Mobile furnace facility

The present invention is a multi-faceted mobile furnace apparatus. The apparatus has a furnace system, an electrical system, a positioning system and a control unit. The furnace system has a set of movable electrodes, and at least two pour configurations, to transform a solid material into a molten state. The electrical system provides the electrode with a predetermined, yet changeable type of regulation, current, voltage, impedance, power, and/or imbalance of current. While the electrode positioning system moves the electrode, this movement determines if the electrode is properly positioned for the furnace to be an open arc system, a submerged resistance system, or submerged arc system. The above systems are monitored by the control unit. There by the furnace system, the electrical system and the positioning system can all be altered to achieve the most efficient and cost saving method to transform the solid material into the molten state.

FIELD OF THE INVENTION 
The present invention relates to a furnace system to melt an array of solid 
materials such as refractory and some metals. 
BACKGROUND OF THE INVENTION 
The prior art is replete with various types of furnaces to melt metals or 
refractory. These furnaces, generally, are those small and medium size 
units used in general foundry practice, heat treating and associated 
processes. Larger units are generally used for melting large quantities of 
metal or refractory as part of specific production processes such as the 
production of high purity alloy steels, processing batches of processes 
parts receiving vitreous enamel, annealing glass, and so on. 
As such, each furnace is, normally, designed for a specific industry and, 
thus, purposes. For example, there are various types of furnaces, two of 
which are arc furnaces and submerged resistance. In arc furnaces heat is 
developed by an arc, or arcs, drawn either to a charge or above the 
charge. Direct arc furnaces are those in which the arcs are drawn to the 
charge itself. In indirect arc furnaces the arc is drawn between the 
electrodes and above the charge. A standard power frequency is used in 
either case, direct current (DC) electric power is an alternative source 
of energy. 
In resistance furnaces of the submerged arc type, heat is developed by the 
passage of current from electrode to electrode through the charge. The 
manufacture of basic products, such as container glass, mineral wools, 
ceramic fiber and fiber glass, is the general service of a submerged 
resistance furnace. Alternating current (AC) at a standard power frequency 
is used. 
Moreover depending on the purpose, the furnace may be a bottom pour, side 
pour or both ("pour configuration"); electrically configured for either 
low voltage, higher current in Delta, or higher voltage, lower current in 
the Wye ("electrical configuration"); and power regulation in either AC or 
DC. 
None of the prior art patents describe a furnace able to change its pour 
configuration, electrical configuration, melting options and power 
regulation (collectively referred to as "Configurations") to determine the 
ultimate furnace for a particular material or process. 
SUMMARY OF THE INVENTION 
The present invention is a multi-faceted furnace apparatus. The apparatus 
has a furnace system, an electrical system, a positioning system and 
control unit. The furnace system has a set of movable electrodes, and at 
least two pour configurations, to transform a solid material into a molten 
state. The electrical system provides the electrode with a predetermined, 
yet changeable type of regulation, current, voltage, impedance, power, 
and/or imbalance of current. While the electrode positioning system moves 
the electrode, this movement determines if the electrode is properly 
positioned for the furnace to be an open arc system, a submerged 
resistance system or submerged arc system. The above systems are monitored 
by the control unit. There by the furnace system, the electrical system 
and the positioning system can all be altered to achieve the most 
efficient and cost saving method to transform the solid material into the 
molten state.

DETAILED DESCRIPTION OF THE PRESENT INVENTION 
FIG. 1 shows a preferred embodiment of a furnace apparatus 10. In the 
preferred embodiment, the furnace apparatus 10 is a mobile unit having a 
platform 9 and a housing 11. The housing 11 is subdivided with furnace 
access doors 8, operator doors 7, operator console doors 6, electrical 
system access panels 5, and other sections 4, including the roof. A 
raising apparatus 3 elevates the apparatus 10, in particular the platform 
9, a minimum distance above the ground, such as by wheels, blocks, or the 
like. Preferably, the apparatus 10 is designed to be transported. As such, 
the dimensions of the apparatus 10 allow it to be mounted onto a tractor 
trailer bed 2 and be transportable on the interstate highway system, i.e., 
under overpasses and without requiring additional highway permits. 
Turning to FIG. 2, the apparatus 10 has the housing 11, a melter/electrode 
positioner unit 12, a power regulation supply 14, a controller unit 16, a 
data acquisition system 170, a motor control system 18, a dust collecting 
system 20, a water cooling system 22, and a multi-faceted furnace 24. The 
controller unit 16 displays operational data from the other subsystems 12, 
14, 18, 20, 22, 24. Each subsystems 12, 14, 18, 20, 22, 24 interconnects 
to the data acquisition system (hereafter "DAS") 170. The data system 170 
collects and monitors this information and displays the results at the 
operator console unit 16. The user, not shown, through the console unit 16 
and various manual override switches operates each subsystem 12, 14, 18, 
20, 22, and 24, to change the apparatus' 10 Configurations. There are over 
90 different configurations that can be set within a predetermined time 
frame. Depending on the Configuration change the time frame ranges between 
seconds to about four hours. By changing the Configurations, the user 
alters the function of the furnace 24 to obtain the ultimate furnace 
qualities for a particular material. Likewise and alternatively, the DAS 
170 operates, by the user's discretion, the apparatus 10 by comparing 
previous inputs from each subsystem 12, 14, 18, 20, 22 and 24 to the 
present readings, and alters each subsystem to obtain the maximum and 
desired Configuration. 
The foundation for apparatus 10 is the furnace 24. The furnace 24 receives 
a material, commonly called a charge, i.e., a metal, a refractory or an 
alloy. The furnace 24 melts it (to be described later), and then pours the 
molten material. The furnace 24, as shown in FIG. 2, has a conical top 
portion 26, a cylindrical middle portion 28 and a rounded bottom portion 
30. Each portion 26, 28, 30 is insulated with conventional furnace 
insulation material, not shown, to retain its heat. On the exterior of the 
furnace 24, the furnace 24 has an operator door 36, various position 
apertures 38, an exhaust aperture 40, and two pour configurations 32, 34. 
In one embodiment, the conical top portion has a manifold 930 that 
reflects some of the heat generated in furnace 24 back to the furnace 24 
and allows some of the heat to escape into the exhaust aperture 40. 
The first pour configuration allows the molten material to pour out a side 
spout 32 of the middle portion 28; the second pour configuration, turn to 
FIG. 3, allows the molten material to pour out the bottom orifice 34 at 
approximately 12" from the nadir of the rounded bottom portion 30. 
When the respective spout and orifice 32, 34, are open, the flow rate of 
the molten material is monitored by load cells 23. Each load cell 23, 
positioned about the furnace 24, generates a signal 200 proportional to 
the weight of the furnace and its charge. The DAS 170, as shown in FIG. 4, 
receives the signal 200, wherein the console unit 16 illustrates the 
results. As time passes, the difference in weight provides a method to 
calculate the flow rate of the molten material. 
Returning to FIG. 3, when the furnace 24 operates with any material, molten 
or solid, within it, the furnace 24 generates gases. As shown in FIG. 5, 
those gases 82 exit to the dust collecting system 20. While in the system 
20, the temperature and velocity of the gases 82 are measured by a 
plurality of thermocouples 53a and air velocity instruments 51 
respectively interspaced throughout the collecting system 20. The dust 
collecting system 20 draws the gases 82 into the aperture 40, at or about 
the apex of the top conical portion 26, into exhaust ducts 42 that leads 
to a cyclone 44. The cyclone 44 collects any particulate over a 
predetermined size. From the cyclone 44, the dust collecting system 20 
further draws the gases through the exhaust ducts 46 into an 
exhaust/filter/dust bag house 48. 
The bag house 48, preferably, has a high temperature filter 49 to collect 
pre-determined particulates, a compact fan 50, and an outlet 52. The 
system 48 is designed to insure that the gases emitted into the local 
environment, from the outlet 52, meet, and preferably exceed, any 
environmental output regulations under research and development 
restrictions. 
The fan 50 is an industrial exhaust fan that draws the gases 82 from the 
furnace 24 through the outlet 52 into the environment. In the preferred 
embodiment, the fan 50 draws the gases from at least 25 feet. As such, the 
fan 50 must have sufficient capacity to draw these gases from the furnace 
24. The amount of power depends on the air system leakage rate. This 
leakage rate is defined, in general terms, as the more the air system 
allows external air in, the harder it is to draw a vacuum on the furnace 
gases. 
As shown in FIG. 4, the fan 50, thermocouples 53a, and air velocity 
instruments 51 interconnect with the console 16 and the DAS 170. The 
instruments 51, 53a transmit their respective measurements 212, 214a to 
the DAS 170 and, in return, to the console 16. The console 16 shows the 
measurements on a touch screen display unit 100. The flow rate of the fan 
can be altered, allowing more or less cooling to occur and thus effect the 
gas temperature. 
To further control the temperature of the gases 82 in the system 20, the 
present invention uses the water cooling system 22 to cool the gases 82 
and other subsystems. 
Turning to FIG. 6, the water cooling system 22 is an open system that 
circulates water, or any other coolant liquid, through water pipes 52. The 
water pipes 52 direct the liquid, by a centrifugal pump 55, through a 
cooling tower 54 that cools the liquid in the pipes 52 to a "cooled 
state". While in the cooled state, the liquid traverses, and thereby 
cools, the dust collecting system 20; in particular around the aperture 
40, the exhaust pipe 42 and the cyclone 44; and the furnace 24. The 
operator can alter the liquid path through various interspaced flow meters 
199, that are in a manifold arrangement. After cooling the various 
subsystems, 14, 20, 24, the liquid is in a "warm state." The warm liquid 
returns through the pipes 52 through the cooling tower 54 so it can return 
to its "cool state." 
The cooling system 22 also has nozzles 56 attached thereto and each nozzle 
56 directs the cooled liquid to the exterior shell of the furnace 24. The 
nozzles 56 ensure the furnace 24 does not overheat while operating; the 
liquid collects in a basin 172. A tank 174 collects the liquid from the 
basin 172. 
The basin 172 has a pump up/pump down system 176. The system 176 pumps the 
hot liquid to pump 55 depending on the water level in the basin 172. If 
the water is high, the system 176 pumps water. In contrast, if the water 
in basin 172 is low, the system 176 does not pump. 
Alternatively, the cooling system 22 can be a closed system, if a water 
jacket surrounds the furnace shell. 
Also within the pipes 52 are interspaced thermocouples 53b. These 
thermocouples 53b measure the temperature of the liquid, supply and return 
liquid. 
Returning to FIG. 4, the flow rate and temperature of the liquid is 
controlled by the operator through the console 16. The DAS 170 acquires 
data from the pump 55 and tower 54. The pump 55 operates the flow rate 90 
of the liquid while the tower 54 outputs a fan rate 88. The flow rate 90 
and fan rate 88, in combination with other parameters, such as variable 
speed pumps or chiller systems, control the temperature of the liquid in 
system 22. If the flow rate 90 is too fast, the fan 54, at any fan rate 
88, will be unable to cool the liquid. Likewise, if the fan rate 88 is too 
slow, the liquid will never cool. Controlling the fan rate 88 and the flow 
rate 90 is critical to cool the liquid. As such, the operator, at the 
control unit 16 or at manual switches, transmits signals 222 and 224, 
respectively, to alter the fan rate 88 and the flow rate 90. 
Each thermocouple 53b transmits its measurements 214b to the console unit 
16 through the DAS 170. The console 16, in return, shows the measurements 
on the display unit 100. There are provisions for the operator to alter 
the fan rate 88 and the flow rate 90 depending on the liquid temperature 
in the system 22. 
Alternatively, each flow monitor 199 interconnects to the DAS 170. As such, 
each monitor 199 transmits a signal 220 identifying the liquid path, the 
pipes 52 to the alternative pipes 52b. The alternative pipes 52b divert 
the liquid from any subsystem 14, 18, 20, 24 if the operator determines 
the subsystem requires a temperature change. 
Turning to FIGS. 4 and 6, each subsystem 14, 20, 24 has at least one 
thermocouple 53c, 53d, 53e, 53f, 53g that measures the temperature of the 
subsystem. Each thermocouple 53c-g performs and transmits, by respective 
signals 214c-g, the relevant information to the DAS 170 and, in one 
embodiment, the information is displayed at the console 16 like 
thermocouples 53a and 53b. 
The liquid in the cooling system 22 becomes a warmed state due to the heat 
generated within the subsystems 14, 20, and particularly the furnace 24. 
The furnace heat is generated in one of two ways: open arc or submerged 
resistance heating. In either case, the operator, at the console unit 16, 
controls the electrical motor system 18, the melter/electrode positioner 
unit 12, and the power regulator supply 14. These three systems determine 
how much heat will be generated in the furnace 24. 
Turning to FIG. 7, each melter/electrode positioner unit 12 has an 
electrode 60, a lateral actuator 62, a vertical actuator 64, 
interconnections 66a and 66b for each actuator 62, 64, a power source 68, 
and an electrode holder 70. The electrode 60 is within the furnace 24, and 
connects to the distal end of the lateral actuator 62d with the electrode 
holder 70. The proximal end of the lateral actuator 62p connects to the 
vertical actuator 64, located on the exterior of the furnace 24, by 
electrode holder 70. As such, the lateral actuator 62 enters the furnace 
through the aperture 38. The lateral actuator 62 moves the electrode 60 in 
a lateral direction. 
In contrast, the vertical actuator 64 moves the electrode 60 in a vertical 
direction. The lowest position the electrode can attain in the furnace 24 
is the nadir of the aperture 38n. In contrast, the highest position the 
electrode can attain in the furnace 24 is the apex of the aperture 38a. As 
such, each electrode 60 can be moved in any lateral or vertical position, 
relative to the aperture 38 and depending on the method selected, open 
arc, submerged resistance, or submerged arc. The positioning of the 
electrode is controlled by the operator remotely at the console unit 16 or 
locally at the furnace 24 and automatically controlled during arc furnace 
operation to optimize the arc required. The electrode positioner unit 12 
moves by any conventional power source. The power source can be hydraulic, 
electric or air. 
Returning to FIG. 4, each power source 68 interconnects to the DAS 170 and 
the console unit 16. The power source 68 transmits a position signal 226 
identifying the position of each vertical and lateral actuator 62, 64, and 
thereby the position of each electrode 60. The console unit 16 converts 
that signal into a display identifying the position of each electrode 60 
in the furnace 24. The operator reviews the position of each electrode 60 
and transmits the signal 226 to each power source 68 to move a particular 
electrode 60 to a desired position. Alternatively, the position of each 
electrode 60 can be manually controlled by a local operator switch unit 
92. Switch unit 92 allows the operator to bypass the console unit 16 and 
move the electrodes 60. 
Controlling the position of each electrode 60, in itself, does not control 
the amount of heat generated in the furnace 24. Each electrode 60 is 
controlled in three ways; at the furnace 24, at the console 16, and 
automatic control during arc furnace operation. Rather, the position of 
the electrode 60 along with the amount and type of power transmitted to 
the electrodes 60 determines the amount of heat. The amount of power is 
determined by the power regulating system 14. 
Each system 14, 18 interconnects to the data system 170, the console unit 
16, and each electrode 60. The system 14 provides the electrode 60 with 
either AC or DC current through line 250. The current can be generated 
within the housing 11 or, alternatively, received from an outside source 
(not shown). The system 14 transmits an AC or DC signal 228 to the DAS 170 
identifying which mode of regulation the electrode 60 is receiving. The 
operator, at the console unit 16, terminates the current to the electrode 
or alters the mode of regulation being received by the electrode 60 by 
transmitting a return signal 228 to the system 14. Alternatively, there is 
a manual switch 182 that allows the operator to manually alter the current 
received by the electrode and/or terminate the electrode from receiving 
any type of current, and add reactance to the system during arc furnace 
operations. 
The power regulator system 14 provides regulated power to the electrode 60 
and operator console 16 provides the adjustment to establish the level of 
voltage, current, wattage, impedance, and imbalance current or imbalance 
of power to the electrode 60. The motor control system 18 consists of 
various electrical systems that control and monitor these various 
parameters, and transmits a control signal 230 for each parameter to the 
DAS 170 and the console unit 16. The operator, at the console unit 16, 
monitors each parameter and adjusts them accordingly from the console unit 
16. Alternatively, the operator can manually adjust each parameter by a 
manual override switch 184, and even shut off, the parameters being sent 
to each electrode 60. 
The display unit 100, alternatively, is a touch screen unit having a 
readout system and allowing the operator to view and alternatively control 
(and adjust) a single measurement or parameter, or a plurality of 
measurements and/or parameters simultaneously. Alternatively, the display 
unit 100 is a combination of the two embodiments to control (and adjust) 
and view the parameters and measurements of the apparatus 10. 
The data acquisition system 170 is, but not limited to, a Pentium.RTM. 
based computer system with an array of analog to digital converters and 
pulse signal to digital converters. This array of signal processing units 
held within the computer adapts the various raw sensor signals for display 
locally at the DAS 170 and remotely at the display unit 100 which is 
mounted on the console 16. 
Numerous variations will occur to those skilled in the art. It is intended 
therefore, that the foregoing descriptions are only illustrative of the 
present invention and that the present invention be limited only by the 
hereinafter appended claims.