Abstract: A directional fluid heat control system for a high temperature kiln with a process zone. The system includes two rigid, coaxially aligned tubes positioned in the kiln. One tube rotates inside the other. One tube has a series of longitudinal openings, while the other has a series of helically arranged openings. Rotating one tube selectively aligns an opening from that tube with an opening in the other. Further rotation aligns different such pairs of openings with different longitudinal orientations in the kiln. The aligned openings release pressurized fluid from the inner tube into desired locations in the kiln's process zone.

Abstract: An evaporative cooling system for a scrap metal furnace with an afterburner, a rotary kiln and a conveyor that loads scrap metal into the kiln. Pressurized water runs through water lines to two water spray subassemblies. The first subassembly sprays atomized water into a heating duct between the afterburner and a gas recycle return duct. The second subassembly sprays water onto the scrap metal on the conveyor. Water flow through the subassemblies is regulated by one or more water flow controllers, pumps and/or flow sensors, which may be computer controlled. A water heater warms the water to a desired temperature.

Abstract: A heating module for a furnace with a process zone. The module includes one or more Silicon Carbide heating elements in a refractory plug. The heating lengths of the elements extend, exposed, from the plug and do not engage one another, but may be positioned to cross over each other. The plug is releasably positioned in the furnace with the heating lengths exposed to the process zone. The plug can be positioned in an array of heating modules, which can be releasably positioned in the furnace with the heating lengths exposed to the process zone.

Abstract: A push gate for a scrap metal furnace with a volatizing chamber and a doorway into that chamber. The push gate includes a door plate to seal against the doorway, a scoop sized to fit in the volatizing chamber, and a plunger attached to the scoop that extends through the door plate. The push gate is movable. When the push gate is positioned such that the door plate seals against the doorway, the plunger can controllably move the scoop in and out of the chamber to push scrap metal to predetermined positions in the chamber for predetermined periods of time.

Abstract: An audible response self-healing target having a generally flat shell mated with a generally flat metal strike plate. The shell has a “self-healing” polymer “target zone”, and tabs that hold the metal plate parallel to the target zone with a small gap of approximately one-half inch. The shell rotatably mounts onto a pole, such that when a projectile, such as a bullet slug, impacts the target's strike zone, the slug penetrates the polymer and strikes the metal plate, kinetically causing the target to rotate about the pole and also causing the metal plate to generate an audible response.

Abstract: A volatiles consuming eductor system for coated scrap metal furnaces with separate delacquering and melt chambers. Motive gas is forced through an inlet into a mixing chamber in a direction opposite a suction port, creating a Venturi that draws gases from the delaquering chamber through the mixing chamber. The motive gas and the drawn gases mix and are forced through a discharge port, ignited, and injected into the melt chamber to help heat the melt chamber. A computer monitors process conditions and controls a regulator that adjusts the motive gas flow in response to those conditions.

Abstract: A vortex metal insertion system for a metal recycling furnace, the system having a molten metal flow cycling through the furnace and through a vortex bowl in the system. The system includes one or more process sensors in the furnace, an automated molten metal flow adjustment device, and a computer controller. The computer controller reads the sensor(s) and adjusts the adjustment device to control the flow of molten metal through the vortex bowl based on the reading(s). The system has an insertion port through which scrap metal and other materials may be controllably inserted into the molten metal flow.

Abstract: A metal furnace header gate system haying a recirculation port in the furnace, a hot gas generator, a gas blower, and a furnace door. The door has an embedded gas manifold and outlet ports that each connect the manifold to a directional nozzle. The blower draws exhaust from the recirculation port into the hot gas generator, which generates additional exhaust and mixes the exhaust gases together. The blower forces this exhaust mixture into the manifold, through the nozzles, and into the furnace. A computer controls the blower and the hot gas generator to regulate the system.

Abstract: A vortex injection system for a metal recycling furnace a delacquering chamber and a melt chamber, and a molten metal flow channel running through each chamber. The system diverts a portion of the molten metal flow through a vortex bowl, after which that portion of the molten metal flow is then returned to the main molten metal flow. The vortex bowl has an insertion port through which scrap metal and other materials may be controllably injected into the molten metal flow.

Abstract: An overflow system for a doorway exhaust hood on a metal melt furnace having an eductor gas circulator. The system includes a manifold with an inlet near the hood's lower lip, and a conduit between the manifold and eductor. A blower draws gas into the manifold and urges that gas through the conduit, into the eductor, and into the furnace. Sensors detect when the door is open and the volatiles level under the hood. An electronic controller instructs the blower to draw exhaust gases through the manifold when the door is open and the volatiles level exceeds a predetermined level.

Abstract: An automatic variable speed eductor recirculation system for metal recycling furnaces having a delacquering chamber and a separate heating chamber. The system includes a recirculation duct between the two chambers, an eductor in the duct, a variable speed blower forcing motive gases into the eductor creating a Venturi that draws VOC's from the delacquering chamber through the eductor, and an infrared opacity sensor proximate the eductor that measures the transparency level of the gases in the eductor. An electronic controller automatically adjusts the blower speed to control the eductor Venturi based upon the transparency level measurements of the opacity sensor.

Abstract: A volatiles consuming eductor system for coated scrap metal furnaces with separate delacquering and melt chambers. Motive gas is forced through an inlet into a mixing chamber in a direction opposite a suction port, creating a Venturi that draws gases from the delaquering chamber through the mixing chamber. The motive gas and the drawn gases mix and are forced through a discharge port, ignited, and injected into the melt chamber to help heat the melt chamber. A computer monitors process conditions and controls a regulator that adjusts the motive gas flow in response to those conditions.

Abstract: An audible response self-healing target having a generally flat shell mated with a generally flat metal strike plate. The shell has a “self-healing” polymer “target zone”, and tabs that hold the metal plate parallel to the target zone with a small gap of approximately one-half inch. The shell rotatably mounts onto a pole, such that when a projectile, such as a bullet slug, impacts the target's strike zone, the slug penetrates the polymer and strikes the metal plate, kinetically causing the target to rotate about the pole and also causing the metal plate to generate an audible response.

Abstract: A volatiles consuming eductor system for coated scrap metal furnaces with separate delacquering and melt chambers. Motive gas is forced through an inlet into a mixing chamber in a direction opposite a suction port, creating a Venturi that draws gases from the delaquering chamber through the mixing chamber. The motive gas and the drawn gases mix and are forced through a discharge port, ignited, and injected into the melt chamber to help heat the melt chamber. A computer monitors process conditions and controls a regulator that adjusts the motive gas flow in response to those conditions.

Abstract: A metal furnace header gate system haying a recirculation port in the furnace, a hot gas generator, a gas blower, and a furnace door. The door has an embedded gas manifold and outlet ports that each connect the manifold to a directional nozzle. The blower draws exhaust from the recirculation port into the hot gas generator, which generates additional exhaust and mixes the exhaust gases together. The blower forces this exhaust mixture into the manifold, through the nozzles, and into the furnace. A computer controls the blower and the hot gas generator to regulate the system.

Abstract: An overflow system for a doorway exhaust hood on a metal melt furnace having an eductor gas circulator. The system includes a manifold with an inlet near the hood's lower lip, and a conduit between the manifold and eductor. A blower draws gas into the manifold and urges that gas through the conduit, into the eductor, and into the furnace. Sensors detect when the door is open and the volatiles level under the hood. An electronic controller instructs the blower to draw exhaust gases through the manifold when the door is open and the volatiles level exceeds a predetermined level.

Abstract: A vortex injection system for a metal recycling furnace a delacquering chamber and a melt chamber, and a molten metal flow channel running through each chamber. The system diverts a portion of the molten metal flow through a vortex bowl, after which that portion of the molten metal flow is then returned to the main molten metal flow. The vortex bowl has an insertion port through which scrap metal and other materials may be controllably injected into the molten metal flow.

Abstract: An automatic variable speed eductor recirculation system for metal recycling furnaces having a delacquering chamber and a separate heating chamber. The system includes a recirculation duct between the two chambers, an eductor in the duct, a variable speed blower forcing motive gases into the eductor creating a Venturi that draws VOC's from the delaquering chamber through the eductor, and an infrared opacity sensor proximate the eductor that measures the transparency level of the gases in the eductor. An electronic controller automatically adjusts the blower speed to control the eductor Venturi based upon the transparency level measurements of the opacity sensor.

Abstract: A float sled comprising a body with a substantially flat upper surface, a lift plate operationally associated with the body and adapted to move from a first position in proximity to the upper surface of the body to a second position above the first position and above the body, a set of pneumatic air bag lifts associated with the lift plate to raise and lower the lift plate to various horizontal orientations with differing degrees of tilt, and an air bearing adapted to raise the body above the ground.

Abstract: A rotary aluminum kiln temperature regulation system comprising a temperature sensing device in the kiln that is configured to take temperature readings in an area of the kiln in proximity to the temperature sensing device. The system including a wireless transmitter operatively associated with the temperature sensing device and a receiver wirelessly associated with the transmitter, such that the transmitter and receiver wirelessly transmit the temperature readings taken by the temperature sensing device from the transmitter to the receiver. The system also including a control unit operatively connected to the receiver that is configured to receive the transmitted temperature readings and determine when the transmitted temperature readings exceed a predefined temperature set point. The control unit operatives one or more forward feed control loop subsystems that assist in safely operating the kiln in accord with a predetermined temperature profile programmed into the control unit.