WO2005062846A2 - Commande du panier de coulee - Google Patents

Commande du panier de coulee Download PDF

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Publication number
WO2005062846A2
WO2005062846A2 PCT/US2004/042886 US2004042886W WO2005062846A2 WO 2005062846 A2 WO2005062846 A2 WO 2005062846A2 US 2004042886 W US2004042886 W US 2004042886W WO 2005062846 A2 WO2005062846 A2 WO 2005062846A2
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WO
WIPO (PCT)
Prior art keywords
tundish
steel
level
slag
vortex
Prior art date
Application number
PCT/US2004/042886
Other languages
English (en)
Other versions
WO2005062846A3 (fr
Inventor
Gregory A. Meszaros
Frederick J. Mannion
Thomas J. Piccone
Frank M. Kemeny
David I. Walker
Original Assignee
Uec Technologies Llc
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Publication date
Application filed by Uec Technologies Llc filed Critical Uec Technologies Llc
Publication of WO2005062846A2 publication Critical patent/WO2005062846A2/fr
Publication of WO2005062846A3 publication Critical patent/WO2005062846A3/fr

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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
    • B22D11/16—Controlling or regulating processes or operations
    • B22D11/18—Controlling or regulating processes or operations for pouring
    • B22D11/181—Controlling or regulating processes or operations for pouring responsive to molten metal level or slag level
    • B22D11/186—Controlling or regulating processes or operations for pouring responsive to molten metal level or slag level by using electric, magnetic, sonic or ultrasonic means
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
    • G01F23/00—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
    • G01F23/22—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water
    • G01F23/28—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water by measuring the variations of parameters of electromagnetic or acoustic waves applied directly to the liquid or fluent solid material
    • G01F23/284—Electromagnetic waves
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
    • G01S13/00—Systems using the reflection or reradiation of radio waves, e.g. radar systems; Analogous systems using reflection or reradiation of waves whose nature or wavelength is irrelevant or unspecified
    • G01S13/88—Radar or analogous systems specially adapted for specific applications

Definitions

  • the level of metal in a tundish is controlled to inhibit vortexing and consequent entrainment of slag into the cast metal.
  • Control is effected with the aid of microwave transmissions directed toward the molten material in the tundish, advantageously toward the well or tap hole in the tundish, optionally combined with other factors and data representing optimum levels of steel and slag in the tundish, product specifications, or disturbances in the mold.
  • the process is particularly useful for transitioning between products of different specifications; the formation of intermix can be minimized.
  • the tundish delivers molten steel to a mold at the top or head of the continuous cast strand at a rate that is dictated by the movement of the strand, i.e. the production rate of the caster. This in turn is governed by numerous factors including major factors such as the cross section of the strand, the cooling and solidification rates in the caster, and the heat-removal capacity of the mold. Disturbances in the mold, at the top of the strand, provide erratic temperature and level inputs to the gate control system. See Asano et al US Patent 5,311,924 for a method of stabilizing metal level in the mold, using a predetermined level maintenance value. A vibration sensor helps control disturbances in Ardell et al US Patent 5,042,700.
  • the level of liquid steel above the tundish well is the important parameter in determining when to close the tundish gate during drainage of the tundish for a low tundish practice intermix transition, for a tundish change operation, or for termination of the cast. If the level of liquid steel is too low, there is a danger of formation of a vortex above the tundish well, resulting in the entrainment of slag into the caster mold, a highly undesirable event. Furthermore, the presence of a vortex may cause turbulence within the caster mold, resulting in mold level fluctuation and steel quality deterioration. If the level is too high, the amount of intermix will be large, or the final solid tundish skull will be larger, negatively affecting acceptable yield.
  • the thickness of the slag layer in the tundish is an indication of how well ladle slag is prevented from entering the tundish as a ladle is drained.
  • the amount of ladle slag entering the tundish should be minimized, because the ladle slag is emulsified when it pours into the tundish and may not be separated completely before the steel enters the mold.
  • Some ladle slags are also very oxidizing with respect to aluminum-deoxidized steel, and promote reoxidation of the steel in the tundish.
  • the ladle In order to maximize yield, however, the ladle is drained as far as possible without excessive slag carryover, so the transfer of some slag from the ladle to the tundish is commonly tolerated. This amount may vary considerably from heat to heat in the casting sequence.
  • tundish operating modes There are three basic tundish operating modes: (1) steady state operation, whereby the steel levels in the tundish and mold are held substantially constant by matching tundish inlet and outlet flows, (2) a transition, desirably smooth, from one ladle or heat to another as the source of molten metal (ladle exchange), and (3) a transition from casting one grade of steel to another grade.
  • Good tundish management during all three of these general operating modes will be facilitated by monitoring or awareness of: 1. Amount of slag in the tundish; 2. Amount of iron oxide in the tundish slag; 3. Quality requirements of the grade being cast; 4. Value of steel being cast; 5. Cost of disposition of intermix volume or downgraded steel; 6. Casting conditions such as nozzle obstructions or mold turbulence.
  • a molten steel at a comfortable level above a predetermined minimum (such as the level at which a vortex may form), so that (1) any included slag will tend to float rather than be poured along with the steel, (2) vortexing will be avoided, (3) control of steel flow will be more manageable because the hydrostatic head (or heel weight) is within a predetermined range, and, importantly also (4) transition from one heat to another can be smooth and trouble free.
  • a predetermined minimum such as the level at which a vortex may form
  • Tundish maintenance is expensive and accordingly it is desirable to extend the number of heats passing through a tundish as long as possible; also there is an economic cost to the entire production line for removing a tundish and replacing it with another. Reducing the frequency of replacement is also desirable for this reason.
  • the accurate measurement of slag depth in the tundish can assist in the dispositioning of steel in relation to quality.
  • Significant slag carryover from ladle to tundish is known to cause defects in certain products with stringent steel cleanliness demands.
  • Knowledge of the slag amount can assist the quality engineer in deciding how to apply steel more efficiently to orders with different quality requirements.
  • a microwave method of slag thickness measurement is described in Meszaros et al US Patents 6,130,637, 6,166,681, and 6,255,983, in which pulsed radar time of flight measurements are used to determine the levels of slag and the steel under it.
  • the measurement is remote, is more indicative of the average slag depth as opposed to depth at a single point, and can be repeated frequently and less dangerously.
  • This method of slag depth measurement is more suitable for the object of the present invention, which is described more fully below. Radar has been used to detect wake turbulence generated by aircraft - see Ooga US Patent 6,424,408 and Rubin 6,480,142.
  • Vortex formation has also been controlled by slag-control "shapes" which are usually objects having a specific gravity between those of molten steel and slag; such objects are placed directly above the discharge opening where a vortex is likely to form - see Koffron US Patent 4,601,415, Forte et al 4,968,007 and 5,421,560 and patents reviewed therein.
  • a lance for injection of inert gas has also been suggested to inhibit vortex formation - Patrushka et al US Patent 5,203,909. Inert gas is also injected in Sao et al US Patent 6,346,212 to inhibit vortex formation.
  • the slag control body of DeMarco US Patent 6,153,146 need not have a specific gravity between that of the steel and that of the slag.
  • the importance of vortex formation as a problem in the art is further illustrated in Dainton US Patent 5,766,543 and Sankaranaryanan et al 5,382,003, both discussing devices for combatting slag entrainment.
  • An object of the present invention is to facilitate low-level tundish operation for application to ladle exchange, transition control, tundish exchange, and termination of a cast strand.
  • a further object of this invention is to improve yield and quality in steel strand casting by accurate prediction of the optimum level to which a tundish should be drained during the above mentioned low-level operations, and to control the tundish level to the optimum level.
  • Our invention includes a method of managing a tundish to control the transition between a first grade of molten steel and a second grade of molten steel to be solidified sequentially in a continuous caster by draining the molten steel through a well in the tundish to a mold at the head of the continuous caster, wherein the first grade of molten steel is covered by a layer of slag in the tundish, comprising draining the first grade of steel to a level in the tundish slightly higher than the level at which a vortex is expected to form above the well, the level of the first grade of steel being determined by directing microwave radiation into the tundish from above the layer of slag and analyzing reflections of the microwave radiation from the slag and the steel, and adding the second grade of molten steel to the tundish at a rate at least that of the rate of draining the first grade of steel.
  • Our invention further includes a method of maintaining the level of molten steel within desired limits in a tundish feeding a continuous caster including a mold comprising monitoring the level of molten steel in the tundish by microwave analysis and controlling the flow of molten steel out of the tundish to maintain the level within the predetermined limits.
  • a predetermined steel level range is maintained in continuous use of the tundish through the passage of from about ten to twenty or more heats of steel; the level is monitored by microwave intermittently or continuously throughout such a term of use.
  • the term of use may include one or more steel heats as supplied to the tundish from a steelmaking vessel - that is, the method may be used substantially continuously throughout several heats.
  • one may monitor the steel volume or weight in the tundish as well as the level, and the control factors may vary with the specifications of the steel as well as real time conditions in the caster.
  • our invention includes a method of managing a tundish containing molten steel and slag during a transition between a grade A of steel and a grade B of steel to be cast sequentially in a continuous caster fed by the tundish comprising (a) establishing a data-base on steel product characteristics affected by at least one of (i) molten steel level in the tundish, (ii) slag depth in the tundish, (iii) flow rates into the tundish, (iv) flow rates out of the tundish, (v) iron content of the slag and (vi) patterns of steel flow which are indicative of the formation of an incipient vortex, (b) determining a lowest level for molten steel of grade A in the tundish at which the probability of a vortex occuring above a well in the tundish, and the probability of slag entrainment into the mold, are deemed acceptably low (c) monitoring for formation of an incipient vortex above a well
  • our invention includes a method of inhibiting the formation of a vortex over a well in a vessel containing molten steel covered by slag comprising (a) directing microwave radiation toward the slag in an area over the well, (b) receiving reflections of the microwave radiation, (c) analyzing the reflections to identify patterns thereof indicative of the incipient formation of a vortex in the well, (d) establishing a reference base of the patterns for comparison with a real time pattern of microwave reflections over the well, and (e) adding additional molten steel to the vessel when the real time pattern resembles the reference base.
  • our invention includes a method of inhibiting the formation of a vortex over a well in a vessel containing molten steel covered by slag comprising (a) directing microwave radiation toward said slag in an area over said well, (b) receiving reflections of said microwave radiation, (c) analyzing said reflections to identify a pattern thereof indicative of the incipient formation of a vortex in said well as predictable from a reference base, and (d) adding additional molten steel to said vessel when said pattern is identified.
  • Figure 1 is a side sectional view of a tundish during normal operation of a typical steel continuous caster, showing placement of a microwave transceiver for purposes of our invention.
  • Figure 2 shows the same tundish as in Figure 1 having a low level of molten steel, leading to the undesirable formation of a vortex over the well.
  • the tundish 2 has a refractory lining 1. It contains molten steel 12 on which floats a layer of slag 14. Molten steel 8 in refractory-lined shroud 9 is more or less continuously provided from a ladle not shown. Shroud 9 penetrates through the slag 14 to minimize the turbulence and exposure of steel to the air.
  • Tundish 2 has a cover 10 having an aperture 11 for shroud 9. Another aperture 13 in cover 10 permits microwaves 22 to be transmitted into the tundish and strike the surface of slag 14.
  • Microwaves 22 emanate from transmitter 20 placed preferably directly above aperture 13. Microwave transmitter 20 and aperture 13 are both directly over well 15 in the bottom of tundish 2.
  • Well 15 is fitted with a sliding gate 27 which may be controlled to be closed or in various open positions.
  • sliding gate 27 When sliding gate 27 is open, molten steel 12 drains through well 15 and conduit 6, through flux layer 18 and into mold 4, which forms the head 16 of a continuously moving strand of steel in the caster as is known in the art.
  • Microwave transmitter 20 is preferably also a microwave receiver and hence a transceiver, typically using the same antenna for sending and receiving reflected microwaves, as is known in the art of radar or microwave transmission and receiving. See the discussion of rod and horn antennas in Fehrenbach et al US Patent 6,404,382, and the level calculators described by Kleib in US Patent 6,300,897 and Diede in US Patent 6,320,532.
  • the transceiver 20 is connected to computer 28, which is enabled to analyze the time-of-flight data to determine not only the upper level of the slag but also the upper level of the molten steel even though it is covered by the slag, as explained in Meszaros et al US Patents 6,130,637, 6,166,681, and 6,255,983, all of which are hereby incorporated into this disclosure in their entireties. Unless otherwise noted herein, our techniques for detection of the levels of slag and steel in the tundish follow those described in the Meszaros et al patents.
  • the microwaves may be pulsed.
  • the microwave transmitter 20 is preferably placed a known or measured distance from the bottom of tundish 2, thus giving the system a reference distance for microwave reflections.
  • interpretation of the reflected microwaves is aided by the quite different conductivities of the slag and the molten steel. During normal continuous casting, therefore, measurement of the level of the steel, and the thickness of the slag, in the tundish are similar to those described in the Meszaros et al patents.
  • Time-of-flight analysis of the reflected microwaves will demonstrate two recognizable patterns, representing reflections from the steel and from the slag; these are correlated to the respective levels of the steel and the slag. As will be seen below, however, such readings may be supplemented by inputs of several other kinds and actions may be taken based on deviation from historical data of these and other kinds.
  • Figure 2 shows the same equipment as in Figure 1 except that here the level of molten steel 12 is low. This means that the incoming steel 26 at the lower end of shroud 9 is undesirably exposed to the air, and a vortex 24 has been formed above well 15. The formation of vortex 24 means that the slag 14 will tend to go down the well 15 along with the steel, an undesirable event.
  • Computer 28 is programmed to recognize the reflected pattern of an incipient vortex, and will generate a signal to alert the system prior to the maturation of the vortex 24. When an incipient vortex is detected, the flow of molten steel to the tundish is increased and the conditions of Figure 2 are averted.
  • our method and apparatus may act to prevent the entrainment of slag into the continuous caster alternatively (a) when a vortex is actually detected, (b) when a vortex is anticipated imminently as detected in the movement, or patterns of movement, of the steel and slag, or (c) when a vortex is anticipated based on historical data correlating vortex formation to the level of molten steel in the tundish.
  • our method of level control in a tundish may be based entirely on measurement, by radar, of the levels of steel and slag in the tundish independently of the possibility of vortex formation.
  • our invention includes a method of maintaining the level of molten steel within desired limits in a tundish feeding a continuous caster including a mold, comprising monitoring the level of molten steel in the tundish by microwave analysis continuously or intermittently throughout a plurality of heats, and controlling the flow of molten steel out of the tundish to maintain the level within the predetermined limits, also throughout the plurality of heats.
  • This method may be practiced while also monitoring the well of the tundish, using microwave or other means (such as vibration monitoring) for vortex formation or flow patterns characteristic of incipient vortex formation.
  • Table 1 contains data generated by a computer model, which correlates molten steel height in a specific commercially used tundish with the volume and weight of steel in the tundish. The data are for a single grade of steel.
  • our invention may take this into account also, and accordingly our invention includes a method wherein the level of steel in the tundish is controlled within predetermined limits by monitoring the level of steel in the tundish by microwave analysis and controlling the level (either incoming or outgoing flow of molten steel, or both) with control signals based upon the level so determined possibly modified by slag level, volume, or weight, or the level, volume or weight of steel in the tundish, together with various factors in the mold of the continuous caster, such as the rate of solidification, the strand production rate, turbulence, and vibrations.
  • our invention may be seen as a method of managing a tundish to control the transition between a first grade of molten steel and a second grade of molten steel to be solidified sequentially in a continuous caster by draining the first and second grades of molten steel through a well in the tundish to a mold at the head of the continuous caster, wherein the first grade of molten steel is covered by a layer of slag in the tundish comprising (a) draining the first grade of steel to a level in the tundish slightly higher than the predetermined level at which a vortex is expected to form above the well, (b) while draining the first grade of steel, monitoring the level of the first grade of steel in the tundish by directing microwave radiation into the tundish from above the layer of slag and analyzing reflections of the microwave radiation from the slag and the steel, and, (c) when step (a) is completed, adding the second grade of molten steel to the tundish at a rate
  • the level of molten steel which is likely to lead to the formation a vortex is ten inches above the bottom of the tundish, and a useful limit slightly higher than the level at which a vortex is likely to form is from 1% to 10% higher than the level at which a vortex is likely to form, as determined by analysis of historical data.
  • Our invention also includes a method of managing a tundish to control the transition between a first grade of molten steel and a second grade of molten steel to be solidified sequentially in a continuous caster by draining the first and second grades of molten steel through a well in said tundish to a mold at the head of the continuous caster, wherein the first grade of molten steel is initially in the tundish and covered by a layer of slag in the tundish, comprising (a) draining the first grade of steel to a level in the tundish as monitored in step (b) which level is (i) slightly higher than the predetermined level at which a vortex is expected to form above the well, or (ii) where vortex formation is indicated as in step (b), whichever is the first level to be reached; (b) while draining the first grade of steel, monitoring the level of the first grade of steel in the tundish by directing microwave radiation into the tundish from above the layer of slag and analyzing reflections of the
  • Another aspect of the invention may be seen as a method of maintaining the level of molten steel within predetermined limits in a tundish, the molten steel being beneath a layer of slag, while the tundish substantially continuously feeds the molten steel to a continuous caster including a mold comprising monitoring the level, volume, or weight of the molten steel in the tundish by microwave analysis and controlling the flow of the molten steel into and out of the tundish to maintain the level, volume or weight within the predetermined limits.
  • Controlling the flow of molten metal out of the tundish may be modified by at least one of (a) steel level in the mold, (b) based on historical records, whether a vortex is likely to form at the level, volume or weight of steel in the tundish, (c) slag level in the tundish, (d) slag volume in the tundish, (e) slag weight in the tundish, (f) iron oxide content in the slag, (g) the composition of steel in the tundish, (h) the rate of solidification of the steel in the mold (i) vibration in the tundish or tundish nozzle, (j) turbulence in the mold of the continuous caster, (k) casting rate, and (1) value of steel being cast.
  • time-of-flight radar microwave analysis may be used to determine the level of various materials covered by other materials.
  • our invention may be used in aluminum processing as well as in steel processing.
  • the molten aluminum in the tundish is covered by a second phase material, called dross, analagous to the slag on the molten steel.
  • Slag whether in steelmaking or in aluminum processing, is made up of many discrete particles and phases, thus having large numbers of surfaces and interfaces, which should be taken into account when analyzing the radar reflectance data to determine the level of molten metal under the blanket of molten slag. While the makeup of the materials in the tundish will generate different specific data for aluminum and steel, and the compositions of their respective slags will also affect the specific data gathered, the analytical process described in the three Meszaros et al US Patents incorporated by reference above is essentially identical for both aluminum and steel. We intend for our invention to include control of a tundish handling any kind of molten metal covered by slag, where microwave analysis can determine the level of the molten metal.
  • the dross of aluminum processing is a type of slag and is included in the term "slag."
  • a tundish or similar vessel includes a nonferrous metal such as copper, covered by a matte as opposed to a slag
  • use of our invention is not recommended, since the matte (containing various sulfides) is likely to have a conductivity too similar to the molten metal, resulting in difficulty in detecting the difference between microwave reflections from the matte and from the underlying molten metal.

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  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Thermal Sciences (AREA)
  • Fluid Mechanics (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)

Abstract

On utilise l'émission et la réception d'ondes ultracourtes et l'analyse de ces dernières pour surveiller le niveau de métal en fusion, spécifiquement de l'acier, dans un panier de coulée recevant du métal en fusion (acier) d'une poche de coulée ou d'une autre cuve et l'envoyant à la tête d'une couleuse en continu, alors que l'acier présent dans le panier de coulée est recouvert de laitier. Les facteurs de commande peuvent comprendre les limites de niveau, de masse ou de volume dans le panier issues de données antérieures ou de données en temps réel, y compris des données représentant un vortex prévisible ou en cours de formation dans le puits alimentant la couleuse en continu. Ce système est particulièrement utile pour réduire au maximum le mélange de transition pendant le changement d'une qualité ou d'une classe de métal à une autre.
PCT/US2004/042886 2003-12-23 2004-12-20 Commande du panier de coulee WO2005062846A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US53195903P 2003-12-23 2003-12-23
US60/531,959 2003-12-23

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WO2005062846A2 true WO2005062846A2 (fr) 2005-07-14
WO2005062846A3 WO2005062846A3 (fr) 2006-03-30

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WO2011113701A1 (fr) 2010-03-19 2011-09-22 Sms Siemag Ag Dispositif et procédé pour obturer une bonde d'une cuve métallurgique
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JP2014153077A (ja) * 2013-02-05 2014-08-25 Nippon Steel & Sumitomo Metal 溶融金属の湯面上に浮遊するスラグの厚さ測定方法
WO2016016967A1 (fr) * 2014-07-30 2016-02-04 新日鐵住金株式会社 Procédé pour mesurer une épaisseur de scories flottant à la surface de métal liquide
CN107398538A (zh) * 2016-05-20 2017-11-28 上海梅山钢铁股份有限公司 变钢种浇注连铸坯混钢区域的判定方法

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