WO2023199257A1

WO2023199257A1 - Method for melting metal by means of an electric immersion heater

Info

Publication number: WO2023199257A1
Application number: PCT/IB2023/053788
Authority: WO
Inventors: Jimenez Matthias; Levacher Guillaume
Original assignee: Lethiguel
Priority date: 2022-04-15
Filing date: 2023-04-13
Publication date: 2023-10-19
Also published as: FR3134528B1; FR3134528A1

Abstract

The invention relates to a method for melting non-ferrous metal by means of at least one electric immersion heater, wherein: - at least one electric immersion heater is brought into contact or into close proximity with non-ferrous metal in the solid state placed inside a vessel, - during a so-called priming step, a so-called initial electrical power corresponding to a fraction of the nominal power of the electric immersion heater is supplied to the electric immersion heater and - during a so-called melting step, the electrical power supplied to the electric immersion heater is increased progressively or in steps so that the non-ferrous metal present in the vessel changes from a solid state to a liquid state without significant input from heat sources other than the at least one electric immersion heater. The invention also relates to a melting device for implementing the method and to a production unit comprising such a device.

Description

DESCRIPTION

TITLE: PROCESS FOR METAL FUSION USING AN ELECTRIC HEAT Immersion Unit

TECHNICAL FIELD OF THE INVENTION

[0001] The present invention relates to the field of foundry equipment and mainly concerns the foundry of non-ferrous metals having a relatively low melting point, typically below 1100°C. It aims at a metal melting process using at least one electric immersion heater. The invention aims more particularly to melt a batch of solid metal, in particular alloys or pure metals of aluminum, magnesium or zinc.

[0002] The present invention also relates to a device for implementing said fusion process which comprises an immersion heater.

STATE OF THE TECHNIQUE

[0003] The non-ferrous metal foundry industry requires a significant quantity of liquid metal for its casting operations. This is the case, for example, of the aluminum industry, which manufactures large quantities of castings, intended for example for the automobile industry. Some of the most commonly used molding operations include gravity casting, pressure injection molding and low-pressure injection molding.

[0004] In all cases, the step prior to molding is the fusion of solid metal. This step is most commonly carried out on site and more occasionally relocated off site, delivery by truck of the liquid metal being necessary in the latter case.

[0005] In foundry plants, two different furnaces are usually used, or a furnace having two chambers, namely a melting furnace (chamber), where the melting of liquid metal is carried out, and a holding furnace (chamber). , where liquid metal is held at a controlled temperature awaiting use by a casting machine. Solid metal melting is mainly carried out in gas-fired melting furnaces. Solid metal, usually in the form of ingots, is inserted into a chamber fusion where several gas burners carry out combustion which generates the heat allowing the metal to be melted.

The melting furnace (chamber) is connected to a holding furnace (chamber) in which the liquid metal is contained awaiting sampling and delivery to a casting point near a molding machine. Such a configuration is for example illustrated in European patent EP 1 136 778 A1 (Nippon Crucible Co.).

[0007] Melting using gas-powered melting furnaces is favored because it has a relatively low cost on average for the melting of a ton of metal. Gas melting also offers good melting speed in tons per hour.

[0008] A disadvantage of gas fusion is that this process is polluting on site because it involves the combustion of gas and because it necessarily relies on the use of fossil energy. In addition, a disadvantage of gas-fired melting furnaces is the phenomenon of “loss on ignition” which corresponds to the oxidation of part of the solid metal.

[0009] To overcome this defect, induction fusion and fusion by heating the metal by radiation are also used, which rely on an electrical power supply.

The induction method allows rapid melting, with very low loss on ignition and excellent metallurgical quality of the molten metal obtained. This method, however, has the drawback of being very energy intensive.

[0011] The radiation fusion method has the advantage of only requiring an inexpensive furnace that is not very complex to maintain. This method, however, has the drawbacks of being very slow, generating a lot of oxides which deteriorate the metallurgical quality of the metal obtained and being energy intensive.

[0012] No fusion method known in the prior art offers a satisfactory solution making it possible both to limit the use of polluting gas and to produce a metal of satisfactory metallurgical quality, without representing an exorbitant cost in terms of electricity supply.

[0013] Furthermore, the melting furnace described above is typically a centralized system within a factory which includes several molding machines. This arrangement requires transporting the liquid metal temporarily contained in the holding chamber to the molding machines; this is done for example in a channel made of ceramic material. In order to keep the metal in liquid form at a perfectly controlled temperature, a tank equipped with an immersion heater can be provided near the pouring point. Such an immersion heater is described in particular in patent FR 2 907 353 B1 of the applicant. [0014] Although the transport of molten metal represents a risk and exposes the liquid metal to oxidation by air, this factory arrangement is favored according to the state of the art because it has the advantage of limiting the the use of gas in part of the factory and because the larger furnaces offer better energy efficiency. In certain molding workshops, however, it would be preferable to have decentralized furnaces, of smaller size, without using gas heating, making it possible to avoid transporting liquid metal throughout the factory and between the different molding machines. This is particularly advantageous in the case where a casting plant simultaneously uses a significant number of different alloys of the same base metal, to the extent that the same furnace cannot deliver two different alloys at the same time. The state of the art does not offer a simple solution to this problem.

[0015] Furthermore, the gas oven is the only oven commonly used which can start dry, that is to say only with a load of solid metal. All other furnaces require a certain amount of liquid metal to operate; those skilled in the art call this quantity of liquid metal the “bath foot”. For example, to melt solid metal in an induction furnace, we first supply a bath base in which said metal is melted, gradually introducing it into the metal heated by induction. The liquid bath foot may come from another furnace operating in the factory. It follows that a casting plant which does not have a gas furnace must always have a certain quantity of liquid metal available to be able to start a stopped furnace. Alternatively, liquid metal can be delivered from an external smelter in a thermally insulated container (called a “ladle”), most often by road. This state of affairs imposes a heavy management constraint on foundries that do not have a gas furnace, knowing that the chemical composition of the bath base used to start a furnace must obviously be compatible with the alloy that we are using. I'm about to prepare in this oven which is starting up.

[0016] It follows from everything that has just been said that it would be desirable to have an electric oven capable of being started without a base, that is to say dry.

OBJECTS OF THE INVENTION

The present invention aims to address all or part of the needs mentioned above or to remedy all or part of the disadvantages mentioned above.

[0018] According to known practices of the prior art, electric immersion heaters are not used to melt non-ferrous metals. More specifically, immersion heaters are only used in contact with liquid metal. Indeed, the very Low air conductivity makes dewatering of an energized immersion heater critical. By “unwatering” we mean the situation of an immersion heater when it presents part of its heating zone in contact with air. The applicant noted that in the absence of contact with liquid metal, electric immersion heaters rise in internal temperature very quickly, so that their maximum temperature is reached in a few seconds. This problem does not arise when the heating part is immersed in the liquid metal and carries out a heat exchange with the molten metal. Conversely, when the heating part of the immersion heater is in the air, the cooling of the immersion heater is not sufficiently significant, so that the maximum temperature tolerated by the internal materials of the electric immersion heater is quickly reached and the latter is damaged.

[0019] It follows that according to the state of the art, immersion heaters are only used when they are permanently immersed in liquid metal; it is then possible to add solid metal to this liquid “bath base” to gradually increase the quantity of liquid metal, but you cannot start an oven loaded with solid metal using an immersion heater.

[0020] The applicant has developed the control process, the subject of the invention, which allows the use of electric immersion heaters for the melting of solid non-ferrous metals.

[0021] Thus, according to a first aspect, the invention aims at a process for melting non-ferrous metal by means of at least one electric immersion heater, in which:

- at least one electric immersion heater is placed in contact or in the immediate vicinity of non-ferrous metal in the solid state placed in a tank,

- during a so-called priming step, a so-called initial electrical power corresponding to a fraction of the nominal power of said electric immersion heater is supplied to said electric immersion heater and

- during a so-called melting step, the electrical power supplied to said electric immersion heater is increased, in particular gradually or in stages, so that the non-ferrous metal present in the tank goes from a solid state to a liquid state.

[0022] Thanks to these arrangements, a fusion of the metal can be carried out without consuming gas, unlike the fusion processes usually implemented. These arrangements improve safety within the factory, which does not have to maintain a gas distribution network, and reduces fossil fuel consumption to zero.

Preferably, the non-ferrous metal melting process using at least one electric immersion heater operates without significant heat input from other heat sources than the at least one electric immersion heater. By contribution we mean significant heat input a heat input which exceeds 1% of the total quantity of heat received by the metal to be melted during the process. In another embodiment, the oven comprises another means of electric heating than the electric immersion heater. For example, the other means of electric heating is a hot plate, preferably placed at the bottom of the oven; said heating plate may include at least one heating resistance, and its heat input can be significant. In another example, the other electric heating means is a heating plate or a high flux resistor positioned near the metal to be melted, preferably positioned above the metal to be melted.

[0024] According to the provisions of the invention, an electrical power lower than the nominal operating power is supplied to the electric immersion heater during the priming phase, then this power is increased, gradually or in stages, so that the maximum temperature tolerated by the internal materials of the electric immersion heater is not reached and it is not damaged.

Another remarkable characteristic of the invention is that the metal melting operation can be carried out in the same tank as that subsequently used to maintain the metal in the liquid state. This has the advantage of simplifying the furnace and avoiding the cost and risk associated with transport operations within the factory and transfer of molten metal between furnaces or tanks.

The present invention is applicable to any non-ferrous metal and any alloy based on a non-ferrous metal which has a melting temperature low enough to be compatible with the use of an electric immersion heater. It is in particular applicable to any metal and alloy having a melting temperature which does not exceed approximately 1100°C. The base metal can for example be chosen from aluminum, zinc, magnesium, copper, tin, lead, lithium, silver. It may also be an alloy based on one of these metals, said alloys may contain other alloy metals and impurities. It is understood that an Al-Fe type alloy remains a non-ferrous alloy within the meaning of the present invention, despite the presence of iron in this aluminum-based alloy.

[0027] By solid state metal is meant a metal in any solid form, and in particular in the form of ingots, in the form of chips, for example obtained by grinding metal sheets, in the form of granules, or even in the form of powder form. The metal to be melted can also be in the form of pieces of various shapes made up of skeletons or scraps from a machining, cutting, stamping, sawing process, or by casting rejects. Some of these product forms may correspond to waste (for example chips, stamping skeletons, scraps). Said metal in the solid state may have been compacted in a press (for example batches of boxes, or used drink cans, or batches of chips).

[0028] Here, nominal power means the power received by a device when it operates under normal conditions. It is expressed in Watt (W) or kilowatts (kW). It is indicated by the manufacturer of the device. In other words, the ideal electrical power supplied to an electrical appliance corresponds to its nominal power. Providing a power greater than the nominal power poses a risk of deterioration of the device and providing a power less than the nominal power may cause an output below its optimal capacities.

[0029] An electric immersion heater is a device which comprises at least one heating zone intended to be brought into contact with the metal to be heated, and a non-heating zone making it possible to make the link between the at least one heating zone and a housing. power supply. The heating zone comprises one or more internal heating elements brought to high temperature by the passage of an electric current; This is resistive heating. This internal heating element transmits its heat to a sheath constituting the body of the immersion heater, which in turn transmits heat to the metal or alloy to be melted or maintained in a liquid state. The mechanism of heat transmission from the immersion heater sheath to the metal in the oven occurs most efficiently by conduction, when the immersion heater is immersed in liquid metal or when its sheath touches a significant fraction of its surface area. solid metal. Outside of these direct contact zones, the heat transfer between the sheath and the metal contained in the oven is radiative and/or convective.

The process which is the subject of the invention comprises at least two stages, namely a first stage called priming, and a second stage called fusion. The priming step aims to create a liquid bath base from a solid metal charge. The melting step aims to melt the rest of the solid metal in said bath base, which will then rise to engulf all of the metal loaded into the furnace.

[0031] It is at this point that we move on to a third so-called maintenance phase, which aims to obtain and maintain fine control of the temperature of the liquid metal with a view to its use in a molding machine. This holding phase corresponds to the usual use of immersion heaters according to the state of the art. During the holding phase, small quantities of solid metal can be added, preferably periodically or continuously, as liquid metal is consumed by the casting machine.

[0032] The priming phase can be preceded by a so-called preheating phase, which aims to preheat the oven, empty or with a low load of solid metal, before loading it with the load of solid metal intended for the merger. Each of the phases named above is characterized by a certain electrical power supplied to the immersion heater, as will be explained below.

According to the invention, during the priming step the immersion heater is brought into contact with solid non-ferrous metal, or in the immediate vicinity of non-ferrous metal in the solid state placed in the tank. By this we mean that no liquid metal is in contact with the immersion heater before the priming step, or that the immersion heater is at least partially flooded, that is to say that the heating part of the immersion heater is at air contact. More precisely, the solid non-ferrous metal is poured or already present in the tank prior to the priming step, so as to at least partially bury the immersion heater. Of course, the geometry of the pile of pieces of solid non-ferrous metal may include air pockets so that the immersion heater will be in direct contact with the non-ferrous metal in places and separated from the metal in other places.

[0034] During this priming step, a so-called “initial” electrical power corresponding to a fraction of the nominal power of said electric immersion heater is supplied to said electric immersion heater. This electrical power must be high enough to allow gradual heating of the metal surrounding the immersion heater, but low enough to avoid premature degradation. During this priming phase, the heat delivered by the immersion heater is dissipated by conduction with the solid metal, and/or by radiation towards the solid metal. Since conduction dissipation is more effective in heating solid metal, it is preferable that the immersion heater be in direct contact with solid metal.

[0035] During the melting step, the immersion heater is at least partially in contact with molten metal, that is to say at least part of its sheath is immersed in liquid metal. The heat delivered by the immersion heater, resulting from the so-called initial electrical power supplied to the immersion heater, is then at least partly, and preferably mainly, dissipated by conduction. During this melting stage, the amount of liquid metal will increase as the solid metal melts, either in contact with the liquid metal or in contact with the immersion heater.

[0036] During one and/or the other of these two stages, solid metal can be added to the tank; this added solid metal (just like the solid metal initially present in the tank when the priming stage begins) can be preheated outside the oven to a temperature between room temperature and the melting point of the metal. Adding metal to the tank during the melting stage can be done directly in the liquid metal.

[0037] According to a characteristic of the method according to the invention, the transfer of heat from the immersion heater to the solid metal is therefore carried out, initially, by radiation and convection, on the one hand, and/or by conduction, on the other hand, with the solid metal in contact with the immersion heater, then gradually by the direct contact of the immersion heater with the liquid non-ferrous metal produced by fusion. The process thus implemented therefore has good energy efficiency, that is to say that almost all of the energy consumed is actually transferred to the metal. As an indication, the applicant estimates that the process which is the subject of this application requires half as much energy as an induction melting process to melt the same quantity of metal. The value of the initial power supplied to the immersion heater during the priming phase advantageously depends on the starting load and the quality of the thermal contact between the immersion heater and the metal. When the immersion heater is in contact with powder, granules or metal shavings, this value may be higher compared to the case where the immersion heater is surrounded by sheet metal skeletons ensuring less good thermal contact, and/or it may be increased more quickly. All the electrical power values supplied to the immersion heater are expressed here as a percentage of the nominal power value of the immersion heater, which is set by the manufacturer to ensure optimal operation without damaging the immersion heater device.

[0038] During the optional oven preheating phase, the refractories and the air in the oven are preheated, the air being able to reach a temperature of around 600° C., without solid metal or with a low solid metal load. This must be done at very low electrical power.

[0039] In embodiments, the initial electrical power supplied to the electric immersion heater during the priming phase is a non-zero power less than 30%, preferably less than 15%, and even more preferably less than 10%, of the nominal power of the electric immersion heater. This initial power can be increased subsequently, gradually or in stages.

[0040] In one embodiment, the initial electrical power supplied to the electric immersion heater during the priming phase is a non-zero power comprised between approximately 0.5% and approximately 5% of the nominal power of the electric immersion heater.

[0041] In one embodiment, during the priming step the power supplied to the immersion heater is increased from a very low value, typically between approximately 0.5% and approximately 5% (and preferably between approximately 0.5% and approximately 2.5%), at a rate of approximately 1% to 3% per hour, until the transition to the melting stage. [0042] During the melting step, the electrical power supplied to the electric immersion heater can be increased gradually or in stages over a long period of time. For example, the long time period is at least 8 hours.

[0043] In advantageous embodiments, the method which is the subject of the invention further comprises a step of maintaining the molten metal in the liquid state in which the power supplied to said electric immersion heater is controlled as a function of a temperature measured in the tank or on the immersion heater. During this holding step, the liquid metal can be taken from the tank to be introduced into the molding machine; to ensure the good quality of the casting process it is necessary to control the temperature of the liquid metal during the holding stage. In a particular embodiment of this holding step, a quantity of well-defined solid metal is added, preferably periodically, to the liquid metal, in order to replace the metal consumed by the molding machine.

[0044] In another embodiment, the non-ferrous metal in the solid state placed in the tank was previously melted and then solidified in the tank, in contact with the immersion heater. The state of the art does not offer any possibility, in an electric holding furnace, of remelting solid metal "frozen" in a tank, that is to say melted then solidified in place, so that the immersion heater is caught in frozen metal. According to particular provisions of the invention, this metal can be melted again to obtain a bath of liquid metal. The metal can be frozen in a tank involuntarily, for example during a power outage or during a strike, or voluntarily, when we decide to interrupt the heating and therefore the maintenance at the same time. liquid state of a metal bath then to resume operations when necessary, without having to drain the metal bath or having to move the immersion heater.

[0045] In embodiments, the nominal power of said immersion heater is determined as a function of the dimensions of the tank.

[0046] The transition from melting mode to holding mode typically results in a reduction in the electrical power supplied to the immersion heater to avoid overheating of the liquid metal, to the extent that during the holding phase it is no longer necessary to provide the furnace with the enthalpy of fusion (except for the small fraction of metal which is added in solid form to replace the liquid metal which is consumed).

[0047] In an advantageous embodiment, switching from fusion mode to hold mode can be done automatically. The transition from the melting stage to the stage of maintaining the molten metal in the liquid state is for example carried out automatically depending on the measurement of a value representative of the temperature of the immersion heater or in the tank or even depending on detecting the smooth or irregular appearance of at least part of the surface of the metal present in the tank For this purpose, a device for measuring the temperature of the liquid metal can be provided, which detects an increase in the temperature when the melting phase is completed. A temperature measuring device can be provided in the immersion heater itself, but this solution is not preferred. It is also possible to provide a device for measuring the temperature in a zone close to the bottom of the tank, capable of detecting the presence of a base of liquid metal bath, and of measuring its temperature.

[0049] According to an advantageous embodiment, the end of the fusion step is determined using an artificial vision system typically associating a camera with a computer machine suitably configured to detect the presence of a surface of smooth metal uninterrupted by protruding pieces of solid metal. This artificial vision system can also be configured to detect the level of liquid metal in the furnace.

[0050] According to a second aspect, the invention aims at a device for melting non-ferrous metal by means of at least one electric immersion heater, which comprises at least one electric immersion heater, a regulator of the power supplied to said immersion heater and a micro -processor configured to control said regulator and in which the microprocessor implements a non-ferrous metal melting program which includes:

- the supply to said electric immersion heater of a so-called initial electrical power corresponding to a fraction of the nominal power of said electric immersion heater and

- the gradual or stepwise increase in the energy supplied to said immersion heater, so that the non-ferrous metal present in the tank passes from a solid state to a liquid state without significant contribution from heat sources other than the electric immersion heater .

[0051] The aims, advantages and particular characteristics of the metal melting device which is the subject of the present invention being similar to those of the process which is the subject of the present invention, they are not recalled here.

[0052] According to a third aspect, the invention aims at a production unit for the molding of non-ferrous metal objects characterized in that it comprises at least one molding machine and a non-ferrous metal melting device according to the invention and in which the entry point of the liquid metal into the molding machine is in direct proximity to the non-ferrous metal melting device or connected to it by means of conveying a flow of liquid metal .

[0053] According to the prior art, a large capacity melting furnace makes it possible to supply molten metal to several production lines for molding. This provision requires to transport the liquid metal temporarily contained in the holding chamber to the production units distributed within a factory. A constraint associated with this arrangement is that the same metal or alloy is supplied to each production unit or molding machine supplied with molten metal by the melting furnace; This is not suitable if two production units or molding machines must be supplied with alloys of different types.

[0054] According to the invention, the production unit comprises a non-ferrous metal melting device according to the invention which melts the metal on site, near the pouring point. It being understood that the production unit has its own means of bringing the metal to the liquid state, the metal or metal alloy can be chosen specifically for this production unit.

Other aims, advantages and particular characteristics of the metal melting device which is the subject of the present invention being similar to those of the process which is the subject of the present invention, they are not recalled here.

BRIEF DESCRIPTION OF THE FIGURES

[0056] Other advantages, aims and particular characteristics of the invention will emerge from the following non-limiting description of at least one particular embodiment of the method, the device and the production unit which are the subject of the present invention. , with regard to the appended drawings, in which:

[0057] [Fig 1] represents, in the form of a flowchart, a particular succession of steps of the non-ferrous metal melting process which is the subject of the present invention, [Fig 2] represents, in graphic form, a mode particular embodiment of a non-ferrous metal melting process according to the invention,

[Fig 3] represents, schematically and in sectional view, an immersion heater capable of being used in a non-ferrous metal melting device according to the invention,

[Fig 4] represents, schematically and in sectional view, a non-ferrous metal melting device according to the invention useful for implementing the process which is the subject of the invention, illustrated at the start of the initiation phase,

[Fig 5] represents, schematically and in sectional view, the device of Figure 4, illustrated at the end of the priming step and

[Fig 6] represents, schematically and in sectional view, the device of Figure 4, illustrated at the end of the fusion step.

DETAILED DESCRIPTION OF THE INVENTION [0058] The present description is given on a non-limiting basis, each characteristic of an embodiment being able to be combined with any other characteristic of any other embodiment in an advantageous manner.

[0059] We now note that, unless otherwise stated, the power supplied to an immersion heater is expressed as a percentage of the nominal power of said immersion heater.

We observe, in Figure 1, in the form of a flowchart, a particular succession of steps of the process 100 for melting non-ferrous metal which is the subject of the present invention.

[0061] In embodiments, preheating, the method 100 comprises a step 103 of preheating the non-ferrous metal melting device which aims to preheat the furnace, empty or with a low load of solid metal, before charge with the solid metal charge intended for fusion. Preferably, the power supplied to the immersion heater during this preheating is fixed and between 5% and 25% of the nominal power of the immersion heater, for example approximately equal to 5% or 10%. Preferably, the duration of the preheating step is between 24 hours and 96 hours.

[0062] The method 100 comprises a step 105 during which at least one electric immersion heater is placed in contact or in the immediate vicinity of non-ferrous metal in the solid state placed in a tank.

Then, during a so-called priming step 110, an initial electrical power corresponding to a fraction of the nominal power of said electric immersion heater is supplied to said electric immersion heater.

[0064] According to an exemplary embodiment, the initial power supplied to the immersion heater is zero. In other embodiments, the initial power supplied to the immersion heater is equal to 1%, 2%, 5%, 10%, 15%, 20%, 25% or 30% of the nominal power of the immersion heater. This initial power can be a fixed value for a given immersion heater, or it can be modified depending on external parameters.

[0065] In embodiments, the power supplied to said electric immersion heater during the priming step 110 is fixed. In other embodiments, the power supplied to said electric immersion heater during the priming step 110 is increased gradually or in stages. The duration of the priming step 110 is preferably over a long period of time. According to an exemplary embodiment, the priming step is carried out over a period of time greater than 40 hours. In other embodiments, it is carried out over a period of time between 20 hours and 40 hours, or between 20 hours and 30 hours. [0066] During the priming step, the power supplied to the immersion heater can be increased gradually or in stages. For example, the power supplied to the immersion heater is increased by 5% compared to the initial power.

[0067] At the end of the priming step, a bath base, that is to say a bottom of liquid metal in the tank, is obtained.

[0068] Then, during a melting step 115, the electrical power supplied to the electric immersion heater is increased gradually or in stages. Preferably, the speed of increase in the electrical power supplied to the immersion heater is faster during the melting step than during the priming step. For example, this rate of increase expressed as a percentage of the nominal power per unit of time is five or ten times greater during the fusion stage compared to the rate of increase during the priming stage.

[0069] Advantageously, during the melting step a means of stirring the aluminum bath base is implemented. The stirring means is configured to stir the liquid aluminum in order to optimize the heat exchange with the immersion heater and thus reduce the melting time and homogenize the temperature of the aluminum bath.

[0070] In embodiments, the transition from the priming step to the melting step and the associated speed change are triggered as a function of a temperature measured in the tank.

[0071] The increase in power, gradually or in stages, during the fusion step, is preferably carried out over a long period of time. According to an example embodiment, the progressive increase in power is carried out over a period of time greater than 12 hours. In other embodiments, it is carried out over a period of time between 12 hours and 24 hours. Preferably, the increase in power supplied to the electric immersion heater, expressed as a percentage of the nominal power of the immersion heater, does not exceed 10% per hour. Preferably, the increase in power supplied to the electric immersion heater does not exceed 6% per hour.

[0072] In an exemplary embodiment, the power during the fusion step is increased by 1% every 15 minutes. So that, during the melting stage, the power supplied to the electric immersion heater goes from an initial power fixed between 5% and 25% of the nominal power to a power of 100% of the nominal power, in space from 1125 minutes to 1425 minutes.

[0073] At the end of steps 105, 110 and 115, the non-ferrous metal present in the tank is melted from a solid state to a liquid state, preferably without significant contribution from heat sources other than at least an electric immersion heater. [0074] In embodiments, the method 100 comprises a step 125 of maintaining the molten metal in the liquid state. During this step, the power supplied to the electric immersion heater can be controlled based on a temperature measured in the tank. This ensures that the liquid metal has a controlled temperature in the holding furnace, making it easier to achieve repeatable quality of castings produced by the molding machine.

[0075] In embodiments, during a step 120 concomitant with step 125 of maintaining the liquid state, solid metal is added to the tank.

[0076] We see in Figure 2 a graph illustrating a process 100 for melting non-ferrous metal according to two particular embodiments of the process which is the subject of the invention. It is recalled that the fusion process according to the invention is based on the use of an electric immersion heater.

[0077] This graph shows a curve 210 illustrating the internal temperature of the immersion heater expressed in °C as a function of time expressed in minutes. In addition, a curve 220 illustrates the variation in the temperature of the aluminum as a function of time.

[0078] It is emphasized that the values illustrated by curves 210 and 220 are theoretical values mentioned for information purposes only. These temperatures are in no way limiting for the process which is the subject of the invention, and the same applies to time.

[0079] We also observe in Figure 2 the curves 250 and 260 which illustrate a power supplied to the electric immersion heater, expressed as a percentage of the nominal power of said immersion heater, as a function of the elapsed time, expressed in minutes. Hereinafter we call “power supply program” a control of the power supplied to the immersion heater as a function of the elapsed time and/or as a function of a temperature measured in the tank.

[0080] Curve 250 illustrates a first program for supplying power to the electric immersion heater while curve 260 illustrates a second program for supplying power to the electric immersion heater.

[0081] According to the power supply program illustrated by curve 250, an initial power of 5% is provided during a preheating step, lasting 3200 minutes. Then, during a priming stage, over the space of 1800 minutes, the power supplied is increased progressively and regularly, so as to bring the power to 10% in total. Then, during a melting stage, over a period of 1000 minutes, the power supplied is increased progressively and regularly, so as to bring the power supplied to the immersion heater to 100% in total. Then, still during the melting stage, 100% power is continuously supplied to the immersion heater for 2500 minutes. At the end of the merging step, a step of maintaining the bath temperature is activated, during which the power supplied to the immersion heater is controlled according to a temperature measured in the tank.

[0082] Note that the transition from the priming step to the melting step can be carried out according to a pre-established power program or according to a temperature value measured in the tank.

[0083] Note that the transition from the melting step to the holding step can be carried out according to a pre-established power program or according to a temperature value measured in the tank.

[0084] According to the power supply program illustrated by curve 260, the power supplied to the immersion heater during the preheating step is 25%. And, the initial 25% power supplied to the immersion heater is raised to 30% during the priming stage and then to 100% during the melting stage.

[0085] Note that curves 250 and 260 merge from 6000 minutes.

[0086] Note that the programs for supplying power to the electric immersion heater illustrated by curves 250 and 260 are given for illustration purposes only. Other power supply programs may be implemented in deviating from the invention, particularly power supply programs whose power values for a given time are between the power values of curves 250 and 260.

[0087] We see in Figure 3, an immersion heater 300 capable of being used in a non-ferrous metal melting device. The immersion heater 300 includes a connection zone 310 equipped with a ceramic sheath and a heating zone 320 housing an electrical resistance. The immersion heater 300 includes an electrical power line 330 connected to an electrical power source 901.

[0088] We observe in Figure 4, a non-ferrous metal melting device according to the invention useful for implementing the process which is the subject of the invention which comprises an immersion heater 300 and a tank 400. The device is illustrated here at the start of the priming phase. Aluminum ingots to be melted, 950, 951, are placed in the tank 400.

[0089] The same device is illustrated in Figure 5 at the end of the priming step. A bath base formed by liquid metal 980 has formed in the tank while at least part of the ingots, 950, 951, are partially melted.

[0090] The same device is illustrated in Figure 6 at the end of the fusion step. All of the ingots initially present in the tank have at this stage been melted into liquid metal 980 and new ingots of metal to be melted, 952, 953, can be added to the tank. [0091] The invention can be implemented in several ways. In a first embodiment, we seek to improve the thermal contact between the external wall of the immersion heater and the solid metal in the oven.

[0092] According to a first embodiment, a sufficient quantity of pieces of metal of a sufficiently small size is loaded into the oven to create a mass which comes into direct contact with at least part of the immersion heater, and which, preferably , surrounds it. Thus, at least part of the metal is in direct contact with the immersion heater, thus ensuring heat transfer by conduction.

[0093] Said pieces can be shavings (obtained for example by grinding metal sheets), granules, powder. This improves the thermal contact between the immersion heater and the solid metal. This makes it possible to select a higher heating power compared to an embodiment in which the immersion heater is not in direct contact with the metal.

[0094] In a first variant of this embodiment, said pieces are loaded into a metal container, such as a bucket or a sleeve, of chemical composition compatible with the metal in question, in order to reduce the necessary quantity of pieces. Typically, this container is positioned below the immersion heater, so that the immersion heater plunges into said container, and the container is filled at least partially with said pieces, so that the immersion heater is, at least on part of its length, in direct contact with metal, namely with said pieces. Around said container, the solid metal intended to be molten is positioned (which can then have any shape), so that it is advantageously in direct contact with said container; You can add metal parts in bulk.

[0095] In a second variant of this embodiment, the immersion heater is surrounded by solid metal in pieces; these may in particular be ingots (for example new metal ingots or remelting ingots), or with briquettes formed by the compaction of chips, metal sheets or metal cans (particularly beverage cans). This arrangement of the solid metal into pieces is preferably done by hand, forming a dense pile which best touches the immersion heater, depending on the size and shape of said pieces. Around this pile we can then load metal parts and loose shavings, in any form.

[0096] In a third variant, the immersion heater is surrounded by ingots or solid pieces of metal in which a channel has been provided with a width slightly greater than the external diameter of the immersion heater; we put these pieces around the immersion heater, and can then load around this pile of metal parts, in contact with the immersion heater pieces of metal, in any form. Said massive pieces can be briquettes formed by the compaction of chips, metal sheets or metal boxes, in which a channel of sufficient diameter has been provided to be able to be threaded around the immersion heater. Said massive pieces can also be ingots of new metal or remelting ingots, in which a channel of sufficient diameter has been dug.

[0097] In a second embodiment, which is compatible with all the other embodiments and variants described in the present patent application, pieces of metal which have been preheated outside this oven are loaded into the oven. .

[0098] In addition to accelerating the melting of the metal, such a step of preheating the pieces of metal outside the oven has the advantage of evaporating residual water on the metal before introduction into the oven or to eliminate any organic matter and thus prevent the appearance of smoke in the oven.

[0099] In a first variant of this embodiment, preheated pieces of metal are loaded when the oven does not yet contain molten metal.

[0100] In a second variant, preheated pieces of metal are loaded into the liquid metal bath. This can be done at regular intervals or not. This can be done by a conveyor which brings said pieces, for example a belt conveyor. Said pieces may be finely divided or not; it can be for example chips, or sheets, sheets or stamping carcasses crushed or not, or even briquettes formed by compacting pieces or beverage cans, or even ingots of new metal or remelting ingots .

[0101] In a third embodiment, which is compatible with all the other embodiments and variants described in the present patent application, the method makes it possible to adapt the initial power and/or the evolution of the power of the immersion heater based on events or parameters detected by the device. Such an event may be, for example, the appearance of liquid metal in the tank as detected by a temperature measuring device at a point located inside the tank. Such a parameter can be, for example, the degree of covering of the immersion heater with chips as detected by a camera associated with suitably configured software.

[0102] In a fourth embodiment, which is compatible with all the other embodiments and variants described in the present patent application, the device according to the invention has a plurality of preconfigured programs which can be selected by the user. These programs make it possible to adapt the initial power and/or the evolution of the power of the immersion heater to certain parameters linked to the tank, in particular its size, and/or the degree of filling of the tank, or the nature of the solid metal placed in the tank.

[0103] In a fifth embodiment, the non-ferrous metal in the solid state placed in the tank was previously melted and then solidified in the tank, in contact with the immersion heater. In other words, the immersion heater is “imprisoned”, engaged in the solidified metal, and thus substantially follows the contours of the immersion heater. This embodiment ensures an excellent contact surface between the immersion heater and the metal to be melted.

[0104] The melting process which is the subject of the invention is carried out using a non-ferrous metal melting device.

[0105] This device is equipped with at least one electric immersion heater which can be lowered into a tank intended to receive the metal to be melted. The device may include a single tank allowing the function of melting the metal then maintaining the temperature or a plurality of tanks connected together.

[0106] The non-ferrous metal melting device further comprises a regulator of the power supplied to said immersion heater and a microprocessor configured to control said regulator and in which the microprocessor is configured to implement a melting program non-ferrous metal of the type described with regard to the process of the present application.

[0107] The device may comprise at least one air blower, and preferably a plurality of air blowers, which may (or may) be mobilized during the preheating step of the device or even during the steps of priming and fusion. Its aim is to improve the dissipation of the heat generated by the immersion heater within the tank; this makes it possible to increase the electrical power supplied to the immersion heater, particularly during the preheating phase, without running the risk of local overheating of the immersion heater.

[0108] According to another embodiment, which is compatible with all the other embodiments, an immersion heater is used which comprises at least two heating circuits configured to be supplied with electric current independently. This allows finer control of the electrical power supplied to the oven. More precisely, two (or more) independent heating resistor circuits can be provided over the entire effective length of the immersion heater, and only one of the two can be used in the case of a low electrical current supply (for example during heating). preheating step, or during the priming step), the second being added when a strong supply of electric current is needed (for example during the melting step). [0109] It is also possible to provide two (or more) electrical resistance circuits in two different zones distributed over the effective length of the immersion heater, one of which is close to the lower end; thus the immersion heater is subdivided along its length into at least two thermal segments which can be controlled independently of each other. In this embodiment, greater electrical power is brought into the lower circuit at the start of the melting phase, when the height of the bath base covers only a part, and typically a small part, of the effective length of the immersion heater.

[0110] It is possible to provide, via a microprocessor, a feedback loop which increases, at least for a certain duration, the electrical power supplied to the lower segment when the device for measuring the temperature in a zone close to the bottom of the tank will have detected the presence of a base of liquid metal bath. Said duration can be pre-programmed. We can predict that as soon as the level of metal in the tank has reached a certain level, we also increase the electrical power supplied to the upper segment.

[0111] It can be expected that the total power supplied to the immersion heater will decrease again when the melting step is completed; this end of the melting step can be detected by an optical method such as a camera, as described above, and/or by means of measuring the temperature of the liquid metal which detects an increase in the temperature when all the solid metal will have melted.

Claims

CLAIMS Process (100) for melting non-ferrous metal by means of at least one electric immersion heater, characterized in that:

- during a first step (105) at least one electric immersion heater is placed in contact or in the immediate vicinity of non-ferrous metal in the solid state placed in a tank,

- during a so-called priming step (110), a so-called initial electrical power corresponding to a fraction of the nominal power of said electric immersion heater is supplied to said electric immersion heater, and

- during a so-called melting step (115), the electrical power supplied to said electric immersion heater is increased gradually or in stages, so that the non-ferrous metal present in the tank goes from a solid state to a liquid state. Method according to claim 1, in which the initial electrical power supplied to the electric immersion heater is a non-zero power less than 30% of the nominal power of the electric immersion heater, preferably less than 15%, and even more preferably less than 10%, of the nominal power of the electric immersion heater. Method according to one of claims 1 or 2, in which the increase in temperature, gradually or in stages, during the melting step is carried out over a period of time at least equal to 8 hours. Method according to any one of claims 1 to 3, in which the increase in the power supplied to the electric immersion heater, expressed as a percentage of the nominal power of the immersion heater, does not exceed 10% per hour. Method according to any one of claims 1 to 4, which further comprises a step of maintaining the molten metal in the liquid state, in which the power supplied to said electric immersion heater is controlled as a function of a temperature measured in the tank or on the immersion heater. Method according to claim 5, in which the passage from the melting step to the step of maintaining the molten metal in the liquid state is carried out automatically as a function of a temperature measured in the tank or on the immersion heater. Method according to claim 5, in which the passage from the melting step to the step of maintaining the molten metal in the liquid state is carried out automatically depending on the detection of a value representative of the appearance of at least part of the surface of the metal present in the tank, for example when a smooth surface uninterrupted by pieces of solid metal which protrude is detected. Method according to any one of claims 1 to 7, in which the non-ferrous metal is chosen from aluminum, zinc, magnesium, tin, copper, or an alloy based on one of these metals, said alloys may contain other alloy metals and impurities. Method according to any one of claims 1 to 8, in which the non-ferrous metal in the solid state placed in the tank has been previously melted and then solidified in the tank, in contact with the immersion heater. . Method according to any one of claims 1 to 9, in which the nominal power of said immersion heater is determined as a function of the dimensions of the tank. . Method according to any one of claims 1 to 10, in which stirring means are implemented during the melting step (115) in order to stir the liquid aluminum. . Method according to any one of claims 1 to 11, which comprises, before the priming phase, a preheating phase (103) during which the tank empty or with a low load of solid metal is heated by means of the immersion heater, before loading the furnace with the solid metal charge intended for fusion. . Method according to any one of claims 1 to 11, in which, during the priming step, a sufficient quantity of pieces of metal of a size small enough to create a mass which comes into direct contact with at least part of the immersion heater. . Method according to claim 13, in which the pieces of metal are loaded into a metal container, such as a bucket or a sleeve, of chemical composition compatible with the metal in question and in which said container is at least partially filled with said pieces, so that the immersion heater is, at least over part of its length, in direct contact with said pieces. . Method according to one of claims 1 to 12, in which, during the priming step the immersion heater is surrounded by ingots or solid pieces of metal in which a channel of a width slightly greater than the external diameter of the immersion heater. . Method according to one of claims 1 to 15, which uses at least one air blower during the preheating step or even during the priming and melting steps, said air blower being configured to generate a flow of air in order to improve the dissipation of the heat generated by the immersion heater within the tank. Method according to one of claims 1 to 16, in which at least one immersion heater comprises at least two heating circuits configured to be supplied with electric current independently. . Method according to claim 17, in which the immersion heater comprises at least two independent heating resistor circuits and in which the number of heating resistor circuits supplied with current in the case of a low supply of electrical current, for example during the step preheating, or during the priming stage, is less than the number of heating resistor circuits supplied with current in the case of a high supply of electric current, for example during the melting stage. . Device for melting non-ferrous metal by means of at least one electric immersion heater, characterized in that it comprises at least one electric immersion heater, a regulator of the power supplied to said immersion heater and a microprocessor configured to control said regulator and in which the microprocessor implements a non-ferrous metal melting program which comprises:

- the supply to said electric immersion heater of a so-called “initial” electrical power corresponding to a fraction of the nominal power of said electric immersion heater and

- the gradual or stepwise increase in the energy supplied to said immersion heater, so that the non-ferrous metal present in the tank goes from a solid state to a liquid state. . Production unit for molding non-ferrous metal parts, characterized in that it comprises at least one molding machine and a non-ferrous metal melting device according to the preceding claim, and in which the casting point of the mold is in direct proximity to the non-ferrous metal melting device or connected to it by means of conveying a flow of liquid metal.