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Application note A portable system for melt process optimization and solid waste remediation By Joseph Purcell Diversified Controls & Systems, Inc. (East Aurora, N.Y.) was founded in 1977 in response to industry’s need for customized process controls for industrial applications. During this more than 40-year journey, we have developed a reliable systems approach to an array of industrial applications, and many of these projects are installed throughout the world. Our multidecade experience includes designing and build- ing power supplies and supporting equipment for melting furnaces used in the glass and ceramic industry. Through this work we gained an understanding of reliable furnace operation practices, including required power utilization, quality, and throughput to sustain a melt campaign. Ensuring reliable furnace operation is a continual challenge because furnace operators are not always able to recognize the “cause and effect” regarding production issues. For example, when manufacturing ceramic fiber insulation, one of the goals is maximizing throughput without sacrificing quality. To achieve this goal, the tendency for most furnace opera- tors is to move the electrodes in closer to maximize melt; however, this approach leads to instability in the current due to low resistance. Understanding the melt process in a submerged resistance furnace starts with optimizing the distance between three electrodes to achieve the longest impedance path. Our field observations led us to question whether there was a creative way to provide a system that harnessed an analytical approach to better understand and optimize the melt process, and thereby improve efficiency, increase melting campaign, and maintain quality. To be valuable in industrial settings, the analytical system needs to integrate multiple systems, including a power regulator system, dust collector, and cooling tower, among others. Additionally, to be fully functional, the analytical system had to meet user expectations for offering various capabilities, such as a better understanding of the melt process through real time data, process for scale-up considerations, and a way to evalu- ate power quality and efficiency. Finally, what if the system could be truck-mounted and taken to customer locations— basically, a self-contained pilot plant on wheels? Thus was the Melt Mizer conceived. Designing such a system was the easy part; scaling it onto a platform that worked with limited space and yet remained fully functional proved challenging. After three and a half years of innovation and persistence, the Melt Mizer was built and granted a world patent. 32 www.ceramics.org | American Ceramic Society Bulletin, Vol. 101, No. 2PDF Image | hydrogen as an alternative fuel
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CO2 Organic Rankine Cycle Experimenter Platform The supercritical CO2 phase change system is both a heat pump and organic rankine cycle which can be used for those purposes and as a supercritical extractor for advanced subcritical and supercritical extraction technology. Uses include producing nanoparticles, precious metal CO2 extraction, lithium battery recycling, and other applications... More Info
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