A large-tonnage light alloy melt real-time purification method and system

Abstract

The application discloses a large-tonnage light alloy melt real-time purification method and system and relates to the technical field of aluminum alloy purification. The method applied to the large-tonnage light alloy melt real-time purification system comprises the following steps: embedding an anti-infiltration gas-permeable brick in the bottom of a smelting furnace, collecting hydrogen content data of the alloy melt in real time through an online hydrogen tester, and blowing dispersed multi-bubble refining argon into the online hydrogen tester in stages, so that the hydrogen content in the aluminum liquid is effectively reduced, and the alloy melt liquid surface is protected from oxidation. Thus, the problems of high element burning loss, high hydrogen content, many inclusions and low production efficiency in the preparation of light alloys by using natural gas heating smelting in the prior art are solved.

Description

Technical Field

[0001] This invention relates to the field of aluminum alloy purification technology, and in particular to a method and system for real-time purification of large-tonnage light alloy melts. Background Technology

[0002] Lightweight alloys, especially aluminum and magnesium alloys, are widely used in weaponry, aerospace, and automotive industries due to their low density and high performance. In industrial production, the single melting capacity of lightweight alloys can reach 5 tons or even more than 50 tons. Electric heating methods are too energy-intensive, so energy-saving and environmentally friendly natural gas heating is usually adopted. Natural gas heating involves direct purging of the liquid surface. The large liquid surface of large-tonnage melts can easily cause quality problems such as high burn-off rates of elements such as Mg and Si, high hydrogen content, and numerous inclusions in the alloy. As a result, after casting solidification, a large number of pinholes, pores, inclusions, and other defects are formed inside the casting, deteriorating the microstructure and properties of the casting, and may even cause the entire furnace melt to be scrapped. Currently, conventional methods involve manually adding refining agents or using a rotary jet refining machine to blow argon and refining agents into the melt for purification. However, this method cannot provide protection during the heating and melting stage. Furthermore, the structure of the natural gas furnace and the large liquid surface and tonnage of the melt make it difficult to find a suitable rotary jet refining machine. The only solution is to divide the melt into many smaller furnaces for refining, resulting in uneven quality, low efficiency, and an inability to meet the needs of large-tonnage melt smelting and large component casting. Therefore, it is necessary to improve existing technology and propose a more reasonable technical solution. Summary of the Invention

[0003] To address the problems of high element loss, high hydrogen content, numerous inclusions, and low production efficiency in the preparation of light alloys using natural gas heating and smelting in existing technologies.

[0004] In a first aspect, embodiments of the present invention propose a real-time purification system for large-tonnage light alloy melts, applied to a smelting furnace. The system includes: an online hydrogen analyzer, a bottom argon blowing device, an electromagnetic stirring device, and a main control unit. The bottom argon blowing device includes: an argon gas source, pipelines, one or more mass flow controllers, and impermeable permeable bricks. The impermeable permeable bricks are installed at the bottom of the smelting furnace and communicate with the furnace's inner cavity. The argon gas source, pipelines, mass flow controllers, and impermeable permeable bricks are connected sequentially. The online hydrogen analyzer is installed at the outlet of the smelting furnace. The liquid inlet is used to collect hydrogen content data of the alloy melt and send it to the main control terminal. The main control terminal is used to receive hydrogen content data of the alloy melt, generate flow control commands and electromagnetic stirring commands based on the hydrogen content data, and send the flow control commands to the mass flow controller and the electromagnetic stirring commands to the electromagnetic stirring device. The mass flow controller is used to receive the flow control commands and change the argon blowing opening degree. The electromagnetic stirring device is located at the lower end of the melting furnace and is used to receive electromagnetic stirring commands and adjust the stirring mode according to the electromagnetic stirring commands.

[0005] Secondly, embodiments of the present invention propose a real-time purification method for large-tonnage light alloy melts, applied to the real-time purification system for large-tonnage light alloy melts as proposed in the above embodiments. The method includes:

[0006] The quantity and location of the impermeable permeable bricks are determined according to the size of the furnace to form a smelting furnace containing impermeable permeable bricks. Each impermeable permeable brick is matched with a mass flow controller.

[0007] After the alloy ingot is added to the furnace, the alloy ingot is heated and melted, and the argon blowing opening degree of the mass flow controller is gradually adjusted from low to high according to the liquid level height of the alloy melt. The argon blowing opening degree range is 0 to 10%.

[0008] After the alloy ingot is completely melted, the temperature inside the furnace is controlled and the argon blowing opening degree of the mass flow controller is adjusted to allow the alloy melt to stand still. The argon blowing opening degree is 0-5%.

[0009] After the alloy melt is allowed to stand, the composition of the alloy melt is monitored by a furnace-front spectrometer. An intermediate alloy ingot is added for correction, and the argon blowing opening degree of the mass flow controller is kept consistent with the argon blowing opening degree when the alloy melt is allowed to stand.

[0010] After the correction alloy ingot is added, the argon blowing opening degree of the mass flow controller is controlled to be ≥50%, and the argon blowing opening degree is kept stable until the correction alloy ingot melts.

[0011] After the alloy ingot is melted, the argon blowing opening degree of the mass flow controller is controlled to be consistent with the argon blowing opening degree of the alloy melt during static settling, and the temperature inside the furnace is controlled for heat preservation.

[0012] The hydrogen content of the alloy melt is monitored in real time by an online hydrogen analyzer. Based on the hydrogen content value, the opening and closing degree of the argon blowing of the mass flow controller is nonlinearly adjusted until the hydrogen content value meets the preset conditions.

[0013] After the hydrogen content value meets the preset conditions, the argon blowing opening degree of the mass flow controller is adjusted to keep the alloy melt at a static temperature. The argon blowing opening degree is 0-5%.

[0014] Preferably, after the alloy ingot has been completely melted, the temperature inside the furnace is controlled and the argon blowing opening and closing degree of the mass flow controller is adjusted to allow the alloy melt to settle. The step of setting the argon blowing opening and closing degree to 0-5% includes:

[0015] After the alloy ingot is completely melted, the temperature inside the furnace is controlled and maintained, and the mass flow controller is adjusted to a specific argon blowing opening degree to allow the alloy melt to stand still. The argon blowing opening degree is 0-5%.

[0016] Preferably, the online hydrogen analyzer has a hydrogen content measurement range of 0–0.99 ml / 100g Al, a hydrogen measurement resolution of 0.01 ml / 100g Al, a correction error of ≤5%, and a monitoring equilibrium time of ≤5 min.

[0017] Preferably, the number of impermeable permeable bricks is ≥3, the maximum argon blowing pressure generated by the impermeable permeable bricks is ≥0.3MPa, and the argon blowing opening degree is 0~100%.

[0018] Preferably, the furnace chamber is provided with a circular furnace bottom, and the number of impermeable air-permeable bricks is 4, with 3 impermeable air-permeable bricks placed at the circular furnace bottom and 1 impermeable air-permeable brick placed at the liquid outlet.

[0019] Preferably, the step of real-time monitoring of the hydrogen content of the alloy melt using an online hydrogen analyzer, and non-linearly adjusting the argon blowing opening and closing degree of the mass flow controller according to the hydrogen content value, includes:

[0020] The online hydrogen analyzer collects hydrogen content data of the alloy melt and sends the hydrogen content data of the alloy melt to the main control terminal;

[0021] The main control unit receives hydrogen content data of the alloy melt, generates flow control instructions based on the hydrogen content data of the alloy melt, and sends the flow control instructions to the mass flow controller.

[0022] The mass flow controller receives flow control commands and changes the argon blowing opening degree of the mass flow controller.

[0023] Preferably, when the hydrogen content of the melt is greater than or equal to 0.7 ml / 100gAl in the hydrogen content data, the flow control command sent by the master control terminal is: argon blowing flow rate of 10.0–15.0 L / min, and argon blowing opening degree of 50–75%; when the hydrogen content of the melt is less than 0.7 ml / 100gAl but greater than or equal to 0.6 ml / 100gAl in the hydrogen content data, the flow control command sent by the master control terminal is: argon blowing flow rate of 8 L / min, and argon blowing opening degree of 40%; when the hydrogen content of the melt is less than 0.6 ml / 100gAl but greater than or equal to 0.5 ml / 100gAl in the hydrogen content data, the flow control command sent by the master control terminal is: argon blowing flow rate of 6 L / min, and argon blowing opening degree of 30%; when the hydrogen content of the melt is less than 0.5 ml / 100gAl but greater than or equal to 0.4 ml / 100gAl in the hydrogen content data... When the hydrogen content of the melt is less than 0.4 ml / 100gAl but greater than or equal to 0.3 ml / 100gAl, the flow control command sent by the master control terminal is: argon blowing flow rate of 5 L / min and argon blowing opening degree of 25%. When the hydrogen content of the melt is less than 0.3 ml / 100gAl but greater than or equal to 0.2 ml / 100gAl, the flow control command sent by the master control terminal is: argon blowing flow rate of 2.5 L / min and argon blowing opening degree of 12.5%. When the hydrogen content of the melt is less than 0.2 ml / 100gAl, the flow control command sent by the master control terminal is: argon blowing flow rate of 0.1 L / min and argon blowing opening degree of 5%.

[0024] Beneficial Effects: The real-time purification method for large-tonnage light alloy melts proposed in this invention, applied to the real-time purification system for large-tonnage light alloy melts as described in the above embodiments, overcomes the severe oxidation and component loss caused by direct flame radiation to the liquid surface in existing natural gas melting furnaces, thus protecting the liquid surface; it reduces the hydrogen content and inclusions in the alloy melt, achieving refining and eliminating the need for further refining; the dispersed bubbles traversing the alloy melt promote heat and mass convection, achieving component homogenization; and the hydrogen content in different areas can be controlled by parallel mass flow controllers. This solves the problems of high element loss rate, high hydrogen content, numerous inclusions, and low production efficiency in the preparation of light alloys using natural gas heating and melting. Attached Figure Description

[0025] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0026] Figure 1 Real-time purification and control curve for large-tonnage light alloy melt;

[0027] Figure 2 This is a schematic diagram of the functional modules of an alloy melt purification system.

[0028] Icons: 20-Furnace chamber; 21-Imperible permeable brick; 22-Mass flow controller; 10-Large-tonnage light alloy melt real-time purification system; 23-Smelting furnace; 24-Online hydrogen analyzer; 25-Bottom argon blowing equipment; 26-Electromagnetic stirring equipment; 27-Main control terminal; 28-Argon gas source; 29-Pipeline; 30-Liquid outlet. Detailed Implementation

[0029] To more clearly illustrate the technical solutions in the embodiments of the invention or the prior art, the invention will be briefly introduced below in conjunction with the accompanying drawings and descriptions of the embodiments or the prior art. Obviously, the following description of the structure of the drawings is only some embodiments of the invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. It should be noted that the description of these embodiments is for the purpose of helping to understand the invention, but does not constitute a limitation on the invention.

[0030] For the first aspect, please refer to... Figure 1 and Figure 2 This invention provides a real-time purification method for large-tonnage light alloy melts, applicable to a real-time purification system for large-tonnage light alloy melts. The method includes:

[0031] The quantity and location of the impermeable permeable bricks 21 are determined according to the dimensions of the furnace chamber 20, forming a smelting furnace 23 containing the impermeable permeable bricks 21. Each impermeable permeable brick 21 is equipped with a mass flow controller 22. Due to the structure of the furnace chamber 20, impermeable permeable bricks 21 can be placed at multiple locations at the bottom of the furnace chamber 20, so that during the purification process, argon gas can fully contact the alloy melt, thereby accelerating the mixing and purification of the alloy melt.

[0032] After the alloy ingot is added to the furnace chamber 20, it is heated and melted. The argon blowing opening degree of the mass flow controller 22 is gradually adjusted from low to high according to the liquid level of the alloy melt. The argon blowing opening degree range is 0 to 10%. After the alloy ingot is added to the furnace chamber 20, as the alloy ingot melts, the liquid level of the alloy melt gradually rises, and the argon blowing opening degree of the mass flow controller 22 gradually increases from 0 to about 10%. In this process, it can protect the alloy melt surface from oxidation and burning, reduce the hydrogen brought by the moisture in the alloy ingot, accelerate the floating of impurities on the surface and inside of the alloy ingot, and promote the homogenization of composition by heat and mass convection.

[0033] After the alloy ingot is detected to be completely melted, the temperature inside the furnace 20 is controlled and the argon blowing opening degree of the mass flow controller 22 is adjusted to allow the alloy melt to settle, wherein the argon blowing opening degree is 0-5%. After the alloy ingot is completely melted, a holding stage is entered, and the argon blowing opening degree is reduced to 0-5% to allow the alloy melt to settle so that hydrogen and inclusions inside the melt float to the surface, while protecting the surface from oxidation. Preferably, the step of controlling the temperature inside the furnace 20 and adjusting the argon blowing opening degree of the mass flow controller 22 to allow the alloy melt to settle after the alloy ingot is detected to be completely melted, wherein the argon blowing opening degree is 0-5%, includes: after the alloy ingot is detected to be completely melted, controlling and holding the temperature inside the furnace 20, adjusting the mass flow controller 22 to a specific argon blowing opening degree, and allowing the alloy melt to settle, wherein the argon blowing opening degree is 0-5%. Specifically, the holding stage time can be set; for example, the holding stage time is 20-30 minutes. It is clear that the liquid level of the alloy melt can be monitored in real time by a liquid level monitor to determine whether it has completely melted.

[0034] After the alloy melt has been allowed to settle, the composition of the alloy melt is monitored by a spectrometer located in front of the furnace. An intermediate alloy ingot is added for correction, and the argon blowing opening degree of the mass flow controller 22 is kept consistent with the argon blowing opening degree during the settling of the alloy melt. After the alloy melt has settled, the alloy composition is quickly monitored by a spectrometer located in front of the melting furnace 23, and an intermediate alloy ingot is added for correction. At this time, the argon blowing opening degree of the mass flow controller 22 remains unchanged, and the parameters of the alloy melt are corrected by adding intermediate alloy ingots containing corresponding unqualified elements.

[0035] After the correction alloy ingot is added, the argon blowing opening degree of the mass flow controller 22 is controlled to be ≥50%, and the argon blowing opening degree is kept stable until the correction alloy ingot melts; after the correction alloy ingot is added, the argon blowing opening degree of the mass flow controller 22 needs to be quickly increased to more than 50% and stabilized to help the correction alloy ingot material melt quickly and become homogenized.

[0036] After the alloy ingot is melted, the argon blowing opening degree of the mass flow controller 22 is controlled to be consistent with the argon blowing opening degree when the alloy melt is allowed to stand, and the temperature inside the furnace 20 is controlled to maintain the temperature. After the alloy ingot is melted, the argon blowing opening degree of the mass flow controller 22 returns to its previous smaller value to maintain the temperature and protect the liquid surface from oxidation. The argon blowing opening degree is 0-5%.

[0037] The hydrogen content of the alloy melt is monitored in real time by an online hydrogen analyzer 24. Based on the hydrogen content value, the opening and closing degree of the argon blowing of the mass flow controller 22 is non-linearly adjusted until the hydrogen content value meets the preset conditions.

[0038] After the hydrogen content meets the preset conditions, the argon blowing opening degree of the mass flow controller 22 is adjusted to keep the alloy melt at a static temperature. The argon blowing opening degree is 0-5%. After the hydrogen content meets the preset conditions, the temperature is kept at a small argon blowing opening degree to protect the liquid surface from oxidation.

[0039] Based on the theory of bubble flotation degassing and slag removal and gas-liquid two-phase fluid motion, impermeable permeable bricks 21 are pre-embedded in the bottom of the melting furnace 23. The hydrogen content data of the alloy melt is collected in real time by an online hydrogen analyzer 24. Dispersed, multi-bubble refining argon gas is blown in stages through the online hydrogen analyzer 24, effectively reducing the hydrogen content in the aluminum melt and protecting the liquid surface from oxidation. Simultaneously, an electromagnetic stirrer can be installed at the bottom of the melting furnace 23 to accelerate the heat and mass transfer of the alloy melt, speeding up the chemical reaction rate and improving the purification / homogenization level of the alloy melt before water transfer. Each impermeable permeable brick 21 is equipped with an independent blowing pipe 29, each with a flow meter and a mass flow controller 22. A pressure regulating device is also installed on the main inlet pipe, which can control the pressure and flow rate of the gas blown in by the mass flow controller 22 as needed, thereby achieving better refining results. The mass flow controller 22 can also be a valve that controls the argon blowing flow rate and the opening and closing degree of the argon blowing.

[0040] The real-time purification method for large-tonnage light alloy melts proposed in this invention overcomes the severe oxidation and component loss caused by direct flame radiation to the liquid surface in existing natural gas melting furnaces, thus protecting the liquid surface; it reduces the hydrogen content and inclusions in the alloy melt, achieving refining and eliminating the need for further refining; the dispersed bubbles traversing the alloy melt promote heat and mass convection, achieving component homogenization; and the hydrogen content in different areas can be controlled by a parallel mass flow controller 22. This solves the problems of high element loss rate, high hydrogen content, numerous inclusions, and low production efficiency in the preparation of light alloys using natural gas heating and melting.

[0041] Preferably, the online hydrogen analyzer 24 has a hydrogen content measurement range of 0 to 0.99 ml / 100g Al, a hydrogen measurement resolution of 0.01 ml / 100g Al, a correction error of ≤5%, and a monitoring equilibrium time of ≤5 min.

[0042] In specific implementation, the hardware parameters of the online hydrogen analyzer 24 are designed as follows: the hydrogen content measurement range of the online hydrogen analyzer 24 is 0~0.99ml / 100g Al; the hydrogen measurement resolution is 0.01ml / 100g Al; the correction error is ≤5%; and the monitoring equilibrium time is ≤5min.

[0043] Preferably, the number of impermeable permeable bricks 21 is ≥3, the maximum argon blowing pressure generated by the impermeable permeable bricks 21 is ≥0.3MPa, and the argon blowing opening degree is 0~100%.

[0044] In practice, the number of permeable bricks for argon blowing at the furnace bottom is ≥3; the mass flow controller 22 controls the maximum argon blowing pressure generated by the impermeable bricks 21 to be ≥0.3MPa; and the argon blowing opening is 0~100%.

[0045] Preferably, the furnace chamber 20 is provided with a circular furnace bottom, and the number of impermeable permeable bricks 21 is 4, with 3 impermeable permeable bricks 21 set at the circular furnace bottom and 1 impermeable permeable brick 21 set at the liquid outlet 31.

[0046] In specific implementation, the number of impermeable permeable bricks 21 can be set according to the furnace bottom structure of the furnace chamber 20. In this embodiment, the furnace chamber 20 is provided with a circular furnace bottom, which facilitates the melting of alloy ingots and the rapid purification of the alloy melt. Among them, three impermeable permeable bricks 21 are set in the circular furnace bottom, and one impermeable permeable brick 21 is set in the liquid outlet 31 to prevent incomplete purification of the alloy melt.

[0047] Preferably, the step of monitoring the hydrogen content of the alloy melt in real time using an online hydrogen analyzer 24, and nonlinearly adjusting the argon blowing opening and closing degree of the mass flow controller 22 according to the hydrogen content value includes:

[0048] The online hydrogen analyzer 24 collects hydrogen content data of the alloy melt and sends the hydrogen content data of the alloy melt to the main control terminal 27.

[0049] The hydrogen content of the alloy melt is monitored in real time by an online hydrogen analyzer 24. Based on the hydrogen content value, the nonlinear adjustment of the argon blowing opening and closing degree of the mass flow controller 22 is matched until the hydrogen content value meets the preset conditions.

[0050] The main control terminal 27 receives hydrogen content data of the alloy melt, generates flow control instructions based on the hydrogen content data of the alloy melt, and sends the flow control instructions to the mass flow controller 22; it generates flow control instructions based on the real-time monitored hydrogen content of the alloy melt. Preferably, when the hydrogen content of the melt is greater than or equal to 0.7 ml / 100gAl in the hydrogen content data, the flow control command sent by the master control terminal is: argon blowing flow rate of 10.0–15.0 L / min, and argon blowing opening degree of 50–75%; when the hydrogen content of the melt is less than 0.7 ml / 100gAl but greater than or equal to 0.6 ml / 100gAl in the hydrogen content data, the flow control command sent by the master control terminal is: argon blowing flow rate of 8 L / min, and argon blowing opening degree of 40%; when the hydrogen content of the melt is less than 0.6 ml / 100gAl but greater than or equal to 0.5 ml / 100gAl in the hydrogen content data, the flow control command sent by the master control terminal is: argon blowing flow rate of 6 L / min, and argon blowing opening degree of 30%; when the hydrogen content of the melt is less than 0.5 ml / 100gAl but greater than or equal to 0.4 ml / 100gAl in the hydrogen content data... When the hydrogen content of the melt is less than 0.4 ml / 100gAl but greater than or equal to 0.3 ml / 100gAl, the flow control command sent by the master control terminal is: argon blowing flow rate of 5 L / min and argon blowing opening degree of 25%. When the hydrogen content of the melt is less than 0.3 ml / 100gAl but greater than or equal to 0.2 ml / 100gAl, the flow control command sent by the master control terminal is: argon blowing flow rate of 2.5 L / min and argon blowing opening degree of 12.5%. When the hydrogen content of the melt is less than 0.2 ml / 100gAl, the flow control command sent by the master control terminal is: argon blowing flow rate of 0.1 L / min and argon blowing opening degree of 5%.

[0051] The mass flow controller 22 receives flow control commands and changes the argon blowing opening degree. The argon blowing pressure and flow rate are mainly achieved by the mass flow controller 22 and the pressure regulating device connected to it to meet the requirements of precise flow control under small flow and small adjustment range. The argon flow control value can be set through the main control terminal 27, and the flow value is measured in real time. The set value and the measured value are compared and corrected to achieve the purpose of accurate flow control.

[0052] Please see Figures 1 to 2This invention provides a real-time purification system 10 for large-tonnage light alloy melt, applied to a smelting furnace 23. The system includes an online hydrogen analyzer 24, a bottom argon blowing device 25, an electromagnetic stirring device 26, and a main control terminal 27. The bottom argon blowing device 25 includes an argon gas source 28, a pipeline 29, one or more mass flow controllers 22, and a permeable, impermeable brick 21. The permeable, impermeable brick 21 is located at the bottom of the smelting furnace 23 and communicates with the inner cavity of the furnace. The argon gas source 28, pipeline 29, mass flow controller 22, and permeable, impermeable brick 21 are connected sequentially. The online hydrogen analyzer 24... 4. A device is installed at the outlet 31 of the melting furnace 23 to collect data on the hydrogen content of the alloy melt and send it to the main control terminal 27. The main control terminal 27 receives the hydrogen content data of the alloy melt, generates flow control commands and electromagnetic stirring commands based on the data, and sends the flow control commands to the mass flow controller 22 and the electromagnetic stirring commands to the electromagnetic stirring device 26. The mass flow controller 22 receives the flow control commands and adjusts the argon blowing opening degree. The electromagnetic stirring device 26 is installed at the lower end of the melting furnace 23 to receive electromagnetic stirring commands and adjust the stirring mode according to the commands. The electromagnetic stirring mode of the electromagnetic stirring device 26 can be forward, reverse, strong, weak, automatic, etc. The electromagnetic stirring current of the electromagnetic stirring device 26 is ≤300A. The electromagnetic cooling method of the electromagnetic stirring device 26 can be water cooling.

[0053] Based on the theory of bubble flotation degassing and slag removal and gas-liquid two-phase fluid motion, impermeable permeable bricks 21 are pre-embedded in the bottom of the melting furnace 23. The hydrogen content data of the alloy melt is collected in real time by an online hydrogen analyzer 24. Dispersed, multi-bubble refining argon gas is blown in stages through the online hydrogen analyzer 24, effectively reducing the hydrogen content in the aluminum melt and protecting the liquid surface from oxidation. Simultaneously, an electromagnetic stirrer can be installed at the bottom of the melting furnace 23 to accelerate the heat and mass transfer of the alloy melt, speeding up the chemical reaction rate and improving the purification / homogenization level of the alloy melt before water transfer. Each impermeable permeable brick 21 is equipped with an independent blowing pipe 29, each with a flow meter and a mass flow controller 22. A pressure regulating device is also installed on the main inlet pipe, which can control the pressure and flow rate of the gas blown in by the mass flow controller 22 as needed, thereby achieving better refining results. The mass flow controller 22 can also be a valve that controls the argon blowing flow rate and the opening and closing degree of the argon blowing.

[0054] The real-time purification method for large-tonnage light alloy melts proposed in this invention overcomes the severe oxidation and component loss caused by direct flame radiation to the liquid surface in existing natural gas melting furnaces, thus protecting the liquid surface; it reduces the hydrogen content and inclusions in the alloy melt, achieving refining and eliminating the need for further refining; the dispersed bubbles traversing the alloy melt promote heat and mass convection, achieving component homogenization; and the hydrogen content in different areas can be controlled by a parallel mass flow controller 22. This solves the problems of high element loss rate, high hydrogen content, numerous inclusions, and low production efficiency in the preparation of light alloys using natural gas heating and melting.

[0055] Finally, it should be noted that the above description is merely a preferred embodiment of the invention and is not intended to limit the scope of protection of the invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. A real-time purification system for large-tonnage light alloy melt, applied to a smelting furnace, characterized in that, The large-tonnage light alloy melt real-time purification system includes: an online hydrogen analyzer, a bottom argon blowing device, an electromagnetic stirring device, and a main control terminal; wherein, the bottom argon blowing device includes: an argon gas source, pipelines, one or more mass flow controllers, and impermeable permeable bricks, the impermeable permeable bricks being installed at the bottom of the melting furnace and communicating with the inner cavity of the melting furnace, the argon gas source, pipelines, mass flow controllers, and impermeable permeable bricks being connected sequentially; the online hydrogen analyzer is installed at the outlet of the melting furnace, used to collect hydrogen content data of the alloy melt and purify the hydrogen content of the alloy melt. Hydrogen content data is sent to the main control terminal; the main control terminal is used to receive the hydrogen content data of the alloy melt, generate flow control instructions and electromagnetic stirring instructions based on the hydrogen content data of the alloy melt, and send the flow control instructions to the mass flow controller and the electromagnetic stirring instructions to the electromagnetic stirring device; the mass flow controller is used to receive the flow control instructions and change the argon blowing opening degree; the electromagnetic stirring device is located at the lower end of the melting furnace and is used to receive the electromagnetic stirring instructions and adjust the stirring mode according to the electromagnetic stirring instructions.

2. A method for real-time purification of large-tonnage light alloy melts, applied to the real-time purification system for large-tonnage light alloy melts as described in claim 1, characterized in that, The method includes: The quantity and position of the impermeable permeable bricks are set according to the size of the furnace to form a smelting furnace containing the impermeable permeable bricks, wherein each of the impermeable permeable bricks is matched with a mass flow controller. After the alloy ingot is added to the furnace, the alloy ingot is heated and melted, and the argon blowing opening degree of the mass flow controller is gradually adjusted from low to high according to the liquid level of the alloy melt, wherein the argon blowing opening degree ranges from 0 to 10%. After the alloy ingot is detected to be completely melted, the temperature inside the furnace is controlled and the argon blowing opening degree of the mass flow controller is adjusted to allow the alloy melt to stand still, wherein the argon blowing opening degree is 0-5%; After the alloy melt is allowed to stand, the composition of the alloy melt is monitored by a furnace-front spectrometer. An intermediate alloy ingot is added for correction, and the argon blowing opening degree of the mass flow controller is kept consistent with the argon blowing opening degree when the alloy melt is allowed to stand. After the correction alloy ingot is added, the argon blowing opening degree of the mass flow controller is controlled to be ≥50%, and the argon blowing opening degree is kept stable until the correction alloy ingot melts. After the alloy ingot for correction is melted, the argon blowing opening degree of the mass flow controller is controlled to be consistent with the argon blowing opening degree for the alloy melt to be allowed to stand, and the temperature inside the furnace is controlled to maintain the temperature. The hydrogen content of the alloy melt is monitored in real time by an online hydrogen analyzer. Based on the hydrogen content value, the opening and closing degree of the argon blowing of the mass flow controller is nonlinearly adjusted until the hydrogen content value meets the preset conditions. After the hydrogen content value meets the preset conditions, the argon blowing opening degree of the mass flow controller is adjusted to keep the alloy melt statically heated, wherein the argon blowing opening degree is 0 to 5%.

3. The method for real-time purification of large-tonnage light alloy melts according to claim 2, characterized in that, After the alloy ingot is detected to be completely melted, the temperature inside the furnace is controlled and the argon blowing opening degree of the mass flow controller is adjusted to allow the alloy melt to settle. The step of setting the argon blowing opening degree to 0-5% includes: After the alloy ingot is detected to be completely melted, the temperature inside the furnace is controlled and maintained, and the mass flow controller is adjusted to a specific argon blowing opening degree to allow the alloy melt to stand still. The argon blowing opening degree is 0 to 5%.

4. The method for real-time purification of large-tonnage light alloy melts according to claim 2, characterized in that, The online hydrogen analyzer has a hydrogen content measurement range of 0–0.99 ml / 100g Al, a hydrogen measurement resolution of 0.01 ml / 100g Al, a correction error of ≤5%, and a monitoring equilibrium time of ≤5 min.

5. The method for real-time purification of large-tonnage light alloy melts according to claim 2, characterized in that, The number of impermeable permeable bricks is ≥3, and the maximum argon blowing pressure generated by the impermeable permeable bricks is ≥0.3MPa and the argon blowing opening degree is 0~100%.

6. The method for real-time purification of large-tonnage light alloy melts according to claim 2, characterized in that, The furnace chamber is provided with a circular furnace bottom, and the number of the impermeable air-permeable bricks is 4, with 3 of the impermeable air-permeable bricks placed at the circular furnace bottom and 1 of the impermeable air-permeable bricks placed at the liquid outlet.

7. The method for real-time purification of large-tonnage light alloy melts according to claim 2, characterized in that, The steps include: real-time monitoring of the hydrogen content in the alloy melt using an online hydrogen analyzer; and non-linear adjustment of the argon blowing opening and closing degree of the mass flow controller based on the hydrogen content value. The online hydrogen analyzer collects hydrogen content data of the alloy melt and sends the hydrogen content data of the alloy melt to the main control terminal; The main control terminal receives the hydrogen content data of the alloy melt, generates a flow control command based on the hydrogen content data of the alloy melt, and sends the flow control command to the mass flow controller. The mass flow controller receives the flow control command and changes the argon blowing opening degree of the mass flow controller.

8. The method for real-time purification of large-tonnage light alloy melts according to claim 7, characterized in that, When the hydrogen content of the melt is greater than or equal to 0.7 ml / 100 g Al in the hydrogen content data, the flow control command sent by the main control terminal is: argon blowing flow rate of 10.0 to 15.0 L / min, and argon blowing opening degree of 50 to 75%; When the hydrogen content of the melt is less than 0.7 ml / 100gAl and greater than or equal to 0.6 ml / 100gAl in the hydrogen content data, the flow control command sent by the main control terminal is: argon blowing flow rate is 8 L / min, and argon blowing opening degree is 40%; When the hydrogen content of the melt is less than 0.6 ml / 100gAl and greater than or equal to 0.5 ml / 100gAl in the hydrogen content data, the flow control command sent by the main control terminal is: argon blowing flow rate is 6 L / min, and argon blowing opening degree is 30%; When the hydrogen content of the melt is less than 0.5 ml / 100gAl and greater than or equal to 0.4 ml / 100gAl in the hydrogen content data, the flow control command sent by the main control terminal is: argon blowing flow rate is 5 L / min, and argon blowing opening degree is 25%; When the hydrogen content of the melt is less than 0.4 ml / 100gAl and greater than or equal to 0.3 ml / 100gAl in the hydrogen content data, the flow control command sent by the main control terminal is: argon blowing flow rate is 4 L / min, and argon blowing opening degree is 20%; When the hydrogen content of the melt is less than 0.3 ml / 100gAl and greater than or equal to 0.2 ml / 100gAl in the hydrogen content data, the flow control command sent by the main control terminal is: argon blowing flow rate is 2.5 L / min, and argon blowing opening degree is 12.5%; When the hydrogen content of the melt is less than 0.2 ml / 100 g Al in the hydrogen content data, the flow control command sent by the main control terminal is: argon blowing flow rate is 0.1 L / min, and argon blowing opening degree is 5%.

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