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

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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 material 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 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 observe 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.

CHAPTER ONE
INTRODUCTION
1.1            Background of Study
Powder metallurgy is a technique concerned with the production of metal powders and converting them into useful shapes. It is a material processing technique in which particulate materials are consolidated to semi-finished and finished products. Metal powder production techniques are used to manufacture a wide spectrum of Metal powders designed to meet the requirements of a large variety of applications. Various powder production processes allow precise control of the chemical and physical characteristics of powders and permit the development of specific attributes for the desired applications. Powder production processes are constantly being improved to meet the quality, cost and performance requirements of all types of applications. Metal powders are produced by mechanical or chemical methods.
The most commonly used methods include water and gas atomization, milling, mechanical alloying, electrolysis, and chemical reduction of oxides.

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