An apparatus and method for simulating a smelting process in a smelter

Abstract

The application discloses a device and method for simulating the smelting slag process of a smelting furnace, which comprises a solution barrel for containing a solution, an electrode for heating the solution and forming an electric field in the solution, a thermocouple for measuring the temperature at different positions of the solution, a potentiometric difference meter for measuring the electric potential at different positions of the solution, and a lifting slide as a mounting member of the electrode, the thermocouple and the potentiometric difference meter. When in use, the solution barrel is filled with the solution, the lifting slide is started to make the first electrode, the thermocouple and the potentiometric difference meter respectively located at different positions of the solution, the electrode is connected to an excitation source to heat the solution and form an electric field in the solution, the thermocouple and the potentiometric difference meter are used to respectively measure the temperature and the electric potential at different positions of the solution, and the geometric features of the smelting furnace are adjusted. The device can measure the temperature and the electric potential at different positions of the solution in the solution barrel.

Description

TECHNICAL FIELD

[0001] The present application relates to a device and method for simulating the process of smelting slag in a smelting furnace. BACKGROUND

[0002] The electric slag remelting furnace is a device for remelting the conditioning material, metal or non-metal by the heat energy generated by the electric current through the high-resistance slag. The electric slag remelting furnace has a wide range of applications, which can be used not only to produce aerospace bearing steel, high-temperature alloy, precision alloy and certain non-ferrous metals, but also to produce hundreds of tons of large-scale high-quality alloy steel ingots, large-scale flat ingots or plate ingots, hollow steel ingots, composite plates, and special-shaped castings such as smelting rollers, gear blanks, turbine discs, pressure vessels, aircraft landing gear, gun barrels, and slag wool.

[0003] In smelting, the current, temperature and other parameters need to be configured according to the process and the remelting object. In order to understand the distribution of the temperature field, electric field and flow field of the smelting furnace and optimize the geometric characteristics of the smelting furnace, the present application is proposed. SUMMARY

[0004] The purpose of the present application is to provide a device for simulating the process of smelting slag in a smelting furnace, which can obtain temperature, electric potential and other parameters under different working parameters.

[0005] The device comprises:

[0006] A solution barrel for containing a solution;

[0007] An electrode for heating the solution and forming an electric field in the solution, comprising a first electrode and a second electrode;

[0008] A thermocouple for measuring the temperature at different positions of the solution;

[0009] A potentiometer for measuring the electric potential at different positions of the solution;

[0010] A lifting slide as a mounting member of the electrode, thermocouple and potentiometer;

[0011] In use, the solution barrel is filled with a solution, and the lifting slide is started to make the first electrode, thermocouple and potentiometer located at different positions of the solution respectively; the electrode is connected to an excitation to heat the solution and form an electric field in the solution, and the thermocouple and potentiometer are used to measure the temperature and electric potential at different positions of the solution respectively, which are used to adjust the geometric characteristics of the smelting furnace.

[0012] In some embodiments, the second electrode is detachably mounted above the solution barrel, which realizes the replaceability of the second electrode to construct different working conditions and meet different needs.

[0013] In some embodiments, the device further comprises a peristaltic pump in communication with the solution tank for feeding air into the solution tank; the air fed by the peristaltic pump into the solution tank through an air flow meter. The peristaltic pump can meet the process requirements of air bubbling; the air fed into the solution tank through the air flow meter can realize the measurement of air flow and accurate control of the amount of air fed.

[0014] In some embodiments, the device further comprises a feed flow pump through which the solution is injected into the solution tank.

[0015] In some embodiments, the device further comprises a discharge flow pump through which the solution in the solution tank is discharged.

[0016] In some embodiments, the discharge port of the discharge flow pump is in communication with a feed tank; the solution in the feed tank is injected into the solution tank through a feed flow pump, realizing the recycling of the solution and reducing the cost.

[0017] In some embodiments, the device further comprises an electrical control device electrically connected to the electrode, the thermocouple and the potentiometer, respectively, for controlling the excitation of the electrode, realizing the control of temperature and electric field, and obtaining the measurement results of the thermocouple and the potentiometer.

[0018] The device for simulating the process of smelting slag in a smelting furnace provided by the application comprises another structure:

[0019] A solution tank is mounted on the frame body for containing solution;

[0020] A feed tank is mounted on the frame body for injecting solution into the solution tank, and the solution injected into the solution tank is injected through a feed flow pump; the solution discharged from the solution tank is discharged into the feed tank through a discharge flow pump;

[0021] An electrode is used for heating the solution and forming an electric field in the solution, and comprises a first electrode mounted on the frame body through a lifting slide and a second electrode mounted in the solution tank;

[0022] A thermocouple is used for measuring the temperature of the solution at different positions, and is configured as a plurality of thermocouples mounted on a thermocouple support, and the thermocouple support is mounted on the frame body through a lifting slide;

[0023] A potentiometer is used for measuring the electric potential of the solution at different positions, and is mounted on the frame body through a lifting slide;

[0024] A peristaltic pump is in communication with the solution tank through an air flow meter for feeding air into the solution tank;

[0025] An electrical control device is used to control the size of the excitation of the electrode, to realize the control of temperature and electric field, to obtain the temperature, electric potential and flow results, and to adjust the geometric characteristics of the furnace, respectively connected with the electrode, the thermocouple, the potentiometer, the feed flow pump, the discharge flow pump and the air flow meter.

[0026] The application also provides a method for simulating by using the device.

[0027] The device can achieve the following beneficial effects:

[0028] 1) The device can measure the temperature and electric potential of the solution at different positions in the solution barrel by moving the thermocouple and potentiometer up and down through the lifting slide, and can adjust the geometric characteristics of the furnace according to the temperature and electric potential, such as thickening the furnace lining of the electric furnace at the position with high temperature, high electric potential and large flow, to increase the durability of the furnace, because the furnace lining is consumed and worn out quickly under these conditions.

[0029] 2) The distance between the electrodes can be changed by moving the electrodes up and down through the lifting slide, to realize the adjustment of the length of the electric arc column (i.e. the arc length), and the arc voltage and the arc length are approximately linearly related, so adjusting the length of the arc length is equivalent to adjusting the height of the arc voltage. When the arc current is constant, adjusting the arc length is equivalent to adjusting the size of the electric arc power; the electrode spacing becomes smaller, the arc voltage becomes lower, and vice versa. Different conditions are configured to meet various conditions.

[0030] 3) The second electrode and the solution barrel of the device can be disassembled, which is convenient for replacing different second electrodes. The size of the electrode and the distance between the electrodes will affect the current of the electric furnace, and the current will heat through the resistance of the molten liquid, thereby affecting the temperature. Replacing the second electrode can provide the state simulation under the working condition of the alternating current electric arc furnace, and can also provide the working state under the condition of different second electrode diameters, thereby improving the applicability of the device.

[0031] 4) The device is configured with a flow pump / meter, which is beneficial to precisely control the injection amount of the solution and air, and to build different production processes.

[0032] 5) The device can obtain the temperature, electric field and flow field distribution of the solution in the solution barrel under different electrode spacings, different second electrode diameters, different bubbling speeds, different feed and discharge flow rates of the solution barrel, etc. BRIEF DESCRIPTION OF DRAWINGS

[0033] The drawings incorporated into the specification and forming a part thereof, illustrate embodiments consistent with the application and, together with the specification, serve to explain the principles of the application. It is apparent that the drawings described below are only some embodiments of the application, and other drawings can be obtained from these drawings without creative labor for those skilled in the art. In the drawings:

[0034] Fig. 1 isometric side view of the device of the present invention;

[0035] Fig. 2 partial perspective isometric view of the device of the present invention;

[0036] Fig. 3 schematic view of the electrical control device of the device of the present invention;

[0037] In the drawings: 1, frame; 2, solution tank; 3, feed flow pump; 4, second lifting slide; 5, feed tank; 6, first lifting slide; 7, fourth lifting slide; 8, discharge flow pump; 9, first electrode; 10, second thermocouple; 11, thermocouple support; 12, first thermocouple; 13, top cover; 14, peristaltic pump; 15, second electrode; 16, electrical control device; 17, potentiometer; 18, temperature patrol instrument; 19, temperature control instrument. DETAILED DESCRIPTION

[0038] In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0039] In the description of the present application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the purpose of facilitating the description of the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. In addition, the terms "first", "second", "third" are only for the purpose of description, and cannot be understood as indicating or implying relative importance.

[0040] In the description of the present application, it should also be noted that, unless otherwise explicitly specified and limited, the terms "mounting", "connection", "connection" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the communication inside two elements. For those of ordinary skill in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0041] The geometry of the finished furnace is determined, and the manufacturer can only know whether it meets the manufacturer's needs during use. If it does not meet the needs, it needs to be adjusted or reordered, increasing the manufacturer's production cost. The device fully considers the working principle, process flow, and structure of the furnace, uses physical simulation to simulate the equipment structure of the furnace, constructs the same working mode, obtains temperature, potential, flow field (flow field refers to the material flow field formed by the flowing process of the liquid slag in the furnace), flow (feed, discharge, air volume, etc.), and adjusts the geometry of the furnace.

[0042] In combination Figs. 1-3 , the device includes a frame body 1, a solution bucket 2, a feed bucket 5, a first electrode 9, a second electrode 15, a thermocouple, a thermocouple support 11, and a potential difference meter 17. The solution bucket 2 and the feed bucket 5 are installed on the frame body 1, the first electrode 9 is installed on the first lifting slide 6, and the second electrode 15 is installed in the solution bucket 2 and matched with the first electrode 9. The thermocouple is installed through the thermocouple support 11, and the thermocouple support 11 is installed on the second lifting slide 4. The potential difference meter 17 is installed on the third lifting slide. The first lifting slide 6, the second lifting slide 4, and the third lifting slide are respectively installed on the frame body 1 and located above the solution bucket 2 to ensure that the first electrode, the thermocouple, and the potential difference meter can be placed in the solution bucket 2 in the working state of the device.

[0043] In the device, the first electrode 9 and the second electrode 15 are used to form an electric arc and generate heat. The electrode lifting control system takes the electrode positioning mechanism as the control object, and its main function is to adjust the length of the arc column (i.e., the arc length). The arc voltage and the arc length are approximately linearly related. Adjusting the length of the arc length is equivalent to adjusting the height of the arc voltage. When the arc current is constant, adjusting the arc length is equivalent to adjusting the size of the arc power. The electrode spacing becomes smaller, and the arc voltage becomes lower, and vice versa. The electrode size and the electrode spacing will affect the furnace current, and the current will heat through the molten liquid resistance, thereby affecting the temperature. The stirring effect of the molten material in the direct current electric arc furnace is strongly dependent on the form of the bottom electrode (second electrode), including the diameter, number, and distribution. Therefore, replacing the second electrode can provide state simulation under the working conditions of the alternating current electric arc furnace, and can also provide working conditions under different bottom anode diameters, so that the second electrode 15 in the device can be detachably installed in the solution bucket 2, and different diameters and numbers of second electrodes can be installed to replace and adjust the electric arc and heat.

[0044] Furthermore, the electrode heating condition is related to the current size, and the heating amount is equal to the square of the current multiplied by the electrode resistance multiplied by the time. Therefore, the current size connected to the electrode can be changed to adjust the electric arc and heat.

[0045] In use, the first electrode, the thermocouple and the potentiometer are respectively placed at the target position by starting the lifting platform, and the thermocouples and the potentiometers are respectively configured as multiple and respectively placed at different positions in the solution barrel; after the solution is injected into the solution barrel, the solution is heated by connecting the excitation to the first electrode and the second electrode, and the thermocouples and the potentiometers distributed at different positions respectively measure the temperature and the electric potential, the thermocouples and the temperature inspection instrument are electrically connected to obtain the temperature of the solution at different regions, and the potentiometer is electrically connected with the electrical control device to obtain the electric potential of the solution at different regions.

[0046] The distance between the first electrode and the second electrode is adjusted to change the conditions in the solution, and the temperature and the electric potential of the solution at different regions under different conditions are obtained to understand the conditions of the solution at different regions under different conditions, which serves as a basis for adjusting the geometric characteristics of the furnace, such as thickening the furnace lining of the electric furnace at the positions with high temperature, high electric potential and large flow rate to increase the durability of the furnace, because the furnace lining is consumed and worn out fast under these conditions.

[0047] The electrical control device of the present disclosure is also provided with an intelligent temperature control instrument, which accurately controls the temperature of the solution in the solution barrel by controlling the heating power of the first electrode and the second electrode.

[0048] To better measure the temperature of the solution at different regions, the thermocouple of the device comprises a first thermocouple 12 for measuring the peripheral heat and a second thermocouple 10 for measuring the central temperature, the first thermocouple 12 is installed on the thermocouple support 11, and the second thermocouple 10 is installed on the fourth lifting platform 7, which is used to place the second thermocouple 10 in the solution barrel 2 at the periphery of the first electrode 9 to measure the temperature of the solution at the region of the periphery of the first electrode 9. The periphery here refers to a position far from the first electrode 9, and the center refers to a position close to the first electrode 9.

[0049] In the present disclosure, the thermocouple adopts armored K-type thermocouple with a diameter of 2 mm, and the outer side is wrapped with an insulating heat shrink tube, and the exposed test head is 10-20 mm during wrapping.

[0050] The top cover 13 of the solution barrel 2 is provided with a feeding port, and the side close to the bottom is provided with a discharging port, the discharging port is connected with the pipeline of the discharging flow pump 8, and the discharging flow pump 8 can accurately control the flow rate of the solution flowing out of the solution barrel. The feeding barrel contains the solution, and the side close to the bottom is provided with a discharging port, which is connected with the feeding port at the top of the solution barrel through the pipeline of the feeding flow pump 3, and the feeding flow pump 3 can accurately control the flow rate of the solution fed into the solution barrel.

[0051] The positions of the feeding and discharging ports can be changed to realize the feeding and discharging at different positions. Different feeding and discharging positions affect the uniformity of the slag, and unreasonable feeding and discharging positions may cause unmelted materials to flow out of the discharging port, affecting the product quality, and the feeding and discharging positions should have a certain angle in space.

[0052] The outlet of the solution tank is communicated with the inlet of the feeding tank through a pipeline, and the solution discharged from the solution tank flows back to the feeding tank, realizing solution circulation and reducing cost.

[0053] The bottom of the solution tank is provided with a small hole for mounting a needle connected with the peristaltic pump 14 and the flow meter, and the air intake of each needle is determined according to the required air intake, such as 10-50 mL / min. The configuration of the peristaltic pump 14 and the flow meter realizes air intake, makes the solution bubble, and the peristaltic pump 14 is used to adjust the speed of the flow intake, and the flow meter is used to measure the air volume. The air volume needs to be introduced into the furnace through the air pipe, and a suitable size of air pipe needs to be left at a suitable position.

[0054] There is a bubbling process, and the position and size of the air pipe need to be left on the furnace; without the bubbling process, the physical stirring device is installed, and the installation position of the physical stirring device needs to be left. The geometric characteristics of the furnace refer to the electrode diameter of the furnace, the installation arrangement position and size of the lining.

[0055] The materials used for the solution tank and the feeding tank of the device are transparent materials such as polyurethane or acrylic, which are convenient for observing the flow rule of the internal simulation liquid. Of course, other materials can also be used, and not only transparent materials can be used, but also non-transparent materials can be used. The thermocouple and the first electrode are respectively fixed on the liftable sliding table, and the stroke of the lifting sliding table is 200-400 mm, or other strokes can be configured according to requirements.

[0056] The solution enters the solution tank 2 through the inlet on the top cover 13, and a plurality of first thermocouples 12 are installed in the space filled with the solution. The test ends of all the first thermocouples 12 are on the same horizontal plane, the first thermocouples 12 are fixed on the thermocouple bracket 11, and the thermocouple bracket 11 is installed on the moving platform of the second lifting sliding table 4. The first electrode 9 is cylindrical and is fixed on the moving platform of the first lifting sliding table 6, and the first electrode 9 is concentric with the solution tank 2. The second electrode 15 is installed at the bottom center of the solution tank 2, and is concentric with the second electrode. A plurality of second thermocouples 10 are distributed around the first electrode 9, and the second thermocouples 10 are metal armored K-type thermocouples, the outer side of which is wrapped with an insulating heat shrink tube, only the test end 10-20 mm is exposed, and the second thermocouples 10 are fixed on the moving platform of the fourth lifting sliding table 7.

[0057] The feed flow pump 3 sends the solution in the feed tank 5 into the solution tank 2 at a certain flow rate, and the discharge flow pump 8 discharges the solution in the solution tank 2 at a certain flow rate, simulating the feeding and discharging process of the smelting furnace; the peristaltic pump 14 sends air into the solution through the flow meter and the pipe from the small hole at the bottom of the solution tank 2, simulating the bubbling process of the smelting furnace; the intelligent temperature control instrument 19 on the electrical control device 16 controls the heating power of the upper and lower electrodes installed in the solution tank 2, simulating the heating process of the smelting furnace; the second lifting slide 4 drives the thermocouple support 11 and the first thermocouple 12 installed thereon to move up and down, which can cover the position of the solution in the solution tank 2, and the third lifting slide 7 drives the second thermocouple 10 to move up and down, covering the area between the first electrode 9 and the second electrode 15, and the temperature inspection instrument 18 and the potential difference meter 17 installed on the electrical control device 16 measure the temperature and potential difference of the solution at different positions through the first thermocouple 12 and the first thermocouple 10, respectively.

[0058] During use, the process parameters that can be changed include: the feed flow pump 3 can accurately control the flow rate of the feed; the discharge flow pump can accurately control the flow rate of the discharge; the first lifting slide 6 drives the first electrode 9 to move up and down, which can control the distance between the first electrode 9 and the second electrode 15; the second electrode 15 and the bottom of the solution tank 2 can be disassembled, and different diameter bottom electrodes can be replaced; the peristaltic pump 14 sends air into the solution tank through the flow meter, and the flow meter adjusts the flow rate of the air sent in, thereby changing the bubbling speed.

[0059] The device can measure the temperature and electric field distribution of the simulation liquid in the smelting furnace simulation tank; the upper electrode can be moved up and down by the lifting slide, which can change the distance between the upper electrode and the lower electrode; the electrode and the smelting furnace simulation tank can be disassembled, and different diameter bottom electrodes can be installed; the small hole at the bottom of the smelting furnace simulation tank is connected to the needle of the peristaltic pump and the flow meter, and the flow meter can accurately control the air inlet flow rate of each needle; the feed and discharge flow pumps can accurately control the flow rate of the feed and discharge. Through the above methods, the temperature, electric field and flow field distribution of the solution in the solution tank under different upper and lower electrode distances, different bottom electrode diameters, different bubbling speeds, and different feed and discharge flow rates of the solution tank can be obtained.

[0060] The device can be used for various smelting slag processes. Liquid solution is added under electricity, and then conditioning material is added into the solution at a certain flow rate. The solid conditioning material is melted by heating. Air is sent in to stir and strengthen the homogenization effect during the melting process. The melting condition is checked by adjusting various parameters. The device not only can simulate the smelting slag melting movement in the direct current furnace, but also can simulate the smelting slag movement in the alternating current furnace after replacing the electrodes, and can simulate the melting performance of different smelting slags after replacing the conditioning liquid.

[0061] The present disclosure has been described with reference to the above embodiments, however, the above embodiments are merely examples of implementing the present disclosure. It must be pointed out that the disclosed embodiments do not limit the scope of the present disclosure. On the contrary, modifications and improvements made without departing from the spirit and scope of the present disclosure are within the scope of patent protection of the present disclosure.

Claims

1. An apparatus for simulating a smelting process of a smelting furnace, characterized in that, The device is used for acquiring parameters of a simulated furnace, adjusting electrode diameter of the furnace, installation arrangement position and size of inner lining, comprising: a solution tank for containing solution; an electrode for heating the solution and forming an electric field in the solution, comprising a first electrode and a second electrode installed in the solution tank; a thermocouple for measuring temperature at different positions of the solution; a potentiometer for measuring electric potential at different positions of the solution; a lifting slide as a mounting member of the electrode, the thermocouple and the potentiometer; In use, the solution tank is filled with solution, the lifting slide is started to make the first electrode, the thermocouple and the potentiometer respectively located at different positions of the solution; the electrode is connected to excitation to heat the solution and form an electric field in the solution, the thermocouple and the potentiometer are used to measure temperature and electric potential at different positions of the solution respectively, for adjusting geometric features of the furnace; the length of an arc column between the first electrode and the second electrode is adjusted by the lifting slide to change the level of arc voltage in the solution tank, and the thermocouple and the potentiometer are used to measure temperature and electric potential at different positions of the solution respectively under different arc voltages.

2. The apparatus of claim 1, wherein, The second electrode is detachably installed in the solution tank.

3. The apparatus of claim 1, wherein, A peristaltic pump in communication with the solution tank is further included for sending air into the solution tank; the air delivered by the peristaltic pump is sent into the solution tank through an air flow meter.

4. The apparatus of claim 1, wherein, A feed flow pump is further included, and the solution is injected into the solution tank through the feed flow pump.

5. The apparatus of claim 1, wherein, A discharge flow pump is further included, and the solution in the solution tank is discharged through the discharge flow pump.

6. The apparatus of claim 5, wherein, The discharge outlet of the discharge flow pump is in communication with a feed tank; the solution in the feed tank is injected into the solution tank through the feed flow pump.

7. The apparatus of claim 1, wherein, An electrical control device is further included for being electrically connected with the electrode, the thermocouple and the potentiometer respectively, controlling the excitation size of the electrode, realizing temperature and electric field control, and acquiring measurement results of the thermocouple and the potentiometer.

8. The apparatus of claim 1, wherein, The thermocouple comprises a first thermocouple for measuring peripheral heat and a second thermocouple for measuring central temperature, and the first thermocouple and the second thermocouple are respectively assembled on the lifting slide.

9. An apparatus for simulating a smelting process of a smelting furnace, characterized in that, The device is used for acquiring parameters of a simulated furnace, adjusting electrode diameter of the furnace, installation arrangement position and size of inner lining, comprising: a frame body, a solution tank assembled on the frame body for containing solution; a feed tank assembled on the frame body for injecting solution into the solution tank, wherein the solution injected into the solution tank is injected through a feed flow pump; the solution discharged from the solution tank is discharged into the feed tank through a discharge flow pump; an electrode for heating the solution and forming an electric field in the solution, comprising a first electrode assembled on the frame body through a lifting slide and a second electrode installed in the solution tank; a thermocouple for measuring temperature at different positions of the solution, configured to be assembled on a thermocouple support, and the thermocouple support is assembled on the frame body through the lifting slide; a potentiometer for measuring electric potential at different positions of the solution, assembled on the frame body through the lifting slide; a peristaltic pump in communication with the solution tank through an air flow meter for injecting air into the solution tank; An electrical control device is used to control the size of the excitation to the electrodes, to control the temperature and electric field, to obtain the temperature, electric potential and flow results, and to adjust the geometric characteristics of the furnace, respectively connected to the electrodes, thermocouples, potentiometers, feed flow pumps, discharge flow pumps and air flow meters; the length of the arc column between the first electrode and the second electrode is adjusted by the lifting platform to change the arc pressure in the solution bucket, and the temperature and electric potential at different positions under different arc pressures are measured by the thermocouples and potentiometers respectively.

10. A method of simulating a direct current electric arc furnace smelting slag process, characterized by, The method is simulated by the device of any one of claims 1-9.

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