DESIGN AND FABRICATION OF MINI COPULA FURNACE AND AN ATOMIZER FOR THE PRODUCTION OF POWDERED METAL FROM WASTE ALUMINIUM CANS

TABLE OF CONTENTS

Cover Page

Title Page i

Certification ii

Dedication iii

Acknowledgements iv

Abstract v

Table of Contents vi

List of Tables xi

List of Figures xii

List of Plates xiii

CHAPTER ONE: INTRODUCTION

1.1 Background of Study 1

1.2 Aims and Objectives of the Study 3

1.3 Problem Statement 4

1.4 Scope of Research Project 5

1.5 Relevance of Study 5

1.6 Limitation of Study 5

CHAPTER TWO: LITERATURE REVIEW

2.1 Introduction to Aluminium and Aluminium Recycling 7

2.2 Introduction to Powder Metallurgy 8

2.2.1Historical Development 8

2.2.2 Atomization Process 9

2.2.3 Classification of Atomization process 10

2.2.4 Uses of Powder Metals 10

2.2.5 Some Common Metal Powder 11

2.3 Introduction to Atomizer 12

2.3.1 Classification of Atomizers 13

2.3.2 Atomizer Requirement 14

2.4 Introduction to Furnace 15

2.4.1 Types of Furnaces 15

2.4.2 Classification of Furnaces 16

2.4.3 Introduction to Copula 17

2.4.4 Parts of a Copula Furnace 17

2.4.5 Zones of Copula 19

2.4.6 Copula Operations 22

2.4.7 Efficiency of Copula Furnace 26

2.4.8 Advantages and Limitations 27

2.4.9 Limitations in Copula Furnace 28

2.5 Introduction to Refractory 28

2.5.1 Refractory Definition 28

2.5.2 Classification of Refractory 29

2.5.3 Properties of Refractory 32

2.5.4 Types of Refractory 36

2.5.5 Selection of Refractory 39

2.5.6 Manufacture of Refractory 39

2.5.7 Functions and uses of Refractory 41

2.5.8 Uses of Refractories 41

2.6 Introduction to Coal 42

2.6.1 Uses of Coal 43

2.6.2 Refined Coal(Coke) 43

2.6.3 Production of Coke 44

2.6.4 Properties of Coke 44

2.6.5 Uses of Coke 45

2.6.6 Advantages of Coal over other Forms of Energy 45

CHAPTER THREE: MATERIALS AND METHODOLOGY

3.1 Introduction 46

3.2 The Design of Copula Furnace 47

3.2.1 Material Balance 47

3.2.2 Reaction Mechanism 48

3.2.3 Energy Balance 49

3.2.4 Enthalpy Change 50

3.2.5 Standard Heat of Reaction 51

3.3 Energy Balance for the Furnace 52

3.3.1 Combustion Chamber 52

3.3.2 Enthalpy of the Reaction 53

3.3.3 Standard Heat of Reaction 53

3.3.4 Enthalpy of Flue Gases 54

3.3.5 The Design of the Furnace 55

3.3.6 Design of the Combustion Chamber 57

3.3.7 Design of the down Section of the Furnace 58

3.4 Design of an Atomizer 62

3.5 Costing and Safety Measures 67

3.