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How do you melt Fe3O4

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Andy

Sat Sept 28 2013, 03:43AM

Registered Member #4266 Joined: Fri Dec 16 2011, 03:15AM
Location:
Posts: 874

Done some working on the crucible, the below should beadle to survive the temperature.
200kg of fire clay = 20%
10kg of earth = 1%
125kg of Calcium silicate = 13%
400kg of paper/mash = 40%
250kg of cement = 25%

The lost of heat should be 780watts at 1120C, with W/m/K of 0.75, and kJ/kg/K of 1.23, with magnetite 0.67 kJ/kg/K

if the magnetite is 1600C, the crucible should be 864C, below the melting point(breakdown point) of fire clay.

Tested at 12volt 0.5amp 2 turns to 1 turn(Nichome wire) with a 47ohm resistor and wasn't registering anything in the volts(amps stuffed). Got to do some more research on air coils..

Edit
test with this setup, getting 4.5volt. Is it ok to use the house ground this way?

I'm hopeful getting a loan for a renewable system for the property, and plan on use the battery's to run the furnace, just interested in the self sufficient aspect. Done some more numbers at the moment that's all I've got to show.
The furnace will have a capacity of 1500kg of sand, I'll be using 147 battery's(approx) with a recharge time of 15 hours with 12 12volt 50 amp battery charges, at the start through mains(7200watt), then through PV/Wind/Fuel cell.
The mixture of the melt is
1500kg Iron oxide
128kg Copper oxide
38kg Coal
The temperature the furnace will reach with losses is 360C at 106kw in 1 hour, at 360C the reaction between copper oxide(+157kj,20kw@360C) and coal(-393kj,15kw@285C) it will raise the temperature of iron oxide up to 1605C.
The cost of the electricity is $29 dollars per batch, sand $7,coal $28, copper oxide will be reused with a PV slowly oxidizing it. The price for the circuit boards is $2805,capacitors $100, copper pipe $300,1 ohm resistors $33, Ferrite cores $1650,battery chargers $2148, just hoping get a discount for buying in bulk the battery's otherwise they are $279 each.
Not 100% sure on the amount of iron made maybe 880kg, but at 12cents scrap price, some of the cost can be payed for, leaving some money for beer.

Type of cross between electric arc furnace and induction

Setup of above, adding more capacitors seems to be increasing volts, haven't got enough to see how high it goes.

Andy

Wed Oct 02 2013, 12:33AM

Registered Member #4266 Joined: Fri Dec 16 2011, 03:15AM
Location:
Posts: 874

Got the parts to make the circuit board

Uv light and Riston developer

Negative

PCB image file, if any one needs it.

]pcb.zip[/file]
Circuit Board

Stuffed up trying to electysis it, the next one will use stripper.

The power output doesn't seem to follow any formula, increased the power supply from 12v/1.5am to 12v/3a,12v/4.5a, and the power output went from 18.8 to 19.6 to 20.1, tried rewinding the blue transformer to output 127v and the output was 20.1.
Any one know why the power isn't increase much?

Bored Chemist

Wed Oct 02 2013, 07:31PM

Registered Member #193 Joined: Fri Feb 17 2006, 07:04AM
Location: sheffield
Posts: 1022

Please note that this will produce something like 80 cubic metres of carbon monoxide.
A litre is roughly enough to kill you.
Have you thought this through?
You are planning to make enough carbon monoxide to kill a good sized stadium full of people.

Andy

Wed Oct 02 2013, 11:29PM

Registered Member #4266 Joined: Fri Dec 16 2011, 03:15AM
Location:
Posts: 874

Hi I didn't think about that part, most of it should be carbon dioxide it should still have risks though. I've burnt roughly 20kg of coal before, and it didn't seem like a issue.
The amount will be based on the power of the coils, and will update the size based on that.

Chris Cristini

Thu Oct 03 2013, 12:46AM

Registered Member #1749 Joined: Fri Oct 10 2008, 02:04AM
Location: Claremont New Hampshire
Posts: 497

Are you going to make a Ferrite core?

Andy

Thu Oct 03 2013, 03:46AM

Registered Member #4266 Joined: Fri Dec 16 2011, 03:15AM
Location:
Posts: 874

I might, I'm just trying to get the thing to work at the moment, making one core instead of 50 store brought ones might come in handy though.

I haven't worked it out yet, but might, you could have zinc oxide,Manganese and iron oxide, with some carbon, heating it up with some nichrome wire the zinc oxide should turn to zinc and carbon monoxide/dioxide and some heat.

What temperature do you need to sinister the ferrite?

A core with 6kg of iron oxide,1.5kg zinc oxide, and 210grams coal should be the mixture, with some Manganese in there, with input of 1.8kw for 1 hour should reach 1380C, if zinc oxide reacts with coal at 1380C, you could use some Mg ribbon to start the process off when it gets to 650C

Andy

Thu Oct 03 2013, 06:56AM

Registered Member #4266 Joined: Fri Dec 16 2011, 03:15AM
Location:
Posts: 874

The induction furnace is to much for me to design at my skill level, so I'm going to build a hot wire, electric arc furnace.
If the electrode are spaced 20cm apart, with the resistance of magnetite and copper oxide, I will need a voltage of 1500v.

Some links to information found

Andy

Tue Oct 08 2013, 05:28AM

Registered Member #4266 Joined: Fri Dec 16 2011, 03:15AM
Location:
Posts: 874

Just made some changes, will be running the below picture, but with 8 N-FET per side, with two battery sources, withe ground on the other side from positive.

I've order 4 battery's, at 24volt, 120amp/side will pass that through 28awg nichrome wire, 30 wires to heat the mixture up to 650C after ... If the capacitance joule heating makes sense(high frequency/high current through a capacitor to heat dialectic) or will use electric arc. The voltage will aim for is 720-1500volt, should cover both ways, 300volt being mainly used for electric arc, and 1500volt for the resistance of magnetite.

Don't use this setup, makes the LC circuit have a invert voltage and will cancel out.

Andy

Sat Oct 12 2013, 10:25PM

Registered Member #4266 Joined: Fri Dec 16 2011, 03:15AM
Location:
Posts: 874

Done the driver schematic, It should be able to driver 24 mosfet per side 3 bridges

A induction furnace might still be doable, instead of trying to get resonance, make a work coil that has 150 turns in parallel and is 0.05meters radius, 2 meters long, and 7 turns in series should have 1.61-07H inductance, driving with the circuit at 500khz should have a impedance of 0.51ohmsZ.

I've got two banks of 24volt and 60amp/hour(50% discharge), boosting the voltage up to 96volts and having a resistance for the bridge of 0.3ohms for 80amp, should have 20amp into the coil.

Throwing the thing into a spreadsheet which compares the power from the transformer to the step down to a one turn coil and amps generated, at 7 turns it should make 137amps in the work piece at 0.1ohms(load)

Order a pcb company to make the pcbs from the below, hopefully there's no errors.

]driver.zip[/file]

Copper oxide, has 40kohm resistance, Its still abit wet.

Andy

Mon Oct 14 2013, 07:50AM

Registered Member #4266 Joined: Fri Dec 16 2011, 03:15AM
Location:
Posts: 874

So I've order the parts for the battery. I've cut up Al to 20*30cm square sheet 2mm thick, and have Stainless Steel 316 which I'm picking up tomorrow. Below is the picture of the construction. The salt I'm using is Iron(3) Sulphate which has the second highest solubility, and increase by double with a double increase in temperature per tests. The voltage per cell should be between 0.66-0.87.
On short circuit the amps behave like a capacitor and decay exponentially. With the above dimensions its should make 200amp at peak, based on e=k*(Area/length), the k of salt water is 0.2, and will update with accurate figure with more tests.
The battery will be used to charge up a capacitor, based on test down on small scale, a 50% duty cycle(tests) or a 20% duty cycle(5RC to 1RC)(theory), these will switch on and off the load, allowing the caps to charge, depending on frequency a max of 24*200 = 4.8kw can be taking out of the batterys, at 20C
300uF caps will be the test values, with 150uF per battery, one side only being cut up, which should make 24-28volt. Below are some picture of info.
The amount of energy stored in Aluminum is 10,605,496Joules/kg

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