DEVELOPMENT OF A 5KG CAPACITY INDUCTION FURNACE FOR MELTING ALUMINIUM

Abstract

Aluminium in Nigeria is a popular metallic element. Widely used to produce single domestic appliances and even industrial engine components. These components display a decrease in performance level after many years of service are discarded and they become waste that tend to be a problem to manage. Furnaces are required for student practice to improve their technical skills, to reduce stress of local blacksmiths and the reduce delays due to frequent power interruption. This project is aimed at developing a 5kg capacity induction furnace solely used to melt aluminium at a faster rate. The design was considered in two phases, the geometrical and the electrical consideration. The crucible used in this project is made of graphite and the charge material (aluminium) was locally sourced for in the environment. The heating process is fundamentally based on electro- magnetic means, where heat energy is transferred directly from the induction coil into the metal to be melted without having contact directly with the metal through the electromagnetic field produced by the induction coil. The fabrication was achieved by cutting with manual hack saw, drilling and joining with electric arc wielding machine. A maximum temperature of 720 oC was achieved in 48 minutes with a power rating of 2800 watts and 220 volts, which was satisfactory as the temperature attained from the project is higher than the conventional standard aluminium temperature which is 660.4 oC and was able to melt aluminium at a faster rate.

CHAPTER ONE

1.0      INTRODUCTION

1.1       Background of Study

In Nigeria institutions today, there are several production machines used as model for the enhancement of student knowledge and technical skills but we hardly can find induction furnace being used in institutions. Perhaps because of the poor availability of electricity power stability situation we are facing in the country, most of the furnace used in institutions are locally made, using charcoal as the main source of heat, which is not the best and most efficient method of melting metals.

Aluminium is a metallic element that has numerous uses especially in Nigeria. It is used for the production of machine components and even in cooking utensils. It is used to primarily used to produce pistons, engine and body parts for cars, beverage cans, door and window (frames), bars wires and also for aircraft components.

Aluminium is primarily produced from bauxite ore. Bauxite is a rock formed from a reddish clay material called laterite soil and is most commonly found in tropical or subtropical regions.  Bauxite is primarily comprised of aluminum oxide compounds (alumina), silica, iron oxides and titanium dioxide. Approximately 70 percent of the world’s bauxite production is refined through the Bayer chemical process into alumina. Alumina is then refined into pure aluminum metal. (Ekpe et al., 2016).

However, the element is rarely available as rich ores, which leads to countries relying on its importation to satisfy demand (Bala, 2005). Another method of obtaining Aluminium is through secondary production, i.e, recycling. This method according to (Ekpe et al.,

2016) saves up to 95 % of energy compared to the primary refinement from ore and is also cheaper.

This research work is centred on developing a small size model of furnace for use in our institutions and outside the institution for learning purposes, enrichment of knowledge, technical skill, small scale production of metals in a short limited (20 minute to 60 minutes) time range before the power goes off again and also empower the student to be self-employed.

1.2       Statement of the Research Problem

Aluminium in Nigeria is a popular element used in various components, and these components displayed a decrease in performance level after many years of service and are discarded (Bala, 2005). These components can be used as raw materials for secondary aluminium production rather than loitering and becoming waste that will become problem to manage. Recycling is a cheaper way of reusing the materials that constitute wastes as environmental pollutants. Most furnaces available for recycling are manually operated and make use of charcoal, which in turn causes deforestation. The development of a new electric induction furnace is conceived to reduce the use of charcoal, protect the environment and also reduce intake of smoke produced from the charcoal.

1.3       Aim and Objectives of the Study

The aim of this project is to develop a 5kg induction furnace for melting aluminium scrap metals. The objectives are to:

1.   Design a 5kg induction furnace for melting aluminium scrap metals.

2.   Fabricate a 5kg induction furnace for melting aluminium scrap metals.

3.   Carryout performance evaluation on the furnace.

1.4       Significance of the Study

The development of a 5kg induction furnace for melting aluminium scrap can be a learning model in our institutions to improve students’ knowledge and technical skills on the subject and a fast, simple method of melting.

1.5        Scope of the Study

The furnace is developed to a maximum capacity of 5kg and it is solely to be used to melt aluminium scarps to a pouring temperature of 720oC, but no casting is to be carried out.

1.6       Limitation of the Study This project is limited to the development of a 5kg induction furnace.

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