Process of forming copper anodes

专利摘要:
The present invention relates to a process of forming copper anodes (6) in a casting wheel (1) from the stage in which the copper is in liquid molten state (5) in a dumping chute (3) and is transferred to a ladle (4) until the anode (6) of solid copper is transformed into an anode (6) and is discharged from a mould (2) located in said casting wheel (1) wherein said process prevents the liquid molten copper (5) from being adhered to the edge of the ladle (4) and in the interstice (14) generated between the surfaces of the ejector rod (13) and the passing through bore (12) located on the mould (2) comprising the stages of: pouring the molten liquid copper from a distributing dumping chute (3) towards a ladle (4); (b) connecting the metallic components of the ladle (4) to the ground in order to produce positive charge (17); (c) spraying towards the edge (lip) of the ladle (4) an air jet (19) with dry dusting release agent (20) which is expelled by a nozzle (21) charging the particles of said dry dusting (20) with high voltage and negative charge (18); (b) connecting the metallic components of the mould (2) to the ground in order to produce a positive charge (17); (e) spraying towards the cavity (11) of the mould (2) and towards the location zone of the ejector rod (13) dry dusting release agent (20) through an air jet (19) which passes through a nozzle (21) which charges the particles of said dry dusting release agent (20) with high voltage and negative charge (18); (f) pouring the molten liquid copper (5) from the ladle (4) towards the cavity (11) of a mould (2) of anodes; (g) waiting until the copper gets cold in order to form the anode (6) by means of the turn of the casting wheel (1); (h) driving the ejector rod (13) to expel the anode (6) from the cavity (11) of the mould (2); and (i) removing the anode (6) from the mould (2) by means of cranes. The nozzle (21) is moved over the ladle zone (4) and mould zone (2) by means of a robotic arm (22) which is mounted on a cart (24) suspended above the casting wheel (1).
公开号:ES2593260A2
申请号:ES201690049
申请日:2015-04-07
公开日:2016-12-07
发明作者:Pablo Suarez Loira
申请人:ASESORIAS Y SERVICIOS INNOVAXXION SpA；
IPC主号:

专利说明:

PROCESS FOR CONFORMATION OF COPPER ANODES TECHNICAL FIELD OF THE INVENTION
The present invention relates to a process for the formation of copper anodes in a molding wheel, since the copper is in the molten liquid state in a tilting gutter and is transferred to a spoon until the solid copper is transformed into an anode and is ejected from a mold located in said molding wheel, wherein said process prevents molten liquid copper from sticking on the lip of the spoon and the mold. More specifically, the invention comprises the application of waterless release agent powder in emptying spoons and in the mold during the copper anode manufacturing process. BACKGROUND OF THE INVENTION
At present, the anode molding process is based on casting molten copper onto a mold (usually also copper) which contains the cavity in the shape of the desired anode. Once the copper is cast, it goes through a process of rapid cooling with sprinklers and an ejector in the form of a rod or steel cylinder, which ejects the anode already solidified.
The molds are usually mounted on a rotating carousel or "molding wheel" such that the rotation of this allows a continuous process of casting, cooling and ejection of the anodes. Each mold when completing a turn of the wheel is again filled with copper and so on.
In order that the liquid copper does not stick to the mold and can be ejected by the rod, it is necessary to add a layer of demoulding material that acts as an insulator and allows the liquid copper not to stick to the solid copper of the mold. The universally used material is a derivation of calcium powder or barite powder, which are mixed with water and projected by sprinklers on the inner faces of the mold. How are materials not


soluble in water, the solution must be permanently agitated so that the powder does not precipitate. When applied with sprinklers it decays by gravity in the mold, so it mostly covers the low areas and generates a layer of less thickness and less coverage on the vertical side faces of the mold.
5 This method of aggregate release is used in virtually all molding wheels that manufacture copper anodes in the world, but it has the big problem that water reacts explosively in contact with liquid copper, so the application Release agent in aqueous solution must be done before emptying liquid copper by
10 the spoons and it must be guaranteed that the mold is hot enough to evaporate 100% of the water applied with the release agent, otherwise any drop will cause an explosive chemical reaction that can leave a crater in the anode, causing its immediate rejection , or in the worst case, cause such an explosion to damage the equipment and personnel in charge, situations both that have happened and of which there is a record.
15 Another problem present is that the mouths of the spoons that empty the liquid copper must be cleaned between castings, to prevent the copper from solidifying and closing the mouths, which prevents the correct emptying and even distribution of the melt in the mold, which It is essential for the proper formation of the anode. In turn, if the mouths of the spoons
20 are closed by agglomeration of solidified copper, there is an effect in which the emptied copper falls in the form of a jet and not a cascade as it should be. This jet concentrates all the emptying of copper at a single point by displacing the release agent applied to the mold and causing the anode to stick to the mold, which means that both anode and mold must be discarded and removed from the molding wheel stopping production.
25 To avoid this situation, an operator must be permanently exposed to heat and liquid copper in order to throw powder-release molds on the mouths of the spoons. As the spoons contain liquid copper, it is unfeasible to apply a sprinkler cover for the explosion that would occur, therefore the operator is obliged to perform a
30 permanent manual application and in large quantities, since the powder itself does not have adhesion and does not stick to the spoon, being quickly displaced in each copper drain on the mold.


In the state of the art, some release agents are disclosed, which have an electrostatic principle. For example, document CA 2345922 discloses a method of coating an aluminum extruder matrix that is at 450 ° C with a boron nitride powder as a separating agent, which is adhered to the matrix by electrostatic charge.
5 GB 1288292 discloses a method for applying a coating to a surface of an ingot mold by projecting said coating from a nozzle against the surface of the mold to be coated, wherein said coating contains an organic liquid suspension of granulated materials which comprise 85 to
10 96% by weight of a refractory material and 4 to 15% by weight of organic dusty material. The coating is applied on the surface of the mold by electrostatic charges.
JPS 58192657 discloses a method for coating a mold material of
Suction casting that attracts powder from the mold coating material and that is applied electrostatically with a positive charge on the surface of the cast iron consisting of a layer of iron sand that has a negative charge.
JPS 61199543 discloses a method to improve the quality of a product
20 by the use of a paint containing electrostatically refractory particles to a shielding part of a mold and the coating of the fixing agent to said element thereby forming a layer of mold coating material.
Document KR 20090082106 discloses an oil-based release agent for a
25 casting mold, characterized in that it contains between 0-7.5% by mass of one or more kinds of water selected from the group consisting of distilled water, ion exchange water, tap water, and water obtained by dissolution of an electrolyte in one of the preceding waters, and 0.3-30% by mass of a solubilizing agent. A method for coating with an agent of this type of release is also described.
30 mold and an electrostatic coating apparatus for an agent of this type of mold release.


US 5437326 discloses the electrostatic application of a powder with thermally insulating particles thermally adherent of dry powder on the work face of a continuous metal die casting machine in which the mold surface or surfaces that provide the work face they rotate in a generally oval course. A dry powder of protective refractory material is applied to the work face after being drawn into an air stream and electrostatically charged by the appropriate electrostatic apparatus. The work face to be dusted is electrically grounded to attract the charged dust particles so that they adhere to the work face. The resulting coating formed by the formation of dust thus deposited is remarkably uniform over a substantial area of the work face, a phenomenon explainable by mutual electrostatic repulsion of the dry dust particles that are deposited. In this method, the powder can be continuously removed to be reapplied on the work face during continuous casting and also replace the dust lost from the work face coating of the rotating mold surface during the casting. Dust can be removed at will by air.
None of the documents described above, addresses the technical problems of preventing copper from sticking on the lip of the spoon, and also of preventing the ejection rod located under the mold of the copper anode from being stuck due to the effect that molten copper sticks between the rod and the mold as the molten copper cools.
The present invention solves these problems using a device that throws the dry powder through an air jet, where it passes through a nozzle that loads the particles with high voltage and negative charge. In turn, the metal parts that make up the spoons are connected to the ground (positive charge) so that the projected particles are attracted and adhere to the surface of the spoon and the metal surfaces due to load difference. In this way it is not necessary to use water as a conductive means of the release agent and can be thrown directly on the spoons containing liquid copper. In turn, the invention can be implemented in the form of a hand tool away from the operator from direct contact with the copper, or it can be mounted on a robotic arm with a sliding rail system in order to make the process automated.


Another advantage of this invention is that the same robotic arm, sliding rails, or hand tool can throw release agent directly on the mold in which the copper will be emptied, thus avoiding the installation of the automatic station that injects liquid release agent used in the present. On the other hand this invention allows to accelerate
5 the anode molding process as it is not necessary to wait for the liquid release agent to evaporate all the water to avoid the explosive reaction with the liquid copper. It also implies an increase in safety by eliminating water in contact with liquid copper from the molding process.
10 Another advantage of this invention is that when using dry powder that adheres to the surfaces with opposite load, the runoff of liquid release agent does not occur, therefore the application will be even and uniform in the cavities and vertical walls of the mold and the spoon .
15 Also the electrostatically charged powder tends to agglomerate so that a thickness of deposited material can be achieved much greater than that achieved with the water-based application.
Finally, when there is no evaporation or boiling, the applied release agent layer
20 electrostatically the mold is very even and smooth, improving the surface quality of the poured anode.
Therefore, it is an object of the present invention to add a powder release agent that electrostatically adheres to the lip of the spoon, to prevent liquid copper
25 melted sticks on it.
Another objective of the present invention is to add a powder release agent that electrostatically adheres to the anode mold, and especially to the ejector rod, to prevent said rod from sticking and thus facilitating the anode to be ejected from the mold.
BRIEF DESCRIPTION OF THE DRAWINGS


The accompanying drawings are included to provide a better understanding of the prior art and to show the details of the present invention.
Figure 1 shows a perspective view of the molding wheel, where the spoons 5 are pouring molten liquid copper into the molds.
Figure 2 shows a perspective view of the molding wheel, where an operator is throwing powder release agent towards the lip of the bucket.
10 Figure 3 shows a perspective view of an anode mold.
Figure 4 shows a perspective view, in half section, of an anode mold with the detail of the ejection rod.
15 Figure 5 shows a front sectional view of an anode mold, with the detail of the ejection rod.
Figure 6 shows a front sectional view of an anode mold, with the detail of the ejection rod, where water is being poured with release agent.
20 Figure 7 shows a perspective view of two molds with molten anodes inside.
Figure 8 shows a front sectional view, where the concept of the present invention is explained.
Figure 9 shows a perspective view of the molding wheel, where a robot is seen spreading dry mold release powder on the spoon lip.
30 Figure 10 shows a perspective view of the molding wheel, where a robot is seen spreading dry mold release powder in the anode mold.


Figure 11 shows a perspective view of the molding wheel, where an operator is seen spreading dry mold release powder in the anode mold, using a hand tool. DESCRIPTION OF THE INVENTION
In figure 1, a molding wheel (1) is shown on which a plurality of anodes (2) are installed. Adjacent and outwardly of said molding wheel (1), there is a tilting distributor channel (3), which has two outlets that feed molten liquid copper (5) to the spoons (4). The spoons (4) once they are filled with a certain amount of molten liquid copper, pour their contents into the molds (2) until they are filled and form an anode (6). To prevent molten liquid copper (5) from sticking to the lip of the spoon (4), an operator (7) manually pours a powder release agent that is stored in a receptacle (8). Note how dangerous the operator's location (7) is when being close to the spoons (4) and molding wheel (1). However, without this powder release agent, the flow of molten liquid copper is interrupted, since it tends to stick on the lip of the spoons (4). Therefore, this dangerous maneuver is necessary, shown in Figure 2.
On the other hand, once the cavity (11) of the mold (2) is full, the molding wheel continues its circular path, whereby the molten liquid copper (5) cools and forms the anode (6) in a state solid, which has a body (9) and ears (10). To disassemble the anode (6) from the mold (2), a through hole (12) is provided inside which an ejection rod (13) is housed, generating between the outer walls of the through hole (12) and the ejection rod (13) an interstitium (14), which gives enough clearance for the ejection rod (13) to move through a drive mechanism (not shown) located under the mold (2).
When the drive mechanism (not shown) acts on the ejection rod (13), there is a high probability that it is stuck inside the through hole (12), since molten liquid copper (5) could fall into the gap ( 14), whereby the ejection rod (13) cannot be lifted, and therefore, the detachment of the anode (6) from the mold (2) does not occur.


It is for this reason that an operator (7) must throw into the mold (2), when it is downstream of the tilt distribution channel (3) with the spoons (4), a suspension
(fifteen) of water with a mold release powder, so that said release agent is distributed evenly in the cavity (11) and in the gap (14). When the suspension is poured
(fifteen) on the mold (2), by effect of the heat the water generates a vapor cloud (16) with which the release agent is adhered to the walls of the mold (2). In this case, the operator (7) is also exposed to risk, because it is very close to the molding wheel (1), and in addition, the water on the mold (2) can generate explosions.
That is why in order to overcome these problems, the present invention proposes spreading in two areas (A, B) of the anode forming process (6), particles of dry mold release powder. These two areas are the area of the spoon lip (4) or zone A, and on the other hand, the cavity (11) of the mold (2) or zone B.
As shown in figure (8), the dry mold release powder (20) is thrown through an air jet (19), which passes through a nozzle (21) that charges the particles with high voltage and negative charge (18). In turn, the metal parts that make up the spoons (4) and the mold (2) are connected to the ground, generating a positive charge (17) so that the projected particles are attracted and adhere to the metal surfaces of the spoon ( 4) and the mold (2) by load difference.
As shown in figures 9 and 10, the air jet (19) with the dry mold release powder (20) through a nozzle (21), can be applied in zones A and B, using a robotic arm (22) which is mounted on a carriage (24) suspended above the molding wheel (1).
Alternatively, as shown in Figure 11, the air jet (19) with the dry powder
(20) release agent through a nozzle (21), can be applied in areas A and B, using a hand tool (23) that operates remotely an operator (7).
In accordance with the foregoing, the present invention specifically relates to a process for forming anodes (6) of copper since the copper is in a state


molten liquid (5) and is transferred to a spoon (4) until the solid copper anode, transformed into the anode (6), is ejected from the mold (2), wherein said process comprises:
5 (a) pour molten liquid copper from a tilt distribution channel (3) to a spoon (4);
(b) connect the metal components of the bucket (4) to ground to produce
a positive charge (17); 10
(c) throw an air jet (19) with dry powder towards the lip of the spoon (4)
(20) of release agent, which is expelled by a nozzle (21) that loads the particles of said dry powder (20) with high voltage and negative charge (18);
15 (d) connect the metal components of the mold (2) to ground to produce a positive charge (17);
(e) throw into the cavity (11) of the mold (2) and towards the location zone of the ejector rod (13), dry mold release powder (20) through an air jet (19), which
20 passes through a nozzle (21) that loads the particles of said dry mold release powder (20) with high voltage and negative charge (18);
(f) pour the molten liquid copper (5) from the spoon (4) into a mold (2) of
anodes; 25
(g) wait until the copper cools to form the anode (6), by turning the molding wheel (1);
(h) actuate the ejection rod (13) to eject the anode (6) from the
mold cavity (11) (2); 30
(i) remove the anode (6) from the mold (2) by means of cranes (not shown).

权利要求:
Claims (1)
[1]
1.-A process for the formation of copper anodes (6) in a molding wheel (1), since the copper is in the molten liquid state (5) in a tilt channel (3) and is transferred to a spoon ( 4), until the solid copper, transformed into an anode (6), is ejected from a mold (2) located in said molding wheel (1), where said process prevents the molten liquid copper (5) from sticking in the lip of the bucket (4) and in the gap (14) generated between the surfaces of the ejection rod (13) and the through hole (12) located in the mold (2), CHARACTERIZED because it comprises the steps:
(to) pour molten liquid copper from a tilt distribution channel (3) to a spoon (4);
(b) connect the metal components of the bucket (4) to ground to produce a positive charge (17);
(c) throw an air jet (19) with dry powder towards the lip of the spoon (4)
(twenty) release agent, which is ejected by a nozzle (21) that loads the particles of said dry powder (20) with high voltage and negative charge (18);
(d)  connect the metal components of the mold (2) to ground to produce a positive charge (17);
(and) throw into the cavity (11) of the mold (2) and towards the location zone of the ejector rod (13), dry powder (20) of release agent through an air jet (19), which passes through a nozzle (21 ) loading the particles of said dry powder (20) of release agent with high voltage and negative charge (18);
(F) pour the molten liquid copper (5) from the spoon (4) into the cavity (11) of a mold (2) of anodes;
(g)  wait until the copper cools to form the anode (6), by turning the molding wheel (1);

(h) actuate the ejection rod (13) to eject the anode (6) from the cavity (11) of the mold (2); Y
(i) remove the anode (6) from the mold (2) by means of cranes.
5. A process for forming anodes (6), according to claim 1, CHARACTERIZED in that said nozzle (21) is moved over the area of the spoon (4) by a robotic arm (22) that is mounted on a carriage (24) suspended above the molding wheel (1).
3. A process for forming anodes (6), according to claim 1, CHARACTERIZED in that said nozzle (21) is moved over the mold area (2) by a robotic arm (22) that is mounted on a carriage ( 24) suspended above the molding wheel (1).
4. A process for forming anodes (6), according to claim 1, CHARACTERIZED because said nozzle (21) is moved by a hand tool
(23) remotely operated by an operator (7).

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CL2014000872A1|2014-04-08|2014-08-22|Asesorias Y Servicios Innovaxxion Spa|Process for the formation of copper anodes in a molding wheel since the copper is in the molten liquid state in a tilting gutter and is transferred to a spoon, because it comprises the steps of pouring molten liquid copper from a tilt distribution channel to a spoon , connect the metal components of the spoon, throw an air jet towards the lip of the spoon, connect the metal components.|CL2014000872A1|2014-04-08|2014-08-22|Asesorias Y Servicios Innovaxxion Spa|Process for the formation of copper anodes in a molding wheel since the copper is in the molten liquid state in a tilting gutter and is transferred to a spoon, because it comprises the steps of pouring molten liquid copper from a tilt distribution channel to a spoon , connect the metal components of the spoon, throw an air jet towards the lip of the spoon, connect the metal components.|

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优先权:

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申请号 | 申请日 | 专利标题

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CL872-2014|2014-04-08|

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CL2014000872A|CL2014000872A1|2014-04-08|2014-04-08|Process for the formation of copper anodes in a molding wheel since the copper is in the molten liquid state in a tilting gutter and is transferred to a spoon, because it comprises the steps of pouring molten liquid copper from a tilt distribution channel to a spoon , connect the metal components of the spoon, throw an air jet towards the lip of the spoon, connect the metal components.|

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PCT/IB2015/052501|WO2015155678A1|2014-04-08|2015-04-07|Process of forming copper anodes|

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