System and method for steam condensation in aluminum direct quench casting pits

Abstract

A direct chilling (DC) casting system can be used to cast metal ingots from molten metal, such as aluminum or an aluminum alloy. The DC casting system includes a steam condensation system that condenses steam generated during the DC casting process into recycled water. The recycled water can be used for subsequent cooling of the metal ingot during the DC casting process.

Description

[0001] Citation of Related Applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 367,061, filed on June 27, 2022, entitled “SYSTEMS AND METHODS FOR STEAM CONDENSATION IN ALUMINUM DIRECT CHILL CASTING PIT,” the contents of which are hereby incorporated by reference in their entirety. Technical Field

[0003] The present application relates generally to metalworking and more particularly to steam generating metalworking such as, but not limited to, direct chill casting. Background Art

[0004] Steam may be generated during various metalworking processes. As an example, a casting process such as direct chill (DC) casting may generate steam when the system directs water to the ingot being cast for the purpose of cooling the ingot. Some water may not become steam during this treatment, and this water in liquid form can be cooled again by the cooling system and reused during the casting process. During the cooling of the ingot, other water may become steam. In the casting pit, this steam may pose a safety hazard by reducing visibility before it is traditionally discharged to the environment. Steam may also rise out of the casting pit and re-condense on the equipment around the casting pit and / or above the molten metal, which may reduce the life cycle of the equipment and potentially cause product defects on the head of the ingot. New water or make-up water must be introduced into the system regularly to compensate for the water lost as steam. From both a financial perspective and a resource perspective, this new water or make-up water demand is expensive. Summary of the invention

[0005] The embodiments covered by this patent are defined by the following claims rather than by this summary. This summary is a high-level summary of various embodiments and introduces some concepts that will be further described in the following detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. This subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all of the drawings, and each claim.

[0006] According to various embodiments, a metalworking system for treating a metal substrate includes a steam condensation system for condensing steam generated during metalworking of the metal substrate.

[0007] According to certain embodiments, a DC casting system includes a steam condensation system for condensing steam generated during a DC casting process.

[0008] According to some embodiments, a DC casting system includes a cooling system for at least partially cooling a metal ingot during a DC casting process. In certain embodiments, the cooling system can cool the metal ingot by directing water from a coolant supply onto the metal ingot. The cooling system can include a steam condensation system for condensing steam generated during the DC casting process.

[0009] According to various embodiments, a method of DC casting a metal ingot includes: cooling the metal ingot by directing water from a coolant supply source onto the metal ingot ejected from a mold; and condensing steam generated by cooling the metal ingot into recirculating water. The method includes providing recirculating water to the coolant supply source.

[0010] According to certain embodiments, a metalworking system for treating a metal substrate includes a steam condensation system for directing a flow of steam by spraying water relative to a direction of the steam flow generated during metalworking of the metal substrate.

[0011] The various embodiments described herein may include additional systems, methods, features, and advantages that may not necessarily be explicitly disclosed herein but will be apparent to one of ordinary skill in the art after reviewing the following detailed description and the accompanying drawings. It is intended that all such systems, methods, features, and advantages should be included in this disclosure and protected by the following claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] This description refers to the following drawings, in which the same reference numerals are used in different drawings to indicate the same or similar components.

[0013] Figure 1 is a block diagram of a metal processing system having a steam condensation system according to an embodiment.

[0014] Figure 2 A steam condensation system according to an embodiment is shown.

[0015] Figure 3 A steam condensation system according to an embodiment is shown.

[0016] Figure 4 A steam condensation system according to an embodiment is shown. DETAILED DESCRIPTION

[0017] Described herein are systems and methods for condensing steam produced by metal processing systems (such as but not limited to casting systems, such as DC casting systems). The systems and methods described herein can condense steam into recirculating water, and in some embodiments, the recirculating water can be returned to the cooling system of the metal processing system so that the recirculating water can be used for cooling of the metal substrate. The systems and methods described herein can reduce the amount of water conventionally lost to the environment, thereby reducing the amount of new water or supplementary water that needs to be introduced into the system. Thus, compared with conventional metal processing systems that discharge any steam produced as a byproduct of metal processing, the systems and methods provided herein are less expensive and less resource-intensive. The systems and methods described herein can also return the recirculating water back to the cooling system of the metal casting system, thereby allowing the recirculating water to be used as a coolant during the casting process. Various other benefits and advantages can be achieved using the systems and methods provided herein, and the above advantages should not be considered to be limiting.

[0018] Figure 1 A metal processing system 100 is shown according to various embodiments. The metal processing system 100 includes one or more metal processing stations 102, a cooling system 104, and a steam condensation system 106.

[0019] The cooling system 104 provides a coolant, such as liquid water, to the metal processing station 102 (indicated by arrow 108). The metal processing station 102 may be various metal processing devices, stations, workstations, etc. that utilize water from the cooling system 104 to cool metal substrates, as desired. The metal processing performed by the metal processing station 102 may generate steam (indicated by arrow 110), and the steam condensation system 106 condenses the steam into recirculating water. Optionally, and as indicated by arrow 112, the steam condensation system 106 may provide the recirculating water back to the cooling system 104 so that the recirculating water may be supplied to the metal processing station 102 as liquid water. The steam condensation system 106 may be various systems and devices for condensing steam from the metal processing station 102, and non-limiting examples of steam condensation systems are discussed in detail below and in Figures 2 to 4 Shown in.

[0020] Figure 2 A non-limiting example is shown in which the metal processing station 102 is a DC casting system 214. Figure 2As shown, the DC casting system 214 generally includes a casting pit having at least one open-ended mold 216, which defines a casting cavity, and molten metal can be introduced into the casting cavity, as indicated by arrow 218. The mold 216 is initially closed at the lower end by a bottom block 220, and the bottom block 220 remains in place until a certain amount of molten metal has accumulated in the casting cavity and begins to cool. The bottom block 220 is then moved away from the mold 216 so that an ingot 222 gradually escapes from the lower end of the mold 216. By the movement of the bottom block 220 and the corresponding continuous supply of molten aluminum to the mold 216, the ingot 222 can be produced to have a desired length, limited only by the space available below the mold 216.

[0021] In various embodiments, the cooling system 104 can be in fluid communication with the mold 216 for supplying water or other coolants to the mold 216. The mold walls are typically cooled to provide cooling of the metal within the casting cavity. The ingot 222 that emerges from the lower end of the mold 216 in DC casting is solid on the outside, but is still molten in its central core. In order to maintain the periphery of the ingot and promote internal cooling and solidification of the ingot, a coolant such as water 224 is applied directly to the surface 225 of the ingot 222 emerging from the mold 216. In this procedure, the water 224 is directed onto the ingot surface 225. Some of the water 224 flows downward over the ingot surface 225, and the remaining water becomes steam 226. As previously mentioned, the steam 226 generated by DC casting is conventionally discharged to the environment.

[0022] like Figure 2 As shown, a steam condensation system 206 is provided for processing steam 226. Figure 2 In the embodiment shown in , the steam condensation system 206 includes one or more nozzles or sprayers 228. The sprayers 228 are configured to spray water 230 into the casting pit for interaction with the steam 226, which in turn causes the steam 226 to condense into recirculating water (indicated by arrow 232). In some embodiments, the sprayers 228 can spray the water 230 in various forms. In one non-limiting example, the sprayers 228 optionally spray the water 240 as fine droplets, although in other embodiments, the sprayers 228 can introduce the water 230 into the casting pit for interaction with the steam 226 as desired. The sprayers 228 can be various types of nozzles as desired, and can introduce the water 230 in various spray patterns as desired. As two non-limiting examples, the sprayers 228 can be nozzles that introduce the water 230 in a flat spray pattern, a hollow cone spray pattern, a full cone spray pattern, and / or other patterns as desired.

[0023] In addition to various types of nozzles as needed, the number and position of the sprinklers 228 should not be considered limiting, because the steam condensation system 206 can include any number of sprinklers 228 in various locations as needed. In certain embodiments, one or more of the type of nozzle, the position of the nozzle, and the number of nozzles can be controlled to control the rate and / or condensation amount of the condensation of the steam 226. Additionally or alternatively, other control parameters of the sprinklers 228 can be controlled to control the rate and / or condensation amount of the condensation of the steam 226, including but not limited to the pressure of the water 230, the flow rate of the water 230 to the sprinklers 228, the temperature of the distributed water 230, their combination, and / or other control parameters as needed. As the conditions for steam generation change, the control parameters can also be controlled and / or changed during the casting process. As a non-limiting example, the casting process can start with a low water flow, move to a high water flow, and then have a reduced water flow during the casting process.

[0024] As mentioned, the water 230 distributed by the sprinkler 228 in turn causes the steam 226 to be condensed into recirculating water 232 (e.g., in liquid form). The water 232 can be collected using various devices, mechanisms, or techniques as needed (including, but not limited to, various collection boxes 234, drains, suction devices, etc. as needed). The collected recirculating water 232 can optionally be returned to the cooling system 204 so that the recirculating water 232 can be cooled again (if necessary) and / or further processed as needed. This water 232 can then be supplied to the DC casting system 214 for cooling the ingot 222 and / or for use by the sprinkler 228. As mentioned, by condensing the steam 226 generated by metal processing (e.g., DC casting), the system is able to reuse the recirculating water 232 for subsequent cooling, thereby providing cost savings and resource savings.

[0025] Figure 3 Another example of a steam condensation system 306 for a metal processing system according to an embodiment is shown. In one non-limiting example, the steam condensation system 306 can be used with the DC casting system 214 instead of or in addition to the steam condensation system 206. Figure 3 In the embodiment of the present invention, the steam condensation system 306 includes a conduit 336, and the steam 226 is condensed into recirculating water within the conduit 336.

[0026] In certain embodiments, and as Figure 3As shown, the conduit 336 includes one or more inlets 338. In some embodiments, the conduit 336 can be elongated between opposite ends 342, 344, and the one or more inlets 338 can be disposed on a sidewall 346 between the ends 342, 344. As indicated by arrows 348, the steam 226 can enter the conduit 336 via the one or more inlets 338. The conduit 336 also includes one or more fluid outlets 356 for discharging the recirculated water 232 after the steam 226 has been condensed within the conduit 336.

[0027] The steam condensation system 306 includes one or more devices or mechanisms for condensing the steam 226 within the interior region 352 of the conduit 336 .

[0028] In some embodiments, and as Figure 3 As shown, the steam condensation system 306 includes one or more of the sprinklers 228 for spraying water 230 onto the steam 226 within the interior region 352. In certain embodiments, the sprinklers 228 are within the interior region 352 of the conduit 336; however, in other embodiments, the sprinklers 228 need not be within the interior region 352, and the sprinklers 228 can introduce the water 230 into the interior region 352. The number, type, and location of the sprinklers 228 within and / or relative to the conduit 336 should not be considered limiting.

[0029] In some embodiments, the sprinkler 228 and / or nozzle can be controlled so that water 230 is directed in all directions relative to steam and / or air flow. In such an embodiment, the sprinkler 228 can also be used to help control the direction of steam and / or air flow. As a non-limiting example, the sprinkler 228 and / or nozzle can be controlled so that water 230 is parallel to steam and / or air flow, relative to steam and / or air flow at a non-zero angle, relative to steam and / or air flow in the lateral flow direction, their combination and / or additionally guided as needed (for example, in droplet form or other desired forms). In certain embodiments, the angle or orientation of the sprinkler 228 and / or nozzle can be adjustable so that the angle (and therefore the ability to control steam and / or air flow) of the water 230 from the sprinkler 228 and / or nozzle can be adjusted as needed. This control can be automatically realized (for example, using a controller (processor and / or memory) coupled to the sprinkler 228 and / or other actuators as needed) and / or realized by an operator.

[0030] Additionally or alternatively, the steam condensation system 306 optionally includes one or more cooler conduits 354 within the interior region 352. A coolant, such as chilled water, may be directed through the cooler conduits 354 to reduce the temperature within the interior region 352, thereby causing condensation of the steam 226. As another non-limiting example, a chilled gas, such as, but not limited to, chilled air, may be used as a coolant. Other devices, materials, and / or mechanisms for condensing the steam 226 within the interior region 352 may be utilized as desired.

[0031] Similar to the steam condensation system 206 , after the steam 226 has been condensed into the recirculating water 232 by the steam condensation system 306 , the recirculating water 232 may optionally be provided to a cooling system before being used as part of cooling during metal processing.

[0032] In some embodiments, the conduit 336 may optionally include one or more suction devices (such as air movers 350) for generating a suction force to draw the steam 226 into the conduit 336. As a non-limiting example, the air mover 350 may be a blower or fan that pulls the air and steam 226 into the conduit 336. In the illustrated embodiment, the steam condensation system 306 includes two air movers 350 disposed at opposite ends 342, 344 of the conduit 336. However, in other embodiments, the steam condensation system 306 may include any number of air movers as desired, including omitting an air mover 350, a single air mover 350, or more than two air movers 350. One or more air movers 350 may be disposed in any suitable location.

[0033] Figure 4 Another example of a steam condensation system 406 for a metal processing system according to an embodiment is shown. Similar to the steam condensation system 306, the steam condensation system 406 includes a conduit 436. The steam 226 can be directed into the conduit 436 (indicated by arrow 458), where the steam 226 is condensed into recirculating water. In some embodiments, similar to the steam condensation system 306, the steam condensation system 406 can include one or more air movers 350 for generating a suction force to draw the steam 226 into the conduit 436.

[0034] Compared to the steam condensation system 306 having an internal cooling device or mechanism for condensing steam, the steam condensation system 406 includes one or more cooling devices or mechanisms on the outer surface 460 of the conduit 436 for cooling the temperature of the conduit 436. The external cooling device or mechanism can be various suitable devices or mechanisms as needed.

[0035] refer to Figure 4In some embodiments, a process gas line or conduit 462 for the metal processing system can be disposed on the outer surface 460 for cooling the conduit 436. In certain embodiments, because the process gas can be provided at a lower temperature, the conduit 462 can have a reduced temperature, and thus, placing the conduit 462 in contact with the conduit 436 can provide cooling of the conduit 436. The process gas line 462 can be a variety of process gas lines as desired and can depend on the specific metal processing system. Non-limiting examples of the process gas line 462 can be one or more of an argon gas line, a nitrogen gas line, a carbon dioxide gas line, a chlorine gas line, combinations thereof, and / or other process gas lines 462 as desired.

[0036] In addition to or in lieu of the process gas line 462, the conduit 436 may include one or more heat exchanger fins 464 along the conduit 436. In some embodiments, the heat exchanger fins 464 may be circular fins on the conduit 436, and may optionally be disposed along the length of the conduit 436. However, in other embodiments, the heat exchanger fins 464 may have other shapes or profiles as desired, and the heat exchanger fins 464 may be disposed along the conduit 436 as desired. In other embodiments, other devices or mechanisms suitable for externally cooling the conduit 436 may be used as desired.

[0037] The external cooling device of the steam condensing system 406 cools the conduit 436, thereby reducing the temperature of the area inside the conduit 436. This reduction in temperature can cause the steam 226 to condense into recirculating water within the conduit. The steam 226 condensed into recirculating water can be optionally stored in the storage tank 434 before being directed to the cooling system or otherwise as needed (indicated by arrow 466).

[0038] Although the steam condensation systems 206, 306, 406 are shown separately, in various embodiments, the metal processing system may employ two or more condensation systems. Figure 2 , the DC casting system 214 can utilize both the steam condensation system 206 and the steam condensation 306, and / or can utilize all of the steam condensation systems 206, 306, 406. Various other combinations or sub-combinations of steam condensation systems can be utilized as desired. Moreover, in other embodiments, other steam condensation systems can be used in addition to or in place of the steam condensation systems 206, 306, 406.

[0039] Return to reference Figure 1, a method of processing a metal substrate using a metal processing system 100 having a steam condensation system 106 includes providing water to a metal processing station 102 for a cooling process. In one non-limiting example, providing water to the metal processing station 102 may include providing water to a DC casting system 214 and cooling a metal ingot 222 ejected from a mold 216 by directing the water onto the metal ingot 222.

[0040] The method includes condensing steam generated by the cooling process into recirculating water using a steam condensation system 106. In some embodiments, condensing the steam may include spraying water into the steam. In certain embodiments, condensing the steam may include drawing the steam into a conduit and condensing the steam using an internal cooling device and / or an external cooling device. Non-limiting examples of internal cooling devices may include sprinklers and / or cooler conduits, and non-limiting examples of external cooling devices may include process gas lines and / or heat exchanger fins.

[0041] In certain embodiments, the method optionally includes providing recycled water from the steam condensation system 106 to the cooling system 104. The method optionally includes using the cooling system 104 or another system as needed to cool and / or otherwise treat the recycled water again. The method includes providing the recycled water from the cooling system 104 to the metal processing station 102 for use in the cooling process.

[0042] A collection of exemplary embodiments is provided below, including at least some embodiments that are explicitly listed as "examples" that provide additional descriptions of various exemplary embodiments according to the concepts described herein. These examples are not meant to be mutually exclusive, exhaustive, or limiting; and the present disclosure is not limited to these exemplary examples, but covers all possible modifications and variations within the scope of the claims set forth and their equivalents.

[0043] Example 1. A DC casting system for casting a metal ingot, the DC casting system comprising a steam condensation system for condensing steam generated during the DC casting process.

[0044] Example 2. The DC casting system of any preceding or subsequent example or combination of examples, wherein the steam condensation system comprises a plurality of sprayers configured to spray water inside a casting pit of the DC casting system.

[0045] Example 3. The DC casting system of any preceding or subsequent example or combination of examples, wherein the plurality of sprayers comprises a plurality of nozzles.

[0046] Example 4. The DC casting system of any preceding or subsequent example or combination of examples, wherein the plurality of sprayers are configured to control the direction of steam flow and / or air flow by spraying the water inside the casting pit.

[0047] Example 5. The DC casting system of any preceding or subsequent example or combination of examples, wherein the plurality of sprayers are adjustable such that the direction of steam flow and / or air flow can be adjusted by spraying the water inside the casting pit.

[0048] Example 6. A DC casting system as described in any preceding or subsequent example or combination of examples, wherein the steam condensation system comprises: a conduit comprising at least one inlet and at least one outlet and configured to receive the steam; a suction device configured to generate a suction force for pulling the steam into the conduit through the at least one inlet; and at least one sprinkler in the conduit, the at least one sprinkler being used to spray water in the conduit.

[0049] Example 7. A DC casting system as described in any preceding or subsequent example or combination of examples, wherein the conduit includes a first end, a second end, and a side wall extending from the first end to the second end, wherein the suction device is disposed on the first end, and wherein the at least one inlet and the at least one outlet are disposed on the side wall of the conduit.

[0050] Example 8. A DC casting system as described in any preceding or subsequent example or combination of examples, wherein the suction device is a first suction device, and wherein the steam condensation system also includes a second suction device on the second end of the conduit for pulling the steam into the conduit.

[0051] Example 9. The DC casting system of any preceding or subsequent example or combination of examples, wherein the steam condensation system includes a conduit for receiving the steam and a cooling device on an outer surface of the conduit for cooling the conduit.

[0052] Example 10. The DC casting system of any preceding or following example or combination of examples, wherein the cooling device comprises at least one of a process gas line or a plurality of heat exchanger fins for the DC casting process.

[0053] Example 11. A DC casting system for casting a metal ingot, the DC casting system comprising a cooling system configured to at least partially cool the metal ingot by directing water from a coolant supply source onto the metal ingot during the DC casting process, the cooling system also comprising a steam condensation system for condensing steam generated during the DC casting process.

[0054] Example 12. The DC casting system of any preceding or subsequent example or combination of examples, wherein the steam condensation system is configured to condense steam generated by cooling the metal ingot into recirculating water and provide the recirculating water to the coolant supply source.

[0055] Example 13. The DC casting system of any preceding or subsequent example or combination of examples, wherein the steam condensation system includes a sprayer configured to spray water to condense the steam.

[0056] Example 14. The DC casting system of any preceding or subsequent example or combination of examples, wherein the steam condensation system further comprises a conduit and a suction device for drawing steam into the conduit, and wherein the sprayer is within the conduit.

[0057] Example 15. The DC casting system of any preceding or following example or combination of examples, wherein the steam condensation system comprises a conduit for receiving the steam and a cooling device for causing condensation of the steam into recirculating water.

[0058] Example 16. The DC casting system of any preceding or subsequent example or combination of examples, wherein the cooling device is at least one sprinkler in the conduit, the at least one sprinkler configured to spray water for condensing the steam into recirculating water.

[0059] Example 17. The DC casting system of any preceding or following example or combination of examples, wherein the cooling device is on an outer surface of the conduit and is configured to cool the conduit.

[0060] Example 18. The DC casting system of any preceding or following example or combination of examples, wherein the cooling device comprises at least one of a process gas line or a plurality of heat exchanger fins for the DC casting process.

[0061] Example 19. A method for DC casting a metal ingot, the method comprising: cooling the metal ingot by directing water from a coolant supply source onto the metal ingot ejected from a mold; condensing steam generated by cooling the metal ingot into recycled water; and providing the recycled water to the coolant supply source.

[0062] Example 20. The method of any preceding or subsequent example or combination of examples, wherein condensing the steam comprises spraying water into the steam.

[0063] Example 21. The method of any preceding or following example or combination of examples, wherein condensing the steam comprises directing the steam into a conduit and condensing the steam within the conduit using a cooling device.

[0064] Example 22. The method of any preceding or subsequent example or combination of examples, wherein the cooling device comprises a sprinkler within the conduit, and wherein condensing the steam comprises spraying water into the steam within the conduit.

[0065] Example 23. The method of any preceding or subsequent example or combination of examples, wherein the cooling device is on an outer surface of the conduit, and wherein condensing the steam includes cooling the conduit using the cooling device.

[0066] Example 24. The method of any preceding or following example or combination of examples, wherein the cooling device comprises at least one of a process gas line or a plurality of heat exchanger fins for the DC casting process.

[0067] Example 25. A metal processing system for treating a metal substrate, the metal processing system comprising a steam condensation system for condensing steam generated during metal processing of the metal substrate.

[0068] Example 26. The metal processing system of any preceding or following example or combination of examples, wherein the metal processing system comprises a casting system for producing a metal ingot from a molten metal.

[0069] Example 27. The metalworking system of any preceding or following example or combination of examples, wherein the casting system is a direct chill (DC) casting system.

[0070] Example 28. A metal processing system as described in any preceding or subsequent example or combination of examples, further comprising a cooling system for distributing water to the metal substrate during metal processing, wherein the steam condensation system is configured to condense the steam into recirculating water and return the recirculating water to the cooling system.

[0071] Example 29. The metalworking system of any preceding or subsequent example or combination of examples, wherein the steam condensation system comprises a plurality of sprinklers configured to spray water in a steam generating region of the metalworking system.

[0072] Example 30. A metal processing system as described in any preceding or subsequent example or combination of examples, wherein the steam condensation system comprises: a conduit comprising at least one inlet and at least one outlet and configured to receive the steam; a suction device configured to generate a suction force for pulling the steam into the conduit through the at least one inlet; and at least one sprinkler in the conduit, the at least one sprinkler being used to spray water in the conduit.

[0073] Example 31. The metalworking system of any preceding or subsequent example or combination of examples, wherein the steam condensation system includes a conduit for receiving the steam and a cooling device on an outer surface of the conduit for cooling the conduit.

[0074] Example 32. The metalworking system of any preceding or following example or combination of examples, wherein the cooling device comprises at least one of a process gas line or a plurality of heat exchanger fins for the DC casting process.

[0075] Example 33. A metal processing system for treating a metal substrate, the metal processing system comprising a steam condensation system for directing a flow of steam by spraying water relative to a direction of the flow of steam generated during metal processing of the metal substrate.

[0076] Example 34. The metalworking system of any preceding or following example or combination of examples, wherein the metalworking system is a direct chill (DC) casting system.

[0077] Example 25. The metalworking system of any preceding or subsequent example or combination of examples, wherein the steam condensation system is configured to spray water parallel to the direction of the steam flow or in a lateral direction relative to the direction of the steam flow.

[0078] Example 36. A metal processing system as described in any preceding or subsequent example or combination of examples, wherein the steam condensation system is adjustable so that the direction of water sprayed by the steam condensation system is adjustable relative to the direction of the steam flow.

[0079] The subject matter of the embodiment is specifically described herein to meet the statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The required subject matter can be embodied in other ways, can include different elements or steps, and can be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any specific order or arrangement among or between various steps or elements, but except when the order of each step or element arrangement is clearly described. Directional references such as "upwards", "downwards", "top", "bottom", "left side", "right side", "front" and "rear" are intended to refer to the orientation shown and described in one (or more) figures referring to parts and directions. In the drawings and descriptions, the same reference numerals are intended to represent the same elements. As used herein, unless the context clearly indicates otherwise, the meaning of "one / kind (a)", "one / kind (an)" and "the / said (the)" includes singular and plural references.

[0080] The above-mentioned various aspects are only possible examples of implementation, which are only set forth for a clear understanding of the principles of the present disclosure. Without departing substantially from the spirit and principles of the present disclosure, many changes and modifications may be made to the above-mentioned one or more embodiments. All such modifications and changes are intended to be included in the scope of the present disclosure herein, and all possible claims for various aspects or combinations of elements or steps are intended to be supported by the present disclosure. In addition, although specific terms are used herein and in the appended claims, these specific terms are used only in a general and descriptive sense and are not used to limit the described embodiments nor the purpose of limiting the appended claims.

Claims

1. A direct chill (DC) casting system for casting a metal ingot, the DC casting system comprising a steam condensing system for condensing steam generated during the DC casting process into recirculating water.

2. The DC casting system of claim 1, wherein the steam condensation system comprises a plurality of sprinklers configured to spray water inside a casting pit of the DC casting system.

3. The DC casting system of claim 2, wherein the plurality of sprayers comprises a plurality of nozzles.

4. The DC casting system of claim 2, wherein the plurality of sprinklers are configured to control a direction of a steam flow and / or an air flow by spraying the water inside the casting pit.

5. The DC casting system of claim 4, wherein the plurality of sprayers are adjustable such that the direction of steam flow and / or air flow can be adjusted by spraying the water inside the casting pit.

6. The DC casting system of claim 1, wherein the steam condensation system comprises: a conduit comprising at least one inlet and at least one outlet and configured to receive the steam; a suction device configured to generate a suction force for drawing the steam into the conduit through the at least one inlet; as well as At least one sprinkler in the conduit, the at least one sprinkler for spraying water in the conduit.

7. The DC casting system of claim 6, wherein the conduit comprises a first end, a second end, and a side wall extending from the first end to the second end, wherein the suction device is disposed at the first end, and wherein the at least one inlet and the at least one outlet are disposed on the side wall of the conduit.

8. The DC casting system of claim 1, wherein the steam condensation system comprises a conduit for receiving the steam and a cooling device on an outer surface of the conduit for cooling the conduit.

9. The DC casting system of claim 8, wherein the cooling device comprises at least one of a process gas line or a plurality of heat exchanger fins for the DC casting process.

10. The DC casting system of claim 1 further comprising means for directing the recirculating water back to the DC casting process and / or for use in other processing steps of the metal ingot.

11. A method for direct chill (DC) casting of a metal ingot, the method comprising: cooling the metal ingot by directing water from a coolant supply onto the metal ingot as it emerges from the mold; condensing steam generated by cooling the metal ingot into recirculating water; and The recirculating water is provided to the coolant supply.

12. The method of claim 11, wherein condensing the steam comprises spraying water into the steam.

13. The method of claim 11, wherein condensing the steam comprises directing the steam into a conduit and condensing the steam within the conduit using a cooling device.

14. The method of claim 13, wherein the cooling device comprises at least one of: a sprinkler within the conduit, and wherein condensing the steam comprises spraying water into the steam within the conduit; or A cooling device is provided on an outer surface of the conduit, and wherein condensing the steam comprises cooling the conduit using the cooling device.

15. A metal processing system for treating a metal substrate, the metal processing system comprising a steam condensation system for directing a flow of steam by spraying water relative to a direction of the flow of steam generated during metal processing of the metal substrate.

16. The metal processing system of claim 15, wherein the metal processing system is a direct chill (DC) casting system for producing metal ingots from molten metal.

17. The metalworking system of claim 15, wherein the steam condensation system is configured to spray water parallel to the direction of the steam flow or in a lateral direction relative to the direction of the steam flow.

18. The metalworking system of claim 15, wherein the steam condensation system is adjustable such that the direction of water sprayed by the steam condensation system is adjustable relative to the direction of the steam flow.

19. The metal processing system of claim 15, wherein the vapor condensation system is further configured to condense vapor generated during metal processing of the metal substrate.

20. The metalworking system of claim 15, wherein the steam condensation system comprises a plurality of sprayers configured to spray water in a steam generating area of ​​the metalworking system.

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