EP3356066A1 - A flux feeding apparatus and flux optimization selection method - Google Patents

A flux feeding apparatus and flux optimization selection method

Info

Publication number
EP3356066A1
EP3356066A1 EP16778725.8A EP16778725A EP3356066A1 EP 3356066 A1 EP3356066 A1 EP 3356066A1 EP 16778725 A EP16778725 A EP 16778725A EP 3356066 A1 EP3356066 A1 EP 3356066A1
Authority
EP
European Patent Office
Prior art keywords
flux
feeding apparatus
silos
process parameters
mold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP16778725.8A
Other languages
German (de)
French (fr)
Inventor
Michael Zinni
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Imertech SAS
Original Assignee
Imerys SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Imerys SA filed Critical Imerys SA
Publication of EP3356066A1 publication Critical patent/EP3356066A1/en
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/10—Supplying or treating molten metal
    • B22D11/108—Feeding additives, powders, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/16—Controlling or regulating processes or operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/16—Controlling or regulating processes or operations
    • B22D11/165—Controlling or regulating processes or operations for the supply of casting powder

Definitions

  • the present disclosure relates to a flux feeding apparatus and method for delivering flux to a mold during a continuous casting process.
  • a mold flux which may be a powder or granular material, onto the top of a slab during continuous casting of a molten metal, such as steel.
  • the flux turns into slag when sufficiently heated by the molten metal.
  • Fluxes are engineered synthetic slags formed by compounds containing oxides, minerals and carbonaceous materials which are selected to provide desired characteristics.
  • the flux may include silica, bauxite, calcium silicate/wollastonite, feldspar, soda ash, fluorospar, lithium carbonate, etc.
  • the flux serves to prevent reoxidation and avoid heat loss so as to prevent premature solidification of the liquid metal.
  • the flux also absorbs non-metallic inclusions at the liquid slag-metal interface, thereby producing cleaner metal.
  • the flux provides lubrication between the solidified metal shell and the mold.
  • the flux also plays an important role in controlling heat transfer, particularly in a horizontal direction. These functions have a direct impact on the quality and operational stability of the cast steel. For example, inadequate lubrication of the flux can cause loss of containment of the liquid steel due to high friction and shell tearing. Insufficient heat removal will result in thin shell that cannot withstand the ferrostatic pressure and lose steel containment.
  • Flux feeding apparatuses which deliver flux automatically or semi- automatically to the mold.
  • load cell weight sensors are used to control the rate of addition of flux to the mold.
  • the present invention seeks to provide an improved flux feeding apparatus and method.
  • a flux feeding apparatus for delivering flux to a mold during a continuous casting process, the apparatus comprising: a plurality of silos each containing a different flux or flux component; a receiver for receiving process parameters of the casting process; and a controller which is configured to: analyse the process parameters received by the receiver; determine whether a current flux composition is appropriate (e.g. optimized) for the received process parameters; and if the current flux composition is not appropriate for the received process parameters, change the delivery of flux or flux components from the plurality of silos to provide a required flux composition to the mold for the received process parameters.
  • a current flux composition is appropriate (e.g. optimized) for the received process parameters
  • change the delivery of flux or flux components from the plurality of silos to provide a required flux composition to the mold for the received process parameters.
  • the process parameters may include user-input parameters and sensed parameters.
  • the process parameters may include one or more of: the grade of metal being cast, casting rate/speed, flux consumption rate, heat transfer rate, slag temperature, metal temperature, slag thickness, width, section size, taper.
  • the controller may select one or more of the plurality of the silos so as to form a mixture of the individual fluxes or flux components.
  • the controller may select one of the silos so as to deliver the flux contained therein to the mold.
  • the flux feeding apparatus may further comprise a feed head which is connected or connectable to the plurality of silos, wherein the controller is configured to supply the feed head with flux or flux components from one or more of the plurality of silos so as to deliver the required flux composition to the mold.
  • the feed head may be connected to the silos via a manifold and one or more valves which selectively couple the silos to the feed head.
  • the one or more valves may be metering valves.
  • one or more mixing devices may be provided to mix the flux or flux components prior to or in the feed head.
  • the flux feeding apparatus may further comprise an intermediate hopper and a transfer apparatus for transferring mold flux from the silos to the intermediate hopper, wherein the feed head is connected to a feed hopper which is configured to receive flux from the intermediate hopper.
  • the transfer apparatus may include a vacuum for transferring flux from the silos to the intermediate hopper, and wherein the controller is further configured to control the operation of the vacuum.
  • the transfer apparatus may further comprise a valve which is operable between a first closed position which prevents mold flux from transferring to the intermediate hopper when the vacuum is on, and a second open position which allows mold flux to transfer to the intermediate hopper when the vacuum is off.
  • valve may be a flapper valve having a counter weight.
  • flux feeding apparatus may further comprise a venturi pump to supply the flux to the feed head.
  • the controller may generate an alert for an operator.
  • the operator in response to the alert, may instruct the controller to change the delivery of flux or flux components from the plurality of silos to provide a required flux composition to the mold for the received process parameters.
  • the flux feeding apparatus may further comprise one or more sensors for determining the process parameters, the one or more sensors being connected to the receiver.
  • a method for delivering flux to a mold during a continuous casting process comprising: receiving process parameters of the casting process at a controller; analysing the process parameters using the controller; determining whether a current flux composition delivered to the mold from a plurality of silos each containing a different flux or flux component is appropriate for the received process parameters; and if the current flux composition is not appropriate for the received process parameters, changing the delivery of flux or flux components from the plurality of silos so as to provide a required flux composition to the mold for the received process parameters.
  • Figure 1 is a front view of a flux feeding apparatus
  • Figure 2 is a rear perspective view of the apparatus of Figure 1 ;
  • Figure 3 is a schematic view of a silo section of the flux feeding apparatus.
  • Figure 1 illustrates an exemplary flux feeding apparatus 10 for delivering flux to a mold 13 during a continuous casting process.
  • the flux feeding apparatus 10 can include four major components: a transfer apparatus 12; an intermediate hopper 14, a control apparatus 16, and a delivery apparatus 18.
  • the transfer apparatus 12 transfers flux in powder or granular form from a silo 20 to the intermediate hopper 14.
  • the silo 20 may include, for example, one or more large bags or barrels or other containment structures suitable for containing flux or flux components.
  • the delivery apparatus 18 feeds flux 1 1 from the intermediate hopper 14 onto molten metal 15, such as steel, within the mold 13.
  • the transfer apparatus 12 can include a vacuum hopper (or vacuum receiver) 22 having an inlet port 24 to which one end 26 of each of a plurality of flexible suction tubes 28 are connected. The other ends 30 of each of the plurality of flexible suction tube 28 extend into the plurality of silos 20 such that each silo is accessed by at least one flexible suction tube.
  • vacuum hopper 22 also includes an outlet at the bottom for transferring mold flux to the intermediate hopper 14.
  • a valve such as a flapper valve 43 with a counter weight attached. While the vacuum of the vacuum hopper 22 is energized this creates a seal between the flapper valve 43 and the bottom of the vacuum hopper 22. When the vacuum stops, the weight of the material that was picked up allows the flapper valve 43 to open and the material drops into the intermediate hopper 14.
  • the intermediate hopper 14 has a fitting on the bottom that extends into the top of a feed hopper 31 of the delivery apparatus 18.
  • the feed hopper 31 includes a pair of outlet ports 32, 34 (although one or more outlets may be provided) which are each connected to a delivery tube 36, 40.
  • the free ends of the delivery tubes 36, 40 terminate in feed heads 46 which deliver the flux to the mold 13 (or a plurality of molds).
  • the feed heads 46 may form or comprise a distributor to spread the mold flux on the mold surface.
  • the mold flux is pneumatically fed from the feed hopper 31 with venturi pumps 41 which are operatively connected to the outlet ports 32, 34.
  • the number of ports or venturi pumps may vary depending on the type of continuous casting machine or shapes cast.
  • control apparatus 16 further includes a one or more load cells 42 which support the intermediate hopper 14.
  • the load cells 42 can be used to determine the weight of the intermediate hopper 14 and the mold flux contained therein.
  • the intermediate hopper 14 can be isolated from the feed hopper 31 to avoid the feed hopper 31 contributing to the measured weight.
  • the weight of the intermediate hopper 14 can be monitored over a period of time so as to allow the consumption of flux to be monitored in real time.
  • the control apparatus 16 further includes a controller 44, such as a programmable logic controller (PLC - which may be part of a SCADA (i.e., supervisory, control and data acquisiton) system) or any other suitable computer processor.
  • PLC programmable logic controller
  • the controller 44 receives inputs from the load cells 42 and/or other process parameters relating to the metal casting process conditions, and controls the operation of the vacuum 22 in response. Specifically, the controller 44 causes the vacuum 22 to turn on, thus causing mold flux to feed into the intermediate hopper 14, based on a predetermined weight of the feed hopper 31 as compared to the consumption or loss of weight of mold flux calculated using the output of the load cells 42.
  • the mold flux composition and rate at which the mold flux is delivered into the mold can be adjusted by the operator using an operator control screen 48 on the controller 44 that can be used for adjusting the feed rate.
  • the mold flux composition and rate at which the mold flux is delivered into the mold 13 can be adjusted by the operator by a wireless handset 50 in communication with a receiver 52 on controller 44.
  • the wireless handset 50 can be used to control the feed rate instead of the operator control screen 48.
  • a plurality of silos 20a, 20b, 20c can be provided, as shown in Figure 3.
  • Figure 3 shows three separate silos, it will be appreciated that any number of silos may be provided.
  • the silos may also be implemented as separate chambers in a single unit.
  • each of the silos 20a-c contain a different flux or flux component having a different composition.
  • the silos 20a-c are each connected to the suction tube 28 at a manifold via a valve 54a-c.
  • the valves 54a-c are actuated via the controller 44 (or a separate, standalone controller). Accordingly, the valves 54a-c can be controlled so as to selectively connect a chosen silo 20a-c to the suction tube 28.
  • the receiver 52 (or a separate, standalone receiver which may be wired or wireless) of the controller 44 receives parameters regarding the casting process.
  • the receiver 52 may receive real time measurements from sensors and/or operator entered characteristics for the casting process.
  • the receiver may receive data including one or more of: the grade of metal being cast (e.g. the grade of steel), casting rate/speed, flux consumption rate (which can be measured using the load cells 42 as described above), heat transfer rate (determined by measuring a temperature increase of cooling water used to cool the mold 13), and the temperature of the slag on top of the mold 13.
  • IR Infrared
  • thermocouples or other temperature sensors may be used.
  • a laser distance measurement device may also be used to determine the thickness of the layer of flux of the molten metal.
  • the parameters may also include the metal temperature, thickness, width, section size, taper, etc.
  • the controller 44 determines the desired composition for the flux and selects the required silo 20a-c by opening the valve 54 associated with the selected silo 20 and closing the other valves 54.
  • the controller 44 may supply flux which is a mixture of the fluxes or flux components from a plurality of the silos 20a-c.
  • the valves 54a-c may allow the relative proportions of each flux to be controlled to provide the desired flux composition.
  • the valves 54a-c may be metering valves which can accurately control the flow of flux.
  • the silos 20a-c could instead contain constituent elements of mold flux (as opposed to flux itself) which can be combined to provide the desired composition.
  • the controller 44 may identify the required flux composition using fuzzy logic, artificial neural networks or other artificial intelligence functions.
  • the controller 44 may determine the correct flux based on the real time process parameters.
  • the flux composition may be adjusted during the casting process or may be fixed for a specific casting run.
  • the controller 44 may determine the flux composition and select the required silo(s) automatically using an algorithm.
  • the controller 44 may determine whether a current flux composition is appropriate (e.g. optimized) for the current process parameters and, if required, make adjustments to the flux or flux components delivered to the mold so as to provide the required flux composition.
  • the controller 44 need not carry out such adjustments autonomously and may instead generate an alert (e.g. an audible or visible alarm) which signals to an operator that a change in flux composition is desirable.
  • an alert e.g. an audible or visible alarm
  • the operator may instruct the controller to make such a change.
  • the precise details regarding the corrective action required may be generated automatically by the controller 44 (such that the operator need only approve the change) or may be provided by the operator.
  • the silos 20a-c have been described as being connected to the suction tubes 28 via valves 54a-c, it will be appreciated that other arrangements may be used.
  • the silos 20a-c may be connected to the tubes 28 using a single valve.
  • each silo 20a-c may have a dedicated suction tube 28 such that no manifold is required.
  • the tubes 28 may deliver the flux or flux component from its respective silo 20a-c directly to the mold 13 such that there is no requirement for the flux or flux components to be mixed.
  • a robotic arm or the like may transfer the suction tube 28 between silos 20a-c in response to instructions from the controller 44.
  • the automatic selection of flux composition may be implemented using alternative flux feeding apparatuses than that described above.
  • the flux feeding apparatus need not have an intermediate hopper 14 nor load cells 42.
  • the flux may also be delivered to the feed heads 46 using alternative means to the vacuum-based system described.
  • a method for delivering flux to a mold during a continuous casting process includes: receiving process parameters of the casting process at a controller; analysing the process parameters using the controller; determining a required flux composition for the received process parameters; and connecting a feed head to one or more of a plurality of silos each containing a different flux or flux component so as to deliver flux of the required composition to the mold.
  • the process parameter received by the flux feeder consists solely of the grade of metal to be cast. For example, the grade of steel being cast in a continuous casting apparatus. As the steel grade is changed (as an example), the plant control system and instruct the flux feeder system change the mold flux. The proper silo would open automatically and the other silos would be closed, allowing the system to vacuum the desired flux from the silo and apply it through the distributor.
  • the flux feeder system can operate to run out the flux in the system before the next flux is selected.
  • flux feeder can receive internal signals from the feeder and from the metal casting process system.
  • the flux feeder can receive internal signals relating to the flux feed rate and process parameters, such as for example, heat removal rate from the caster, which when combined are good indicators of flux performance and can be adjusted in real time by mixing fluxes to establish and maintain an optimal balance.
  • This embodiment would also involve metering out of the silos with inline mixing of the fluxes.
  • a flux feeding apparatus for delivering flux to a mold during a continuous casting process, the apparatus comprising:
  • a feed head selectably connectable to a plurality of silos each containing a different flux or flux component
  • a controller which is configured to:
  • Para 2 A flux feeding apparatus as described in Para 1 , wherein the process parameters include user-input parameters and sensed parameters.
  • Para 3 A flux feeding apparatus as described in Para 1 or 2, wherein the process parameters include one or more of: the metal being cast, casting rate/speed, flux consumption rate, heat transfer rate, and slag temperature.
  • Para 4 A flux feeding apparatus as described in any preceding Para, wherein the controller connects the feed head to a plurality of the silos so as to form a mixture of the individual fluxes or flux components.
  • Para 5 A flux feeding apparatus as described in any preceding Para, wherein the controller connects the feed head to one of the silos so as to deliver the flux contained therein to the mold.
  • Para 6 A flux feeding apparatus as described in any preceding Para, wherein the feed head is connected to the silos via a manifold and one or more valves which selectively couple the silos to the feed head.
  • Para 7 A flux feeding apparatus as described in Para 6, wherein the one or more valves are metering valves.
  • Para 8 A flux feeding apparatus as described in any preceding Para, further comprising one or more sensors for determining the process parameters, the one or more sensors being connected to the receiver.
  • a flux feeding apparatus as described in any preceding Para further comprising an intermediate hopper and a transfer apparatus for transferring mold flux from the silos to the intermediate hopper, wherein the feed head is connected to a feed hopper which is configured to receive flux from the intermediate hopper.
  • Para 10 A flux feeding apparatus as described in Para 9, wherein the transfer apparatus includes a vacuum for transferring flux from the silos to the intermediate hopper, and wherein the controller is further configured to control the operation of the vacuum.
  • Para 1 1 A flux feeding apparatus as described in Para 9 or 10, wherein the transfer apparatus further comprises a valve which is operable between a first closed position which prevents mold flux from transferring to the intermediate hopper when the vacuum is on, and a second open position which allows mold flux to transfer to the intermediate hopper when the vacuum is off.
  • Para 12 A flux feeding apparatus as described in Para 1 1 , wherein the valve is a flapper valve having a counter weight.
  • a flux feeding apparatus as described in any preceding Para further comprising a venturi pump to supply the flux to the feed head.
  • Para 14 A continuous casting apparatus comprising a flux feeding apparatus as described in any preceding Para.
  • Para 15 A method for delivering flux to a mold during a continuous casting process, the method comprising:

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

A flux feeding apparatus 10 for delivering flux to a mold 13 during a continuous casting process is described. The apparatus comprises: a plurality of silos 20a-20c each containing a different flux or flux component; a receiver 52 for receiving process parameters of the casting process; and a controller 44 which is configured to: analyse the process parameters received by the receiver 52; determine whether a current flux composition is appropriate for the received process parameters; and if the current flux composition is not appropriate for the received process parameters, change the delivery of flux or flux components from the plurality of silos to provide a required flux composition to the mold 13 for the received parameters. A corresponding method is also described.

Description

A FLUX FEEDING APPARATUS AND FLUX OPTIMIZATION SELECTION METHOD
TECHNICAL FIELD The present disclosure relates to a flux feeding apparatus and method for delivering flux to a mold during a continuous casting process.
BACKGROUND OF THE INVENTION It is customary to apply a mold flux, which may be a powder or granular material, onto the top of a slab during continuous casting of a molten metal, such as steel. The flux turns into slag when sufficiently heated by the molten metal. Fluxes are engineered synthetic slags formed by compounds containing oxides, minerals and carbonaceous materials which are selected to provide desired characteristics. For example, the flux may include silica, bauxite, calcium silicate/wollastonite, feldspar, soda ash, fluorospar, lithium carbonate, etc.
At the zone of contact with the liquid metal, the flux serves to prevent reoxidation and avoid heat loss so as to prevent premature solidification of the liquid metal. The flux also absorbs non-metallic inclusions at the liquid slag-metal interface, thereby producing cleaner metal. Further, at the zone of contact with the solidified metal, the flux provides lubrication between the solidified metal shell and the mold. The flux also plays an important role in controlling heat transfer, particularly in a horizontal direction. These functions have a direct impact on the quality and operational stability of the cast steel. For example, inadequate lubrication of the flux can cause loss of containment of the liquid steel due to high friction and shell tearing. Insufficient heat removal will result in thin shell that cannot withstand the ferrostatic pressure and lose steel containment. Excessive heat removal can cause cracks to form on the steel surface, etc. Flux feeding apparatuses are known which deliver flux automatically or semi- automatically to the mold. For example, in US 2013/0081777, load cell weight sensors are used to control the rate of addition of flux to the mold.
The present invention seeks to provide an improved flux feeding apparatus and method. SUMMARY OF THE INVENTION
According to an aspect of the invention, there is provided a flux feeding apparatus for delivering flux to a mold during a continuous casting process, the apparatus comprising: a plurality of silos each containing a different flux or flux component; a receiver for receiving process parameters of the casting process; and a controller which is configured to: analyse the process parameters received by the receiver; determine whether a current flux composition is appropriate (e.g. optimized) for the received process parameters; and if the current flux composition is not appropriate for the received process parameters, change the delivery of flux or flux components from the plurality of silos to provide a required flux composition to the mold for the received process parameters.
According to another aspect, the process parameters may include user-input parameters and sensed parameters.
According to another aspect, the process parameters may include one or more of: the grade of metal being cast, casting rate/speed, flux consumption rate, heat transfer rate, slag temperature, metal temperature, slag thickness, width, section size, taper.
In another aspect, the controller may select one or more of the plurality of the silos so as to form a mixture of the individual fluxes or flux components.
In yet another aspect, the controller may select one of the silos so as to deliver the flux contained therein to the mold.
In another aspect, the flux feeding apparatus may further comprise a feed head which is connected or connectable to the plurality of silos, wherein the controller is configured to supply the feed head with flux or flux components from one or more of the plurality of silos so as to deliver the required flux composition to the mold.
In another aspect, the feed head may be connected to the silos via a manifold and one or more valves which selectively couple the silos to the feed head. In another aspect, the one or more valves may be metering valves. In another aspect, one or more mixing devices may be provided to mix the flux or flux components prior to or in the feed head.
In yet another aspect, the flux feeding apparatus may further comprise an intermediate hopper and a transfer apparatus for transferring mold flux from the silos to the intermediate hopper, wherein the feed head is connected to a feed hopper which is configured to receive flux from the intermediate hopper.
In another aspect, the transfer apparatus may include a vacuum for transferring flux from the silos to the intermediate hopper, and wherein the controller is further configured to control the operation of the vacuum.
In another aspect the transfer apparatus may further comprise a valve which is operable between a first closed position which prevents mold flux from transferring to the intermediate hopper when the vacuum is on, and a second open position which allows mold flux to transfer to the intermediate hopper when the vacuum is off.
In another aspect, the valve may be a flapper valve having a counter weight. In another aspect, the flux feeding apparatus may further comprise a venturi pump to supply the flux to the feed head.
In another aspect, if the current flux composition is not appropriate for the received process parameters, the controller may generate an alert for an operator.
In another aspect, in response to the alert, the operator may instruct the controller to change the delivery of flux or flux components from the plurality of silos to provide a required flux composition to the mold for the received process parameters. In another aspect, the flux feeding apparatus may further comprise one or more sensors for determining the process parameters, the one or more sensors being connected to the receiver.
According to another aspect of the invention, there is provided a method for delivering flux to a mold during a continuous casting process, the method comprising: receiving process parameters of the casting process at a controller; analysing the process parameters using the controller; determining whether a current flux composition delivered to the mold from a plurality of silos each containing a different flux or flux component is appropriate for the received process parameters; and if the current flux composition is not appropriate for the received process parameters, changing the delivery of flux or flux components from the plurality of silos so as to provide a required flux composition to the mold for the received process parameters.
BRIEF DESCRIPTION OF THE DRAWINGS For a better understanding of the invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:-
Figure 1 is a front view of a flux feeding apparatus;
Figure 2 is a rear perspective view of the apparatus of Figure 1 ; and
Figure 3 is a schematic view of a silo section of the flux feeding apparatus. DETAILED DESCRIPTION
It is to be understood that at least some of the figures and descriptions of the invention have been simplified to illustrate elements that are relevant for a clear understanding of the invention, while eliminating, for purposes of clarity, other elements that those of ordinary skill in the art will appreciate may also comprise a portion of the invention. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the invention, a description of such elements is not provided herein. Figure 1 illustrates an exemplary flux feeding apparatus 10 for delivering flux to a mold 13 during a continuous casting process.
In one embodiment the flux feeding apparatus 10 can include four major components: a transfer apparatus 12; an intermediate hopper 14, a control apparatus 16, and a delivery apparatus 18. The transfer apparatus 12 transfers flux in powder or granular form from a silo 20 to the intermediate hopper 14. The silo 20 may include, for example, one or more large bags or barrels or other containment structures suitable for containing flux or flux components. The delivery apparatus 18 feeds flux 1 1 from the intermediate hopper 14 onto molten metal 15, such as steel, within the mold 13. In one embodiment, the transfer apparatus 12 can include a vacuum hopper (or vacuum receiver) 22 having an inlet port 24 to which one end 26 of each of a plurality of flexible suction tubes 28 are connected. The other ends 30 of each of the plurality of flexible suction tube 28 extend into the plurality of silos 20 such that each silo is accessed by at least one flexible suction tube.
In one embodiment vacuum hopper 22 also includes an outlet at the bottom for transferring mold flux to the intermediate hopper 14. On the bottom of the vacuum hopper 22, there can be a valve such as a flapper valve 43 with a counter weight attached. While the vacuum of the vacuum hopper 22 is energized this creates a seal between the flapper valve 43 and the bottom of the vacuum hopper 22. When the vacuum stops, the weight of the material that was picked up allows the flapper valve 43 to open and the material drops into the intermediate hopper 14. The intermediate hopper 14 has a fitting on the bottom that extends into the top of a feed hopper 31 of the delivery apparatus 18. The feed hopper 31 includes a pair of outlet ports 32, 34 (although one or more outlets may be provided) which are each connected to a delivery tube 36, 40. The free ends of the delivery tubes 36, 40 terminate in feed heads 46 which deliver the flux to the mold 13 (or a plurality of molds). The feed heads 46 may form or comprise a distributor to spread the mold flux on the mold surface. The mold flux is pneumatically fed from the feed hopper 31 with venturi pumps 41 which are operatively connected to the outlet ports 32, 34. The number of ports or venturi pumps may vary depending on the type of continuous casting machine or shapes cast.
In one embodiment, the control apparatus 16 further includes a one or more load cells 42 which support the intermediate hopper 14. The load cells 42 can be used to determine the weight of the intermediate hopper 14 and the mold flux contained therein. In one embodiment the intermediate hopper 14 can be isolated from the feed hopper 31 to avoid the feed hopper 31 contributing to the measured weight. The weight of the intermediate hopper 14 can be monitored over a period of time so as to allow the consumption of flux to be monitored in real time. As shown in Figure 2, in one embodiment, the control apparatus 16 further includes a controller 44, such as a programmable logic controller (PLC - which may be part of a SCADA (i.e., supervisory, control and data acquisiton) system) or any other suitable computer processor. The controller 44 receives inputs from the load cells 42 and/or other process parameters relating to the metal casting process conditions, and controls the operation of the vacuum 22 in response. Specifically, the controller 44 causes the vacuum 22 to turn on, thus causing mold flux to feed into the intermediate hopper 14, based on a predetermined weight of the feed hopper 31 as compared to the consumption or loss of weight of mold flux calculated using the output of the load cells 42.
In one embodiment, the mold flux composition and rate at which the mold flux is delivered into the mold can be adjusted by the operator using an operator control screen 48 on the controller 44 that can be used for adjusting the feed rate. Alternatively, the mold flux composition and rate at which the mold flux is delivered into the mold 13 can be adjusted by the operator by a wireless handset 50 in communication with a receiver 52 on controller 44. The wireless handset 50 can be used to control the feed rate instead of the operator control screen 48. Although only one silo 20 is shown in Figure 1 , a plurality of silos 20a, 20b, 20c can be provided, as shown in Figure 3. Although Figure 3 shows three separate silos, it will be appreciated that any number of silos may be provided. The silos may also be implemented as separate chambers in a single unit. In one embodiment, each of the silos 20a-c contain a different flux or flux component having a different composition. The silos 20a-c are each connected to the suction tube 28 at a manifold via a valve 54a-c. The valves 54a-c are actuated via the controller 44 (or a separate, standalone controller). Accordingly, the valves 54a-c can be controlled so as to selectively connect a chosen silo 20a-c to the suction tube 28.
In one embodiment, the receiver 52 (or a separate, standalone receiver which may be wired or wireless) of the controller 44 receives parameters regarding the casting process. In particular, the receiver 52 may receive real time measurements from sensors and/or operator entered characteristics for the casting process. For example, the receiver may receive data including one or more of: the grade of metal being cast (e.g. the grade of steel), casting rate/speed, flux consumption rate (which can be measured using the load cells 42 as described above), heat transfer rate (determined by measuring a temperature increase of cooling water used to cool the mold 13), and the temperature of the slag on top of the mold 13. In particular, Infrared (IR) sensors may be used to measure the surface temperature. Alternatively, thermocouples or other temperature sensors may be used. A laser distance measurement device may also be used to determine the thickness of the layer of flux of the molten metal. The parameters may also include the metal temperature, thickness, width, section size, taper, etc. In one embodiment, in response to the received parameters, the controller 44 determines the desired composition for the flux and selects the required silo 20a-c by opening the valve 54 associated with the selected silo 20 and closing the other valves 54. Alternatively, the controller 44 may supply flux which is a mixture of the fluxes or flux components from a plurality of the silos 20a-c. The valves 54a-c may allow the relative proportions of each flux to be controlled to provide the desired flux composition. For example, the valves 54a-c may be metering valves which can accurately control the flow of flux. It will be appreciated that the silos 20a-c could instead contain constituent elements of mold flux (as opposed to flux itself) which can be combined to provide the desired composition.
In one embodiment, the controller 44 may identify the required flux composition using fuzzy logic, artificial neural networks or other artificial intelligence functions. The controller 44 may determine the correct flux based on the real time process parameters. The flux composition may be adjusted during the casting process or may be fixed for a specific casting run. The controller 44 may determine the flux composition and select the required silo(s) automatically using an algorithm. The controller 44 may determine whether a current flux composition is appropriate (e.g. optimized) for the current process parameters and, if required, make adjustments to the flux or flux components delivered to the mold so as to provide the required flux composition. The controller 44 need not carry out such adjustments autonomously and may instead generate an alert (e.g. an audible or visible alarm) which signals to an operator that a change in flux composition is desirable. If appropriate, the operator may instruct the controller to make such a change. The precise details regarding the corrective action required may be generated automatically by the controller 44 (such that the operator need only approve the change) or may be provided by the operator. Although the silos 20a-c have been described as being connected to the suction tubes 28 via valves 54a-c, it will be appreciated that other arrangements may be used. In particular, the silos 20a-c may be connected to the tubes 28 using a single valve. Alternatively, each silo 20a-c may have a dedicated suction tube 28 such that no manifold is required. In fact, the tubes 28 may deliver the flux or flux component from its respective silo 20a-c directly to the mold 13 such that there is no requirement for the flux or flux components to be mixed. As a further alternative, a robotic arm or the like may transfer the suction tube 28 between silos 20a-c in response to instructions from the controller 44.
It will be appreciated that the automatic selection of flux composition may be implemented using alternative flux feeding apparatuses than that described above. In particular, the flux feeding apparatus need not have an intermediate hopper 14 nor load cells 42. The flux may also be delivered to the feed heads 46 using alternative means to the vacuum-based system described.
In one embodiment, a method for delivering flux to a mold during a continuous casting process is provided. In one embodiment, the method includes: receiving process parameters of the casting process at a controller; analysing the process parameters using the controller; determining a required flux composition for the received process parameters; and connecting a feed head to one or more of a plurality of silos each containing a different flux or flux component so as to deliver flux of the required composition to the mold. In another embodiment, the process parameter received by the flux feeder consists solely of the grade of metal to be cast. For example, the grade of steel being cast in a continuous casting apparatus. As the steel grade is changed (as an example), the plant control system and instruct the flux feeder system change the mold flux. The proper silo would open automatically and the other silos would be closed, allowing the system to vacuum the desired flux from the silo and apply it through the distributor. In another embodiment, the flux feeder system can operate to run out the flux in the system before the next flux is selected.
In another embodiment, flux feeder can receive internal signals from the feeder and from the metal casting process system. For example, the flux feeder can receive internal signals relating to the flux feed rate and process parameters, such as for example, heat removal rate from the caster, which when combined are good indicators of flux performance and can be adjusted in real time by mixing fluxes to establish and maintain an optimal balance. This embodiment would also involve metering out of the silos with inline mixing of the fluxes.
The invention is not limited to the embodiments described herein, and may be modified or adapted without departing from the scope of the present invention.
For the avoidance of doubt, the present invention includes the subject matter as defined in the following numbered paragraphs (abbreviated "Para"):
Para 1 . A flux feeding apparatus for delivering flux to a mold during a continuous casting process, the apparatus comprising:
a feed head selectably connectable to a plurality of silos each containing a different flux or flux component;
a receiver for receiving process parameters of the casting process; and
a controller which is configured to:
analyse the process parameters received by the receiver;
determine a required flux composition for the received process parameters; and connect the feed head to one or more of the plurality of silos so as to deliver flux of the required composition to the mold.
Para 2. A flux feeding apparatus as described in Para 1 , wherein the process parameters include user-input parameters and sensed parameters.
Para 3. A flux feeding apparatus as described in Para 1 or 2, wherein the process parameters include one or more of: the metal being cast, casting rate/speed, flux consumption rate, heat transfer rate, and slag temperature. Para 4. A flux feeding apparatus as described in any preceding Para, wherein the controller connects the feed head to a plurality of the silos so as to form a mixture of the individual fluxes or flux components.
Para 5. A flux feeding apparatus as described in any preceding Para, wherein the controller connects the feed head to one of the silos so as to deliver the flux contained therein to the mold. Para 6. A flux feeding apparatus as described in any preceding Para, wherein the feed head is connected to the silos via a manifold and one or more valves which selectively couple the silos to the feed head.
Para 7. A flux feeding apparatus as described in Para 6, wherein the one or more valves are metering valves.
Para 8. A flux feeding apparatus as described in any preceding Para, further comprising one or more sensors for determining the process parameters, the one or more sensors being connected to the receiver.
Para 9. A flux feeding apparatus as described in any preceding Para, further comprising an intermediate hopper and a transfer apparatus for transferring mold flux from the silos to the intermediate hopper, wherein the feed head is connected to a feed hopper which is configured to receive flux from the intermediate hopper.
Para 10. A flux feeding apparatus as described in Para 9, wherein the transfer apparatus includes a vacuum for transferring flux from the silos to the intermediate hopper, and wherein the controller is further configured to control the operation of the vacuum.
Para 1 1 . A flux feeding apparatus as described in Para 9 or 10, wherein the transfer apparatus further comprises a valve which is operable between a first closed position which prevents mold flux from transferring to the intermediate hopper when the vacuum is on, and a second open position which allows mold flux to transfer to the intermediate hopper when the vacuum is off.
Para 12. A flux feeding apparatus as described in Para 1 1 , wherein the valve is a flapper valve having a counter weight.
Para 13. A flux feeding apparatus as described in any preceding Para, further comprising a venturi pump to supply the flux to the feed head. Para 14. A continuous casting apparatus comprising a flux feeding apparatus as described in any preceding Para. Para 15. A method for delivering flux to a mold during a continuous casting process, the method comprising:
receiving process parameters of the casting process at a controller;
analysing the process parameters using the controller;
determining a required flux composition for the received process parameters; and connecting a feed head to one or more of a plurality of silos each containing a different flux or flux component so as to deliver flux of the required composition to the mold.

Claims

1 . A flux feeding apparatus for delivering flux to a mold during a continuous casting process, the apparatus comprising:
a plurality of silos each containing a different flux or flux component;
a receiver for receiving process parameters of the casting process; and a controller which is configured to:
analyse the process parameters received by the receiver;
determine whether a current flux composition is appropriate for the received process parameters; and
if the current flux composition is not appropriate for the received process parameters, change the delivery of flux or flux components from the plurality of silos to provide a required flux composition to the mold for the received process parameters.
2. A flux feeding apparatus as claimed in claim 1 , wherein the process parameters include user-input parameters and sensed parameters.
3. A flux feeding apparatus as claimed in claim 1 or 2, wherein the process parameters include one or more of: the grade of metal being cast, casting rate/speed, flux consumption rate, heat transfer rate, slag temperature, metal temperature, thickness, width, section size, taper.
4. A flux feeding apparatus as claimed in any preceding claim, wherein the controller selects a plurality of the silos so as to form a mixture of the individual fluxes or flux components.
5. A flux feeding apparatus as claimed in any preceding claim, wherein the controller selects one of the silos so as to deliver the flux contained therein to the mold.
6. A flux feeding apparatus as claimed in any preceding claim, further comprising a feed head which is connected or connectable to the plurality of silos, wherein the controller is configured to supply the feed head with flux or flux components from one or more of the plurality of silos so as to deliver the required flux composition to the mold.
7. A flux feeding apparatus as claimed in claim 6, wherein the feed head is connected to the silos via a manifold and one or more valves which selectively couple the silos to the feed head.
8. A flux feeding apparatus as claimed in claim 7, wherein the one or more valves are metering valves.
9. A flux feeding apparatus as claimed in any of claims 6 to 8, wherein one or more mixing devices are provided to mix the flux or flux components prior to or in the feed head.
10. A flux feeding apparatus as claimed in any of claims 6 to 9, further comprising an intermediate hopper and a transfer apparatus for transferring mold flux from the silos to the intermediate hopper, wherein the feed head is connected to a feed hopper which is configured to receive flux from the intermediate hopper.
1 1 . A flux feeding apparatus of claim 10, wherein the transfer apparatus includes a vacuum for transferring flux from the silos to the intermediate hopper, and wherein the controller is further configured to control the operation of the vacuum.
12. A flux feeding apparatus of claim 10 or 1 1 , wherein the transfer apparatus further comprises a valve which is operable between a first closed position which prevents mold flux from transferring to the intermediate hopper when the vacuum is on, and a second open position which allows mold flux to transfer to the intermediate hopper when the vacuum is off.
13. A flux feeding apparatus of claim 12, wherein the valve is a flapper valve having a counter weight.
14. A flux feeding apparatus of any preceding claim, further comprising a venturi pump to supply the flux to the feed head.
15. A flux feeding apparatus as claimed in any preceding claim, wherein, if the current flux composition is not appropriate for the received process parameters, the controller generates an alert for an operator.
16. A flux feeding apparatus as claimed in claim 15, wherein in response to the alert, the operator instructs the controller to change the delivery of flux or flux components from the plurality of silos to provide a required flux composition to the mold for the received process parameters.
17. A flux feeding apparatus as claimed in any preceding claim, further comprising one or more sensors for determining the process parameters, the one or more sensors being connected to the receiver.
18. A continuous casting apparatus comprising a flux feeding apparatus as claimed in any preceding claim.
19. A method for delivering flux to a mold during a continuous casting process, the method comprising:
receiving process parameters of the casting process at a controller;
analysing the process parameters using the controller;
determining whether a current flux composition delivered to the mold from a plurality of silos each containing a different flux or flux component is appropriate for the received process parameters; and
if the current flux composition is not appropriate for the received process parameters, changing the delivery of flux or flux components from the plurality of silos so as to provide a required flux composition to the mold for the received process parameters.
EP16778725.8A 2015-09-28 2016-09-28 A flux feeding apparatus and flux optimization selection method Pending EP3356066A1 (en)

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GBGB1517130.9A GB201517130D0 (en) 2015-09-28 2015-09-28 A flux feeding apparatus and method
PCT/EP2016/073157 WO2017055377A1 (en) 2015-09-28 2016-09-28 A flux feeding apparatus and flux optimization selection method

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WO1983002911A1 (en) * 1982-02-24 1983-09-01 Yaji, Motoyasu Method of controlling continuous casting facility
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JPH01118350A (en) * 1987-10-29 1989-05-10 Nippon Supingu Kk Method and device for supplying powder for continuous casting
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ES2733680T3 (en) * 2011-09-29 2019-12-02 Stollberg Inc System and method to monitor mold cast consumption
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RU2018112155A3 (en) 2020-02-14
BR112018005709A2 (en) 2018-10-02
RU2729273C2 (en) 2020-08-05
US20180304348A1 (en) 2018-10-25
WO2017055377A1 (en) 2017-04-06
US20240139801A1 (en) 2024-05-02
GB201517130D0 (en) 2015-11-11
BR112018005709B1 (en) 2021-08-24
RU2018112155A (en) 2019-10-28

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