Melting furnaces and charging of melting furnaces
A feedstock charger includes a charger conduit and a feedstock conveyor rotatably and translatably carried in the charger conduit. According to a method of using the feedstock charger, feedstock is supplied to the feedstock conveyor of the feedstock charger, feedstock is allowed to fall through the charger conduit and out of an outlet of the charger conduit, and the feedstock conveyor is rotated and linearly advanced in the charger conduit. Also, a disclosed system includes the feedstock charger is coupled to a submerged combustion melter wherein the charger conduit extends into the melter through a feedstock inlet of the melter.
1 . A feedstock charger, comprising:
a charger conduit extending along a longitudinal charger axis, and including an inlet to receive feedstock into the charger conduit, and an outlet to transmit feedstock out of the charger conduit; and
a feedstock mover cooperative with the charger conduit to move feedstock in a direction from the inlet toward the outlet, and including
a feedstock conveyor carried in the charger conduit, and
at least one actuator coupled to the feedstock conveyor and including
a rotary actuator configured to rotate the feedstock conveyor about the longitudinal charger axis, and
a linear actuator coupled to the charger conduit and to the feedstock conveyor and configured to linearly translate the feedstock conveyor along the longitudinal charger axis,
wherein the charger conduit also includes a spout including a spout downstream end establishing the outlet and wherein the spout is fluid-cooled and includes:
an outer wall,
an inner wall,
an annular space between the outer and inner walls,
downstream and upstream closures that close off the annular space,
inlet and outlet ports proximate an upstream end of the outer wall and extending therethrough in fluid communication with the annular space, and
a plurality of circumferentially spaced and longitudinally staggered baffles extending radially between and in contact with the outer and inner walls and extending longitudinally between the downstream and upstream closures to establish a serpentine path along and around the fluid-cooled spout between the inlet and outlet ports.
2 . The feedstock charger of claim 1 , wherein the charger conduit also includes a spout including a spout downstream end establishing the outlet, and wherein the at least one actuator is configured to linearly translate the feedstock conveyor relative to the spout so that a downstream end of the feedstock conveyor extends axially past the outlet.
3 . The feedstock charger of claim 1 , further comprising:
a fluid conduit extending longitudinally into the feedstock conveyor and having an upstream inlet end to receive fluid into the fluid conduit and a downstream outlet end to transmit fluid out of the fluid conduit and into an annular space radially between the fluid conduit and the feedstock conveyor; and
a rotary fluid coupling having an inlet in fluid communication with the upstream inlet end of the fluid conduit and an outlet in fluid communication with the annular space.
4 . The feedstock charger of claim 1 , wherein the charger conduit also includes:
an actuator mount conduit upstream of and coaxial with a charger junction conduit, and including an outwardly extending drive mount coupled to the linear actuator; and
a conveyor guide conduit upstream of and coaxial with the actuator mount conduit and including seal and bushing assemblies including mounting rings, seal rings carried by the mounting rings, and bushings carried by the mounting rings.
5 . A feedstock charger, comprising:
a charger conduit extending along a longitudinal charger axis, and including an inlet to receive feedstock into the charger conduit, and an outlet to transmit feedstock out of the charger conduit;
a feedstock mover cooperative with the charger conduit to move feedstock in a direction from the inlet toward the outlet, and including
a feedstock conveyor carried in the charger conduit, and
at least one actuator coupled to the feedstock conveyor and configured to rotate the feedstock conveyor about the longitudinal charger axis and linearly translate the feedstock conveyor along the longitudinal charger axis; and
a gate intersecting the charger conduit downstream of the inlet and including a closed state wherein a downstream end of the feedstock conveyor is positioned in a location upstream of the gate and an open state wherein the downstream end of the feedstock conveyor is movable through the gate to a location downstream of the gate,
wherein the charger conduit includes:
a spout including a spout upstream portion having a spout upstream end downstream of the gate; and
a charger junction conduit including a feedstock mover portion coaxial with the feedstock mover, a feedstock inlet portion transversely oriented with respect to the feedstock mover portion, and a junction downstream end upstream of the gate.
6 . The feedstock charger of claim 5 , wherein at least portions of the charger conduit and the feedstock mover are fluid cooled, and wherein the gate is not fluid cooled.
7 . The feedstock charger of claim 5 , wherein the gate includes:
upper and lower annular mounts coupled to and between corresponding portions of the charger conduit and establishing a passageway through the gate;
an actuator frame coupled to the upper and lower annular mounts;
a linear actuator coupled to the actuator frame; and
a gate blade coupled to the linear actuator and slidable between the upper and lower annular mounts to open and close the passageway.
8 . A feedstock charger, comprising:
a charger conduit extending along a longitudinal charger axis, and including an inlet to receive feedstock into the charger conduit, and an outlet to transmit feedstock out of the charger conduit; and
a feedstock mover cooperative with the charger conduit to move feedstock in a direction from the inlet toward the outlet, and including
a feedstock conveyor carried in the charger conduit, wherein the feedstock conveyor is an auger including:
a hollow shaft having a downstream portion with a closed downstream end and composed of a first material and an upstream portion with an open upstream end and composed of a second material different than the first material, and
a helical flight around the downstream and upstream ends; and
at least one actuator coupled to the feedstock conveyor, and including a rotary actuator coupled to the feedstock conveyor to rotate the feedstock conveyor about the longitudinal charger axis, and the at least one actuator configured to linearly translate the feedstock conveyor along the longitudinal charger axis.
9 . A feedstock charger, comprising:
a charger conduit extending along a longitudinal charger axis, and including an inlet to receive feedstock into the charger conduit, and an outlet to transmit feedstock out of the charger conduit; and
a feedstock mover cooperative with the charger conduit to move feedstock in a direction from the inlet toward the outlet, and including
a feedstock conveyor carried in the charger conduit, and
at least one actuator coupled to the feedstock conveyor and configured to rotate the feedstock conveyor about the longitudinal charger axis and linearly translate the feedstock conveyor along the longitudinal charger axis,
wherein the charger conduit also includes:
an actuator mount conduit upstream of and coaxial with a charger junction conduit, and including an outwardly extending drive mount coupled to the linear actuator; and
a conveyor guide conduit upstream of and coaxial with the actuator mount conduit and including seal and bushing assemblies including mounting rings, seal rings carried by the mounting rings, and bushings carried by the mounting rings; and
wherein the feedstock mover also includes:
a feedstock conveyor guide including an outer guide having an outer guide cylinder coaxial with and extending into the conveyor guide conduit in contact with the seal rings, and including an outwardly extending driven mount coupled to the linear actuator.
10 . The feedstock charger of claim 9 , wherein the feedstock conveyor guide further includes an inner guide having an inner guide cylinder extending into the outer guide cylinder and including an upper fixed end coupled to an upstream portion of the outer guide cylinder and a downstream free end carrying a bushing in contact with the feedstock conveyor.
11 . The feedstock charger of claim 9 , wherein the feedstock mover additionally includes:
an alignment rod extending along a longitudinal alignment axis laterally offset from the longitudinal charger axis and including a downstream end fixed with respect to the charger conduit and an upstream end relatively translatably coupled with respect to the feedstock conveyor guide.
12 . The feedstock charger of claim 11 , wherein the feedstock conveyor guide also includes a mounting flange carrying an alignment rod bearing through which the alignment rod translatably extends, and wherein the conveyor guide conduit includes radially outwardly projecting alignment rod mounting portions with semi-circular reliefs, wherein the alignment rod is carried by the semi-circular reliefs and coupled to the conveyor guide conduit.
13 . The feedstock charger of claim 9 , wherein the feedstock mover also includes:
a rotary actuator coupled to the feedstock conveyor to rotate the feedstock conveyor;
a rotary actuator pedestal coupled to the feedstock conveyor guide and including a downstream plate coupled to the feedstock conveyor guide, an upstream plate to carry the rotary actuator, and support gussets extending between the downstream and upstream plates; and
a roller bearing mounted to the downstream plate and through which the feedstock conveyor rotatably extends.
14 . The feedstock charger of claim 13 , wherein the feedstock mover further includes:
a rotary encoder disc carried by the feedstock mover; and
a rotary encoder sensor carried by the rotary actuator pedestal to sense rotation of the feedstock mover via the rotary encoder disc.
15 . The feedstock charger of claim 14 , wherein the feedstock mover additionally includes:
a shaft collar fastened to the feedstock conveyor in a location between the rotary encoder disc and the roller bearing.
16 . A feedstock charger, comprising:
a charger conduit extending along a longitudinal charger axis, and including an inlet to receive feedstock into the charger conduit, and an outlet to transmit feedstock out of the charger conduit; and
a feedstock mover cooperative with the charger conduit to move feedstock in a direction from the inlet toward the outlet, and including
a feedstock conveyor carried in the charger conduit, and
at least one actuator configured to rotate the feedstock conveyor about the longitudinal charger axis and linearly translate the feedstock conveyor along the longitudinal charger axis so that a downstream end of the feedstock conveyor extends axially past the outlet,
wherein the at least one actuator includes a rotary actuator configured to rotate the feedstock conveyor and a linear actuator configured to translate the feedstock conveyor,
wherein the feedstock mover also includes a feedstock conveyor guide including
an outer guide including
an outer guide cylinder, and
an actuator mount coupled to the outer guide cylinder and coupled to the linear actuator, and
an inner guide including
an inner guide cylinder extending into the outer guide cylinder, and
a pedestal coupled to the inner guide cylinder and carrying the rotary actuator.
17 . The feedstock charger of claim 16 , wherein the charger conduit also includes a fluid-cooled spout including a spout downstream end establishing the outlet.
18 . The feedstock charger of claim 16 , wherein the feedstock mover also includes a feedstock conveyor guide coupled to both the rotary actuator and the linear actuator.
19 . The feedstock charger of claim 18 , wherein the feedstock conveyor guide includes an outer guide including an outer guide cylinder, and an inner guide including an inner guide cylinder extending into the outer guide cylinder.
20 . The feedstock charger of claim 19 , wherein the feedstock mover also includes a pedestal coupled to the inner guide cylinder and carrying the rotary actuator.
21 . The feedstock charger of claim 19 , wherein the feedstock mover also includes an actuator mount coupled to the outer guide cylinder and coupled to the linear actuator.
22 . The feedstock charger of claim 19 , wherein the feedstock mover also includes a pedestal coupled to the inner guide cylinder and carrying the rotary actuator, and an actuator mount coupled to the outer guide cylinder and coupled to the linear actuator.
23 . The feedstock charger of claim 19 , wherein the outer guide also includes an upper alignment flange coupled to the outer guide cylinder and carrying an alignment rod bearing.
24 . The feedstock charger of claim 23 , wherein the feedstock mover also includes an alignment rod extending along a longitudinal alignment axis laterally offset from the longitudinal charger axis and including a downstream end fixed with respect to the charger conduit and an upstream end extending translatably through the alignment rod bearing.
25 . The feedstock charger of claim 19 , wherein the feedstock mover also includes an alignment rod extending along a longitudinal alignment axis laterally offset from the longitudinal charger axis and including a downstream end fixed with respect to the charger conduit and an upstream end relatively translatably coupled with respect to the feedstock conveyor guide.
26 . The feedstock charger of claim 16 , wherein the outer guide also includes an upper alignment flange coupled to the outer guide cylinder and carrying an alignment rod bearing.
27 . The feedstock charger of claim 26 , wherein the feedstock mover also includes an alignment rod extending along a longitudinal alignment axis laterally offset from the longitudinal charger axis and including a downstream end fixed with respect to the charger conduit and an upstream end extending translatably through the alignment rod bearing.