A new type of contactless stirrer and/or pump has been developed for Aluminium industry.Large scale synchronously rotating permanent magnet cylinders,which are magnetized orthogonal to the axes,are used to create trav...A new type of contactless stirrer and/or pump has been developed for Aluminium industry.Large scale synchronously rotating permanent magnet cylinders,which are magnetized orthogonal to the axes,are used to create travelling magnetic field in Aluminium furnace through a thick bottom or wall,which induces stirring in a liquid metal pool similarly to traditional AC three-phase inductors.Flowrate of up to 600 tons per hour can be achieved with negligible energy dissipation even if the total wall thickness of the furnace is 30 cm.The advantage of the permanent magnet inductor is much lower energy consumption-maximum energy consumption of the stirrer to produce sufficiently high mechanical torque does not exceed 20 kW even for 600 ton per hour stirrer.Produced metal flow is quite similar to that,which is achieved by the AC three-phase induction stirrers offered by ABB and other companies.AC three-phase inductors exhibit very high Joule losses in the coils of the machine,but the permanent magnet system working at frequency in the range from 0.5 Hz to 2 Hz produces negligible Joule losses both in liquid Aluminium as well as in stainless steel plate of the furnace bottom enclosure and in the permanent magnet material itself,so relatively weak air cooling is sufficient.The linear permanent magnet stirrer has been experimentally tested on a small scale lab model in a shallow pool of InGaSn eutectic. The tests confirm the predicted flow intensities and flow pattern,and give sufficient results for validation of the large scale flow simulations.Principal schematics of investigated system and the free surface deformation of the liquid metal due to action of the stirrer are shown below.The linear permanent magnet system may be used also as a contactless pump for liquid Aluminium in two-chamber furnaces,for tapping the liquid metal or for transportation and precision dozing.If high flow rate is required simultaneously with considerable elevation of the liquid metal level,the wall thickness of the channel should be lower and frequency of the travelling magnetic field higher comparing to the case of stirring application.Two sided pump has also been considered for a fiat channel,promising two times higher magnetic field induction and four times higher delivered pressure head.Seeing in perspective wide range applications of the proposed system a patent has been obtained.展开更多
文摘驱动液态金属用平面感应电磁泵,电磁驱动力主要由泵沟内部感应磁场与液态金属中形成的感应电场共同作用产生,而感应电场由感应磁场激发产生.研究电磁泵泵沟处感应磁场的分布情况及变化规律,有利于电磁泵的优化设计及其性能的提高.利用有限元软件ANSYS进行平面感应电磁泵仿真研究,得知电磁泵泵沟处感应磁场在三维空间均有分布,但以沿X轴变化为主.电磁泵泵沟内通入液态金属Zn或Sn后,感应磁场强度相比液态金属未通入前的值要小.参考模拟模型及计算结果,设计并制造实体平面感应电磁泵,在相同加载条件下,位于电磁泵泵沟处的感应磁场强度的实际测量值与模拟计算值存在允许误差,最大为8.3%,验证了模拟计算的准确性.依据计算数据,在75~85 V电压调节范围内改变电磁泵加载电压,可实现电磁泵对液态金属Sn的变流量泵送.Sn液泵送流量较大且流速比较稳定时加载的电压值为80 V,对应泵沟处感应磁场强度均值为0.137 T.
文摘利用数值模拟分析软件ANSYS,模拟分析平面交流感应电磁泵对泵沟内流通的液态金属作用的电磁驱动力变化.通过模拟结果得知,在相同加载条件下,液态Na-K合金液、Ga液、Zn液及Sn液由于电阻率值不同,所受电磁泵电磁驱动力依次减小;改变电磁泵窄面泵沟材料分别为不锈钢板、铜板、银板及陶瓷板时,可知窄面泵沟材料为铜板或银板时液态金属Zn受到的电磁驱动力较大且两者值相近,同时增加铜板厚度也有利于电磁驱动力的提高;在三相交流电源供电条件下,电磁泵加载不同电流频率,液态金属Zn受力呈现随频率增大先升后降的趋势,得到最佳使用频率范围为40～ 60 Hz.
文摘A new type of contactless stirrer and/or pump has been developed for Aluminium industry.Large scale synchronously rotating permanent magnet cylinders,which are magnetized orthogonal to the axes,are used to create travelling magnetic field in Aluminium furnace through a thick bottom or wall,which induces stirring in a liquid metal pool similarly to traditional AC three-phase inductors.Flowrate of up to 600 tons per hour can be achieved with negligible energy dissipation even if the total wall thickness of the furnace is 30 cm.The advantage of the permanent magnet inductor is much lower energy consumption-maximum energy consumption of the stirrer to produce sufficiently high mechanical torque does not exceed 20 kW even for 600 ton per hour stirrer.Produced metal flow is quite similar to that,which is achieved by the AC three-phase induction stirrers offered by ABB and other companies.AC three-phase inductors exhibit very high Joule losses in the coils of the machine,but the permanent magnet system working at frequency in the range from 0.5 Hz to 2 Hz produces negligible Joule losses both in liquid Aluminium as well as in stainless steel plate of the furnace bottom enclosure and in the permanent magnet material itself,so relatively weak air cooling is sufficient.The linear permanent magnet stirrer has been experimentally tested on a small scale lab model in a shallow pool of InGaSn eutectic. The tests confirm the predicted flow intensities and flow pattern,and give sufficient results for validation of the large scale flow simulations.Principal schematics of investigated system and the free surface deformation of the liquid metal due to action of the stirrer are shown below.The linear permanent magnet system may be used also as a contactless pump for liquid Aluminium in two-chamber furnaces,for tapping the liquid metal or for transportation and precision dozing.If high flow rate is required simultaneously with considerable elevation of the liquid metal level,the wall thickness of the channel should be lower and frequency of the travelling magnetic field higher comparing to the case of stirring application.Two sided pump has also been considered for a fiat channel,promising two times higher magnetic field induction and four times higher delivered pressure head.Seeing in perspective wide range applications of the proposed system a patent has been obtained.
