown in  FIG. 11( a )  and  FIG. 11( b ) . In  FIG. 13  electrically conductive discontinuous bottom mesh  30 ; continuous bottom mesh  30 ′; or wire assemblage  30 ″ is disposed within bottom refractory  28  with bottom mesh  30  adjacent to the lower boundary of lining  12  at the bottom of the furnace. For the bottom lining wear system shown in  FIG. 14( a ) , bottom mesh  30  forms an electrically discontinuous circular mesh boundary between bottom refractory  28  and the bottom of lining  12 . In alternative applications of the invention, the bottom mesh boundary may be formed from a continuous circular mesh  30 ′ as shown in  FIG. 14( b )  between bottom cast flowable refractory  28  and the bottom of lining  12 , or one or more electrically conductive wire assemblage  30 ″ as shown in  FIG. 14( c ) . In examples of the invention where the electrically discontinuous bottom mesh  30  is used, at least one discontinuous radial side  30   a  of bottom mesh  30  is suitably connected to a positive electric potential established by a suitable voltage source V dc  that has its other terminal connected to furnace electrical ground (GND). A bottom lining wear detection circuit is formed between the positive electric potential connected to the electrically conductive bottom mesh or wire assemblage and the negative electric potential connected to the furnace electrical ground. In applications where it is used, the at least one radial electrical discontinuity  30   c  in mesh  30  is sized to prevent short circuiting between opposing radial sides  30   a  and  30   b  of mesh  30  and may include multiple discontinuities  30   c ,  30   c ′ and  30   c ″ as shown in  FIG. 14( a ) . In alternative applications of the invention, the bottom mesh boundary may be formed from a continuous circular mesh  30 ′ as shown in  FIG. 14( b )  between bottom cast flowable refractory  28  and the bottom of lining  12 , or one or more electrically conductive wire assemblage  30 ″ as shown in  FIG. 14( c ) . Alternatively the mesh may be fabricated in a manner so that the mesh is electrically isolated from itself. As shown in the alternative arrangements of  FIG. 14( a ) ,  FIG. 14( b )  and  FIG. 14( c ) , the bottom lining wear detection circuit can be connected to a bottom lining wear control and/or indicating circuits, which are collectively referred to as a detector. As the bottom of lining  12  is gradually consumed during the service life of the furnace, DC leakage current will rise, which can be sensed in the bottom lining wear control and/or indicating circuits. For a particular furnace design, a leakage current rise level set point can be established for indication of lining replacement, based on bottom lining wear, when the furnace is properly operated and maintained. 
         [0060]    In some examples of the invention, electrically conductive wire assemblage  27  or  35  may extend for the entire vertical height of lining  12 , that is, from the bottom ( 12   BOT ) of the furnace lining to the very top ( 12   TOP ) of the furnace lining that is above the nominal design melt line  25  for a particular furnace as shown, for example, in  FIG. 17  for electrically conductive wire assemblage  27 . 
         [0061]    In other applications, electrically conductive wire assemblage  27  may be provided in one or more selected discrete regions along the vertical height of lining  12 . For example in  FIG. 18( a )  electrically conductive wire assemblage comprises two vertical electrically conductive wire assemblages  53   a  and  53   b  that are electrically isolated from each other and connected to separate lining wear detection circuits so that lining wear can be sensed as being on either one half side of the furnace lining. Further any multiple of separate, vertically oriented and electrically isolated wall electrically conductive wire assemblage regions may be provided along the vertical height of lining  12  with each separate wall region being connected to a separate lining wear detection circuit so that lining wear could be localized to one of the wall regions. Alternatively the multiple electrically conductive wire assemblages  53   a  and  53   b  in  FIG. 18( a )  can be horizontally oriented with each electrically isolated electrically conductive wire assemblage connected to a separate lining wear detection circuit and control and/or indicating circuits (D) so that lining wear can be localized to one of the isolated wire assemblage regions. One or more of the vertical risers may be oriented in different directions. For example wire assemblage  55   a  at the top of the furnace in  FIG. 18( b )  has the protection wires oriented with horizontal while wire assemblages  55   b ,  55   c  and  55   d  are vertically oriented. Most generally as shown in  FIG. 18( c )  the multiple electrically conductive wire assemblage  59   a  through  59   p  can be arrayed around the height of the replaceable lining wall with each electrically conductive wire assemblage connected to a separate lining wear detection circuit (D) with control and/or indicating circuit so that lining wear can be localized to one of the isolated electrically conductive wire assemblage regions that can be defined by a two-dimensional X-Y coordinate system around the circumference of the replaceable lining wall with the X (horizontal) coordinate defining a position around the circumference of the lining and the Y (vertical) coordinate defining a position along the height of the lining. 
         [0062]    In similar fashion bottom, discontinuous mesh  30 , continuous mesh  30 ′ or wire assemblage  30 ″ may cover less than the entire bottom of replaceable lining  12  in some examples of the invention, or comprise a number of electrically isolated bottom meshes or wire assemblages with each of the electrically isolated bottom meshes or wire assemblages connected to a separate lining wear detection circuit so that lining wear could be localized to one of the bottom mesh or wire assemblages regions. 
         [0063]    As an alternative to a separate detector (control and/or indicating circuits) for each lining wear detection circuit in the above examples, a single detector can be switchably connected to the lining wear detection circuits associated with two or more of the electrically conductive meshes or wire assemblages in all examples of the invention. 
         [0064]    While the figures illustrate separate wall electrically conductive wire assemblage and bottom lining wear detection systems, in some examples of the invention, a combined wall electrically conductive wire assemblage and bottom lining wear detection system may be provided either by (1) providing a continuous side electrically conductive wire assemblage and bottom mesh or wire assemblage embedded in a refractory with a single lining wear detection circuit and detector or (2) providing separate side electrically conductive wire assemblage and bottom meshes or wire assemblages embedded in a cast flowable refractory with a common lining wear detection circuit and detector. 
         [0065]      FIG. 15( a )  through  FIG. 15( h )  illustrate examples of fabrication of an electric induction furnace with a lining wear detection system of the present invention with a side electrically conductive wire assemblage. Induction coil  16  can be fabricated (typically wound) and positioned over suitable foundation  18 . As shown in  FIG. 15( a )  trowelable refractory (grout) material  20  can be installed around the coil as in the prior art. One suitable proprietary trowelable refractory material  20  is INDUCTOCOAT™ 35AF (available from Inductotherm Corp., Rancocas, N.J.). If a bottom lining wear detection system is used, an alternative bottom mesh  30  or  30 ′, or wire assemblage  30 ″ can be fitted at the top of foundation  18  and embedded in cast flowable refractory by pouring the cast flowable refractory around the selected bottom mesh or wire assemblage so that the mesh or wire assemblage is embedded within the refractory after it sets as shown in  FIG. 15( b ) . Alternatively the bottom mesh or wire assemblage can be cast in refractory  28  in a separate mold and then the cast refractory embedded bottom mesh or wire assemblage can be installed in the bottom of the furnace after the cast flowable refractory sets. 
         [0066]    A suitable temporary cast flowable refractory mold  90  (or molds forming a formwork) for example, in the shape of an open right cylinder, is positioned within the volume formed by coil  16  and refractory material  20  to form a wire assemblage refractory annular volume between refractory material  20  and the outer wall perimeter of the mold as shown in  FIG. 15( c ) . Electrically conductive wire assemblage  27 , for example as shown in  FIG. 11( a ) , is fitted around the outer perimeter of temporary mold  90  and the wire assemblage refractory  23 , such as INDUCTOCOAT™ 35AF-FLOW (available from Inductotherm Corp., Rancocas, N.J.), can be provided into the wire assemblage refractory annular volume to set and form hardened wire assemblage refractory  23  as shown in  FIG. 15( f ) . 
         [0067]    Alternatively for the electrically conductive wire assemblage  35  shown in  FIG. 12( a )  top fitting  51  is positioned at the top of temporary mold  90  in  FIG. 15( d ) . A bottom fitting  52  is positioned at the bottom of temporary mold  90  and continuous electrically conductive wire  35  is weaved vertically around the outer circumference of the temporary mold in this example of the invention by using the top and bottom fittings as further illustrated in  FIG. 12( d )  which temporary fittings are removed after wire  35  is weaved. 
         [0068]    An alternative method of forming the electrically conductive wire assemblage  27  in  FIG. 11( a )  is to weave continuous electrically conductive wire  35  shown in  FIG. 12( a )  vertically around the outer circumference of temporary mold  90  as described in the previous paragraph and then cut off all the top loops  35   a  and bottom loops  35   b  shown in  FIG. 12( a )  of the continuous electrically conductive wire to form the protective riser wires  27   1  to  27   26  in  FIG. 11( a ) ; then connect the riser wires together, for example, at the bottom of the furnace to form collector wire  29  to form the electrically conductive wire assemblage  27  shown in  FIG. 11( a ) . 
         [0069]    Vibrating compactors can be used to release trapped air and excess water from a cast flowable refractory (if used) so that the refractory settles firmly in place in the formwork before setting. Electrically conductive wire assemblage  27  or  35  will be at least partially embedded in wire assemblage refractory  23  when it sets inside of the wire assemblage refractory annular volume. 
         [0070]    In other examples of the invention electrically conductive wire assemblage  27  or  35  can be embedded anywhere within the thickness, t, of cast flowable refractory  24 . For example as shown in  FIG. 16 , electrically conductive wire assemblage  27  is offset by distance, t 1 , from the inner wall perimeter of wire assemblage refractory  23 . Offset embedment can be achieved by installing suitable standoffs  91  around the outer perimeter of mold  90  as shown in  FIG. 15( e )  and then fitting electrically conductive wire assemblage  27  around the standoffs before providing the wire assemblage refractory. In the broadest sense as used herein, the terminology mesh or wire assemblage “embedded” in a refractory means the mesh or wire assemblage is either fixed within the refractory; at a surface boundary of the refractory, or sufficiently, but not completely, embedded at a surface boundary of the refractory so that the mesh or wire assemblage is retained in place in the refractory after the refractory sets. 
         [0071]    After wire assemblage refractory  23  sets, temporary mold  90  is removed, and a replaceable lining mold  92  that is shaped to conform to the boundary wall and bottom of interior furnace volume  14  can be positioned within the volume formed by set wire assemblage refractory  23  (with embedded wire assemblage  27 ) to form a replaceable lining annular volume between set cast flowable refractory  23  and the outer wall perimeter of the lining mold  92  as shown in  FIG. 15( g ) . A conventional powdered refractory can then be fed into the lining volume according to conventional procedures. If lining mold  92  is formed from an electrically conductive mold material, lining mold  92  can be heated and melted in place according to conventional procedures to sinter the lining refractory layer that forms the boundary of furnace volume  14 . Alternatively the lining mold may be removed and sintering of the lining refractory layer may be accomplished by direct heat application. 
         [0072]    Distinction is made between the replaceable lining refractory, which is typically a powdered refractory and the cast flowable refractory in which the electrically conductive mesh or wire assemblage is embedded. The cast flowable refractory is used so that the electrically conductive mesh or wire assemblage can be embedded in the refractory. The cast flowable refractory is also referred to herein as castable refractory and flowable refractory. 
         [0073]      FIG. 15( h )  illustrates an electric induction furnace with one example of a lining wear detection system of the present invention with side wire assemblage  27  addition of typical furnace ground leak detector system probe wires  22   a  and electrical ground lead  22   b  that is connected to a furnace electrical ground (GND). 
         [0074]    The fabrication processes described above and as shown in  FIG. 15( a )  through  FIG. 15( h )  illustrate non-limiting examples of fabrication steps exemplary to the present invention. Additional conventional fabrication steps may be required to complete furnace construction. 
         [0075]    In alternative examples of the invention rather than using a separate trowelable refractory (grout) around coil  16 , cast flowable refractory  24  can be extended to, and around coil  16 . 
         [0076]    The induction furnace of the present invention may be of any type, for example, a bottom pour, top tilt pour, pressure pour, or push-out electric induction furnace, operating at atmosphere or in a controlled environment such as an inert gas or vacuum. While the induction furnace shown in the figures has a circular interior cross section, furnaces with other cross sectional shapes, such as square, may also utilize the present invention. While a single induction coil is shown in the drawing for the electric induction furnace of the present invention, the term “induction coil” as used herein also includes a plurality of induction coils either with individual electrical connections and/or electrically interconnected induction coils. 
         [0077]    Further the lining wear detection system of the present invention may also be utilized in portable refractory lined ladles used to transfer molten metals between locations and stationary refractory lined launders. 
         [0078]    The examples of the invention include reference to specific electrical components. One skilled in the art may practice the invention by substituting components that are not necessarily of the same type but will create the desired conditions or accomplish the desired results of the invention. For example, single components may be substituted for multiple components or vice versa.