ABSTRACT
This research is centered on the design and fabrication of copula furnace and atomizer for the production aluminium powder metal with the available material.0.4kg of refined coke was chosen as the basis for material and energy balance calculations and the design calculations performed from whose values are used to produce the design drawings.Mild steel was used for the internal linings of the furnace casing while other materials were selected based on functionality, durability, cost and local availability.The furnace and atomizer were assembled and the furnace inner wall of the casing was lined with refractory bricks made from a heated mixture of kaolin, clay, sawdust, and water after which the cylindrical shell was positioned.Testing was subsequently performed to evaluate the performance of the furnace and the atomizer by first gathering of the aluminum cans.The furnace was heated to 8700c and it was observed that the furnace has 36.9% efficiency which is within the acceptable value for furnace efficiencies.Atomizer produced various sizes of powder metal depending on the type of mesh used and the shape obtained was irregular in shape.
TABLE OF CONTENTS
Cover Page
Title Pagei
Certificationii
Dedicationiii
Acknowledgementsiv
Abstract v
Table of Contentsvi
List of Tables xi
List of Figures xii
List of Plates xiii
CHAPTER ONE:
INTRODUCTION
1.1Background of Study1
1.2Aims and Objectives of the Study3
1.3Problem Statement4
1.4Scope of Research Project5
1.5Relevance of Study5
1.6Limitation of Study5
CHAPTER TWO:
LITERATURE REVIEW
2.1 Introduction to Aluminium and Aluminium Recycling7
2.2 Introduction to Powder Metallurgy 8
2.2.1Historical Development8
2.2.2 Atomization Process9
2.2.3 Classification of Atomization process10
2.2.4 Uses of Powder Metals10
2.2.5 Some Common Metal Powder11
2.3 Introduction to Atomizer12
2.3.1 Classification of Atomizers13
2.3.2 Atomizer Requirement14
2.4 Introduction to Furnace15
2.4.1 Types of Furnaces15
2.4.2 Classification of Furnaces16
2.4.3 Introduction to Copula17
2.4.4 Parts of a Copula Furnace17
2.4.5 Zones of Copula19
2.4.6 Copula Operations22
2.4.7 Efficiency of Copula Furnace26
2.4.8 Advantages and Limitations27
2.4.9 Limitations in Copula Furnace28
2.5 Introduction to Refractory28
2.5.1 Refractory Definition28
2.5.2 Classification of Refractory29
2.5.3 Properties of Refractory32
2.5.4 Types of Refractory36
2.5.5 Selection of Refractory39
2.5.6 Manufacture of Refractory39
2.5.7 Functions and uses of Refractory41
2.5.8 Uses of Refractories41
2.6 Introduction to Coal42
2.6.1 Uses of Coal43
2.6.2 Refined Coal(Coke)43
2.6.3 Production of Coke44
2.6.4 Properties of Coke44
2.6.5 Uses of Coke45
2.6.6 Advantages of Coal over other Forms of Energy45
CHAPTER THREE:
MATERIALS AND METHODOLOGY
3.1 Introduction46
3.2 The Design of Copula Furnace47
3.2.1 Material Balance47
3.2.2 Reaction Mechanism48
3.2.3 Energy Balance49
3.2.4 Enthalpy Change50
3.2.5 Standard Heat of Reaction51
3.3 Energy Balance for the Furnace52
3.3.1 Combustion Chamber52
3.3.2 Enthalpy of the Reaction53
3.3.3 Standard Heat of Reaction53
3.3.4 Enthalpy of Flue Gases54
3.3.5 The Design of the Furnace55
3.3.6 Design of the Combustion Chamber57
3.3.7 Design of the down Section of the Furnace58
3.4 Design of an Atomizer62
3.5 Costing and Safety Measures67
3.5.1 Costing67
3.5.2 Safety Measures69
3.6 Materials of Constructions70
CHAPTER FOUR:
RESULTS, OBSERVATION AND DISCUSSION
4.1 Results79
4.2 Observations and Discussion80
4.3 The Size of the Metal Powder produced81
4.4 The Shape of Aluminum metal powder produced81
CHAPTER FIVE:
CONCLUSION AND RECOMMENDATIONS
5.1 Conclusion83
5.2 Recommendations83
REFERENCES85
APPENDIX A88
APPENDIX B94
APPENDIX C97
LIST OF TABLES
Table 2.1 Melting point Chart of pure Compounds33
Table 2.3 Classes of Fire Clay Brick38
Table 3.1 Material Balance Table49
Table 3.2 Specification Sheet for the Designed Atomizer67
Table 3.3 Cost of Materials68
Table 3.4 Fabrication cost68
Table 3.5 Additional Expenses69
Table 4.1 Results from the Copula Furnace79
LIST OF FIGURES
Figure 2.1 Broad Classification of Furnace19
Figure2.2 Copula Furnace21
Figure 3.1 The Combustion Chamber (Materials)48
Figure 3.2 Balance Around the combustion Chamber52
Figure 3.3 Balance around the Furnace55
Figure 3.4 Internal and External diameters58
Figure 3.5 2D And 3D views of the copula Furnace59
Figure 3.6 3D View of the Cupola Furnace Sections60
Figure 3.7 Front View of the Cupola Furnace 61
Figure 3.8 2D Sectioned view of the Lower Section of the Atomizer63
Figure 3.9 2D Sectioned view of the Middle Section of the Atomizer64
Figure 3.10 2D View of the Lower Section of the Atomizer65
Figure 3.11 3-D Section view of the Atomizer66
LIST OF PLATES
PLATE 1 ALIEN KEY
PLATE 2 VERNIER CALIPER
PLATE 3 HAND FILES
PLATE 4 TAP WRENCH
PLATE 5 TWO WAY GRIDING MACHINE
PLATE 6 LATHE MACHINE
PLATE 7 DRILL BIT