Continuous casting spray water performance monitoring and water control chemistry

Abstract

A method of analyzing water in a continuous casting process and controlling chemical addition to the water may involve measuring, with a plurality of sensors, at least one characteristic of the water in a plurality of different locations of a water circulation system for the continuous casting process. The continuous casting process may have a plurality of nozzles that spray water onto the metal being cast, and the water circulation system may include a gravity settling tank, a filter, and a cooling tower. A processor may use the measured at least one characteristic of the water from the plurality of sensors to determine a composite water mass value for the water in the water circulation system. Chemical additives may be controllably added to the water circulation system based on the determined composite water mass value.

Description

[0001] Related Applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 358,418, filed on July 5, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to metal casting, and more particularly to water circulation systems for metal casting operations. Background Art

[0004] Continuous casting is a method of converting molten metal into semi-finished metal products such as billets, blooms or slabs, and can be used for mass and continuous production. The method is commonly used to form steel, but can also be used to form other metals, such as aluminum and copper. Typically in continuous casting, the molten metal is collected in a trough called a tundish and then enters a primary cooling zone. In the primary cooling zone, the molten metal enters a solid mold that is usually cooled with water. The solid mold absorbs heat from the molten metal, resulting in the formation of a solid "skin" of metal around the still liquid core. The solid coating of the liquid metal is called a cast billet. The cast billet then enters a secondary cooling zone, in which water is sprayed directly onto the metal cast billet to further cool the metal.

[0005] Water used as a heat transfer medium to cool the metal being cast is often collected and reused to limit the amount of water consumed in the casting process. The water may be collected after direct or indirect contact with the hot metal and passed through a cooling tower which cools the water by evaporative cooling before being reused in the casting process.

[0006] In practice, water collected from the casting process may contain contaminants, such as corrosive compounds and particles, which are released from the metal being cast when the spray water comes into direct contact with the hot metal. Over time, these contaminants may accumulate in the water system, causing water-related problems for the casting process. Summary of the invention

[0007] Generally speaking, the present disclosure relates to systems and techniques for casting metals, and more specifically to systems and techniques for analyzing water used in a continuous casting process and / or controlling the chemical composition added to water used in a continuous casting process. In some specific implementations, a system according to the present disclosure includes: a continuous casting machine that sprays water directly onto the metal being cast; and a water circulation system that collects the water for recycling and reuse after the water is sprayed onto the hot metal. The water circulation system can treat the collected water by gravity settling, filtration, evaporative cooling, and / or other treatment steps before conveying the recycled water back to the continuous casting machine to be sprayed again onto another portion of the hot metal being cast.

[0008] In practice, it may be difficult for operators of continuous casting water systems to assess the quality of water in the water circulation system to detect and respond to incipient problems. Operators may lack insight into the characteristics of the water in the water circulation system and / or may lack an understanding of how discrete water measurements affect the overall quality and efficacy of the water circulation system. In addition, since the composition of water may change as the water moves through different stages of the water circulation system, it may be challenging to assess how a water measurement made in one part of the water circulation compares to another water measurement made in another part of the water circulation system to evaluate and implement corresponding control actions.

[0009] According to some examples of the present disclosure, a water analysis and chemical control system for a continuous casting process is described, the system including a plurality of sensors arranged at different positions in a water circulation system to measure one or more characteristics of water at each position in the circulation system. For example, the system may include one or more sensors located upstream of a cooling tower in the water circulation system and one or more sensors located downstream of a cooling tower in the water circulation system. Each sensor in the system may measure one or more characteristics of water, which indicates the quality of the water, with different sensors measuring the same characteristics or different sensors measuring different characteristics. In either case, the system may aggregate water measurement data obtained from different sources at different locations and on the system to determine a composite water quality value. The composite water quality value may provide a single value indicating the overall quality or health of the water in the water circulation system. The system may then use the composite water quality value to control the addition of one or more chemical additives to the water in the water circulation system. Chemical additives may maintain or improve the quality of water that is circulated and reused in the water circulation system.

[0010] The system can aggregate water measurement data obtained from different locations and / or different sources in a variety of different ways to determine a composite water quality value. In some examples, the system applies a weighting factor to each water measurement result measured by each different sensor in the system. The weighting factor can be different for different water measurements. Therefore, a water measurement made at one location of the water circulation system can be given greater importance in assessing the overall quality of the water in the system than a water measurement made at another location. A specific weighting factor can be assigned based on the type of water characteristic measured, the location of the measurement, and / or other factors indicating water quality and the corresponding impact on the water circulation system.

[0011] By determining a composite water quality value from multiple different sources and locations that provide individualized measurements indicating water quality, an easily monitorable and comparable metric can be provided to an operator for evaluating the overall quality of water in a water circulation system for a continuous casting process. This can eliminate the complexity and uncertainty associated with attempting to evaluate multiple different water measurements in a water circulation system, which may appear unrelated and / or appear to be providing contradictory water quality information to an operator. This can allow an operator to take more consistent and predictable actions to control the water in the water circulation system, for example, by introducing fresh or supplemental water into the system and / or by introducing one or more chemical additives into the system to help control the performance of the water. In some specific implementations, the system is implemented to automatically control the water in the water circulation system (e.g., by controlling chemical additions to the water) in response to a composite water quality value, which is determined by the system using measurements made by multiple sensors arranged throughout the water circulation system.

[0012] In one example, a water analysis and chemical control system for a continuous casting process is described. The system includes a continuous casting machine, a water circulation system, a plurality of sensors, a pump, and a controller. The continuous casting machine has a cooling zone, which includes a plurality of nozzles configured to spray water onto the metal being cast. The water circulation system includes at least a gravity settling tank, a filter, and a cooling tower. The gravity settling tank is fluidly connected to the cooling zone of the continuous casting machine and is configured to receive water from the cooling zone of the continuous casting machine after the water contacts the metal being cast, and gravity separates the received water to provide a gravity-separated water flow. The filter is located downstream of the gravity settling tank, and is configured to receive the gravity-separated water flow and filter the gravity-separated water flow to provide a filtered water flow. The cooling tower is located downstream of the filter, and is configured to receive the filtered water and reduce the temperature of the filtered water flow by evaporative cooling to provide cooling water supplied to a plurality of nozzles of the continuous casting machine. The example specifically illustrates that a plurality of sensors are configured to measure at least one characteristic of a water sample being analyzed, wherein each of the plurality of sensors is fluidly connected at a different location in a water circulation system to measure at least one characteristic of the water sample at each different location. A pump is positioned to introduce a chemical additive into water in the water circulation system. A controller is communicatively coupled to the plurality of sensors and the pump. The example specifically illustrates that the controller is configured to receive data from each of the plurality of sensors indicating at least one characteristic of the water sample measured by each of the plurality of sensors, determine a composite water quality value based on the data received from each of the plurality of sensors, and control the pump based on the determined composite water quality value to control the addition of the chemical additive to the water.

[0013] In another example, a method of analyzing water in a continuous casting process and controlling chemical additions to the water is described. The method includes measuring at least one property of water in a plurality of different locations of a water circulation system for the continuous casting process with a plurality of sensors. The example specifically describes that the continuous casting process has a plurality of nozzles that spray water on the metal being cast, and the water circulation system includes at least a gravity settling tank, a filter, and a cooling tower. The method also includes determining a composite water quality value of the water in the water circulation system by a processor using the at least one property of the water measured from the plurality of sensors, and controlling the addition of a chemical additive to the water in the water circulation system based on the determined composite water quality value.

[0014] In another example, a water analysis system for a continuous casting process is described. The system includes a continuous casting machine, a water circulation system, a plurality of sensors, a display and a controller. The continuous casting machine has a cooling zone, which includes a plurality of nozzles configured to spray water onto the metal being cast. The water circulation system includes at least a gravity settling tank, a filter and a cooling tower. The gravity settling tank is fluidly connected to the cooling zone of the continuous casting machine and is configured to receive water from the cooling zone of the continuous casting machine after the water contacts the metal being cast, and gravity separates the received water to provide a gravity-separated water flow. The filter is located downstream of the gravity settling tank, and is configured to receive the gravity-separated water flow and filter the gravity-separated water flow to provide a filtered water flow. The cooling tower is located downstream of the filter, and is configured to receive the filtered water and reduce the temperature of the filtered water flow by evaporative cooling to provide cooling water supplied to a plurality of nozzles of the continuous casting machine. The example specifically illustrates that a plurality of sensors are configured to measure at least one characteristic of a water sample under analysis, wherein each of the plurality of sensors is fluidly connected at a different location in a water circulation system to measure at least one characteristic of the water sample at each different location. The example specifically illustrates that a controller is configured to receive data from each of the plurality of sensors indicating at least one characteristic of the water sample measured by each of the plurality of sensors, determine a composite water quality value based on the data received from each of the plurality of sensors, and control a display to display information indicating the composite water quality value.

[0015] The details of one or more examples are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a diagram of an example continuous casting machine that may be used to cast ferrous (steel) metal slabs.

[0017] Figure 2is a diagram of another example continuous casting machine that may be used to cast non-ferrous metal ingots.

[0018] Figure 3 is compatible with continuous casting machines (such as Figure 1 and Figure 2 Figure 2 is a diagram of an example water circulation system for use with the continuous casting machine described above. DETAILED DESCRIPTION

[0019] The present disclosure relates generally to metal casting, and more specifically to systems and techniques for monitoring and / or controlling water used in metal casting processes. In some specific implementations, cooling water is applied directly to hot metal in the metal casting process and is collected after direct contact with the metal being cast. For example, cooling water can be sprayed directly onto the metal being cast as part of a secondary cooling system located downstream of the trough from which the molten metal leaves. The cooling water sprayed onto the molten metal can be collected and circulated for reuse in the casting process after direct contact with the metal. In the water circulation system, the water can be subjected to one or more steps to remove particles present in the water. In addition or alternatively, one or more chemical additives can be injected into the water to control the chemical composition and properties of the water in the casting process and / or water circulation system.

[0020] In order to provide information about the characteristics of water collected and processed within a water circulation system for a metal casting process, multiple sensors may be implemented at different locations throughout the water circulation system. Each sensor may measure one or more of a variety of different measurable characteristics of water, such as optical properties (e.g., turbidity), electrical properties (e.g., redox potential), and / or chemical properties (e.g., pH). Different sensors may measure one or more characteristics of water at different points in the water circulation system, such as before and / or after the circulated water has undergone various processing steps in the water circulation system. Each sensor may provide measurement data indicative of one or more characteristics of the measured water.

[0021] Measurements made by a plurality of sensors within the water circulation system may be made in real time and / or intermittently in conjunction with the operation of the water circulation system and / or the casting process. The sensory measurement data may be used alone to assess the overall water quality in the water circulation system, or may be combined with one or more other data sources to assess the overall water quality. For example, measurements made by a plurality of sensors within the water circulation system may be combined with data generated from one or more offline measurements (e.g., offline chemical analysis of the water) and / or data from a water distribution system in the casting process (e.g., the temperature, pressure, and / or flow rate of water supplied to one or more zones and / or nozzles of the water distribution system that spray water on the molten metal being cast).

[0022] In either case, the composite water quality value can be determined by a plurality of different measurements associated with the continuous casting process and / or the water in the water circulation system. For example, the composite water quality value can be determined by aggregating different individual water property measurements from different sensors arranged at different locations throughout the water circulation system. The composite water quality value can be a numerical value indicating the quality of the water used in the casting process and circulated to the water circulation system, which is a composite of different water measurements. The composite water quality value can be displayed on a display observed by a person operating the water circulation system for individual evaluation and / or control actions. In addition or alternatively, one or more control actions for the water circulation system can be automatically implemented based on the determined composite water quality value. For example, the determined composite water quality value can be compared with one or more threshold values, and one or more chemical pumps can be controlled based on the comparison to introduce one or more chemical additives into the water of the water circulation system.

[0023] Additional details regarding example water circulation systems and related techniques for controlling water circulation systems are described in detail below. Figure 3 3. However, first of all, Figure 1 and Figure 2 An example continuous casting process is described that may include a water circulation system and associated water analysis and / or chemical control techniques according to the present disclosure.

[0024] Figure 1 1 is a diagram of an example continuous casting machine 10 that can be used to cast ferrous (steel) metal slabs. In the example shown, liquid metal flows from the bottom of a ladle 12 into a small intermediate container called a tundish 14. The liquid metal leaves the bottom of the tundish through an immersed nozzle 16, and a plug rod or sliding gate flow control system can control the volume of liquid metal discharged from the tundish. The liquid metal is directed into a solid mold 18 (usually made of copper), which may have water-cooled walls. Within the mold 18, the liquid metal may form a thin solid shell or skin around the liquid core.

[0025] In a steady state, the solid shell with the liquid core can leave the mold 18 as a stable strand, exhibiting sufficient mechanical strength to support the liquid metal core. The casting machine 10 can include a motor-driven drive roller 20 (and / or idler rollers) located just below the mold to continuously draw the strand downward. The closely spaced positioning rollers 20 can help support the strand and prevent the shell from expanding outward due to the ferrostatic pressure generated from the liquid steel core. Other strategically placed rollers 20 can bend the shell to follow a curved path and then straighten it before the welding torch that cuts the strand into individual slabs.

[0026] To aid in cooling the cast metal strand as it is drawn from the mold 18 and through the rollers 20, the casting machine 10 may include a plurality of nozzles 22 positioned to spray water directly and / or indirectly onto the cast metal strand as it is drawn downward from the mold 18. For example, the nozzles 22 may be spaced between the rollers 20 and may spray high pressure water toward the strand to aid in cooling the strand during the solidification process.

[0027] Figure 2 is a diagram of another example continuous casting machine 10 that may be used to cast non-ferrous metal (eg, aluminum, copper) ingots. Figure 2 The casting machine 10 further includes a tundish 14 and a mold 18. Figure 2 Different from the fully continuous casting process, Figure 2 The casting machine 10 in FIG. 1 may be implemented for semi-continuous casting, wherein the cast metal having an outer solidified shell and a molten core is drawn vertically downward from the mold 18 for a short length (e.g., 10 meters) until the resulting ingot reaches the bottom of the casting pit. The delivery of molten metal to the mold 18 may be repeatedly stopped and restarted as the continuously formed ingot is removed from the casting pit to cool. In either case, Figure 2 The casting machine 10 may also include a plurality of nozzles 22 for spraying water directly onto the solid shell emerging from the mold 18 .

[0028] exist Figure 1 and Figure 2 In the casting machine 10 of FIG. 1 , heat energy from the metal being cast can be removed from the primary cooling system and / or from the secondary cooling system. Heat energy can be initially removed from the metal being cast by using a water-cooled mold in which cooling water is separated from the metal by the walls of the mold 18 to indirectly cool the metal. Heat transfer in the liquid pool inside the mold 18 and at the mold / metal interface can affect the initial solidification at the meniscus and the growth of the solid shell on the mold. This heat transfer at the metal / mold interface can be referred to as mold cooling or primary cooling.

[0029] After exiting the mold 18, the cast strand may also be cooled by direct contact of water with the hot metal surface. This may be referred to as secondary cooling. For example, when casting a strand such as Figure 1 When steel is cast in a molten-metal configuration, rows of nozzles 22 may be located between contact rollers 20 below mold 18 to spray water to cool the moving metal strand. The nozzles may be arranged in groups or cooling zones assigned to the top and bottom surfaces of a particular strand segment. Water may be extruded from nozzles 22 in droplets at high pressure, forming a mist that continuously impinges on the metal surface. When casting a strand such as Figure 2 When the non-ferrous metal in the construction of the water jet nozzle 22 can come out from the hole located below the water-cooled mold 18 and directly contact the metal surface. These jets can form a continuous water film, which wets the vertical ingot surface and rolls down.

[0030] Regardless of the specific configuration of the casting machine 10, water used to cool the molten metal during the casting process may be recovered and recycled for reuse in the casting process. Figure 3 is an example water circulation system 50 (such as described above with respect to Figure 1 and Figure 2 The system described in FIG. Figure 3 In the example of , the water circulation system 50 is illustrated as a network of one or more fluidly connected processing units that sequentially process water used to cool metal cast on the casting machine 10 and return the water to the casting machine for reuse in subsequent stages of cooling the metal being cast. The water circulation system 50 may include one or more settling tanks, filters, heat transfer units (e.g., heat exchangers, cooling towers), screens, and / or other processing units that effectively circulate water for reuse in the casting machine 10. As will be described in more detail below, a variety of sensors may be implemented at different locations in the water circulation system 50 for analyzing water characteristics at different points in the water circulation system. The measurement data from the different sensors can be used to evaluate a composite water quality value for the entire water circulation system.

[0031] exist Figure 3 In the example of , the water circulation system 50 is shown as including a trough or trough 52 that collects water from the cooling zone of the casting machine 10. For example, the trough 52 can be configured to collect cooling water sprayed directly onto the metal being cast via the nozzles 22 after the cooling water has contacted the metal and fallen downward into the trough relative to gravity. The waterway 52 can be fluidly connected to one or more downstream processing units in the water circulation system 50 to process the collected cooling water for reuse. The cooling water collected for processing in the circulation system 50 can include scale, particles, oil (e.g., which can be applied and used to help cool the steel), and / or other possible contaminants, which can be partially or completely removed by the water circulation system 50 before reusing the water in the casting machine 10.

[0032] For example, the water circulation system 50 may include one or more gravity settling tanks 54. Figure 3 In the example of , the gravity settling tank is shown as including a scale pit. The gravity settling tank 54 may include an oil separator and a solid scraper. In the gravity settling tank 54, the received water can be gravity settled during the retention time to remove larger scale and particles, as well as remove oil from the water. In some specific implementations, the water circulation system 50 including the gravity settling tank 54 can receive wastewater from various other processes of the hot roller and the entire mill. This can contribute organic matter, heavy metals and other contaminants to the scale pit that is also processed in the water circulation stream. In either case, the gravity settling tank 54 can gravity separate the received water to provide a gravity-separated water stream 56.

[0033] As described above, the water circulation system 50 may include a plurality of gravity settling tanks 54. For example, in addition to utilizing a scale pit that receives cooling water from the water tank 52, the cooling water system 50 may also include a settling tank 58 located downstream of the scale pit 54. In the settling tank 58, the velocity of the cooling water may be reduced below the suspension velocity, and the suspended particles settle out of the water due to gravity. The settling tank 58 may be generally rectangular or circular with a radial or upward water flow pattern.

[0034] One or more filters 60 may be located between the gravity settling tank 54 and the cooling tower 62 in the water circulation system 50. For example, one or more filters 60 may be located downstream of the settling tank 56 in the water circulation system and upstream of the cooling tower 50. One or more filters 60 may be implemented as a deep bed filter having one or more layers of media (e.g., gravel). The deep bed filter may be used to remove fine particles suspended in the water and coalesce the remaining oil. One or more filters 60 may receive the gravity separated water stream 56 (directly received from the gravity settling tank 54 or indirectly received via one or more intermediate processes) and filter the gravity separated water stream to provide a filtered water stream 64.

[0035] The cooling tower 62 in the water circulation system 50 is located downstream of the filter 60 and is configured to receive the filtered water 64 and reduce the temperature of the filtered water flow by evaporative cooling to provide cooling water, which is then supplied to the plurality of nozzles 22 of the continuous casting machine 10. For example, at the cooling tower 62, the heat energy of the cooling water flow transferred to the casting machine 10 can be removed and discharged to the atmosphere. The cooling tower 62 can directly contact the cooling water flow with the air, thereby reducing the temperature of the cooling water flow by evaporative cooling. The cooling water can be transported to a storage tank or reservoir before being discharged downstream to the casting machine 10.

[0036] The water discharge cooling tower 62 may be supplied downstream to the nozzle 22, which supplies water to the metal being cast in the casting machine 10. The water may be supplied directly from the cooling tower 62 to the nozzle 22 without intermediate treatment, or the water may undergo one or more additional treatment steps downstream of the cooling tower before being supplied to the nozzle. For example, a filter screen 66 may be fluidly connected between the cooling tower 62 and the plurality of nozzles 22 in the casting machine 10. The filter screen 66 may filter the cooling water before it is supplied to the plurality of nozzles 22 of the continuous casting machine 10. This may provide a final polish or cleaning of the cooling water, thereby helping to remove residual particles that may otherwise clog or interfere with the operation of the nozzle 22.

[0037] To help remove contaminants from the cooling water in the water circulation system 50 and / or reduce or eliminate potential scaling conditions in the cooling water flow through the system, one or more chemical additives may be added to the cooling water. Figure 1In the configuration of, the water circulation system 50 includes one or more pumps 68 fluidly connected to one or more chemical additive reservoirs 70. The pump 68 is operable to add one or more chemical additives to the cooling water. The chemical additives may be selected to act as one or more of a coagulant, a flocculant, a dispersant, a biocide, an anti-corrosion additive, and / or a pH control agent. Example chemical additives that may be injected into the cooling water include, but are not limited to, polymers (antiscalants), organophosphorus compounds such as zinc polyphosphate, zinc orthophosphate, and / or zinc organophosphorus compounds (antiscalants and corrosion inhibitors), and biocides. In addition or alternatively, one or more chemical additives may be injected into the cooling water to adjust the pH of the cooling water. Examples of pH adjusting compounds include inorganic acids, organic acids, and inorganic bases.

[0038] exist Figure 3 In the illustrated construction, pump 68 is shown to add chemical additives to the cooling water in gravity settling tank 54. In practice, one or more chemical additives may be introduced into the cooling water at any suitable location, including downstream of cooling tower 62, upstream of the cooling tower, and / or at the cooling tower, such as at a storage tank associated with the cooling tower. Figure 3 The system 50 in FIG. 5 shows a single pump 68 fluidly coupled to a single chemical additive reservoir 70 , but the pump 68 may be in selective fluid communication with multiple reservoirs containing different chemicals, and / or the system 50 may include multiple pumps, each configured to introduce a different chemical into the cooling water.

[0039] To help monitor the condition of cooling water collected by the water tank 52 and / or processed by the water circulation system 50, a plurality of sensors 80A, 80B, ... 80Z (collectively referred to as sensors 80) may be used to monitor cooling water at different locations in the processing loop of the water circulation system. Each sensor 80 may measure one or more characteristics of cooling water at a specific location in the water circulation system 50, thereby providing an indication of the condition of the cooling water at the measurement location. Example characteristics of cooling water that may be measured by the sensor 80 include, but are not limited to, characteristics indicating the concentration and / or size of particles in the water (e.g., turbidity, total suspended solids), electrical characteristics of the water (e.g., conductivity, redox potential), concentration or amount of one or more compounds in the water (e.g., concentration of oil in the cooling water), pH of the water, and / or other characteristics indicating the presence and / or extent of one or more contaminants in the cooling water. Each sensor may be communicatively connected to a controller 90 for processing data measured by the sensor, determining a composite water quality value, and optionally controlling one or more chemical additives dispensed in the water flowing through the water circulation system 50.

[0040] Each sensor 80 can be implemented to measure one or more characteristics of the cooling water being processed in the water circulation system 50 at multiple locations in the water circulation system. In some examples, the water circulation system 50 includes at least one sensor 80 located upstream of one or more processing units in the water circulation system, and also includes at least one sensor 80 located downstream of one or more processing units in the water circulation system. This can provide different measurements and insights into changes in the characteristics of the water as it is processed through one or more processing units in the water circulation system.

[0041] For example, in one embodiment, the water circulation system 50 includes at least one sensor 80 positioned to measure at least one characteristic of water forming the gravity separated water flow 56 (e.g., by measuring water in and / or discharged from one or more gravity settling tanks 54). The water circulation system 50 may additionally or alternatively include at least one sensor 80 positioned to measure at least one characteristic of water forming the filtered water flow 64 (e.g., by measuring water in and / or discharged from one or more filters 60). As another additional or alternative example, the water circulation system 50 includes at least one sensor 80 positioned to measure at least one characteristic of water downstream of the filter screen 66 (e.g., between the filter 66 and the plurality of nozzles 22 to which the water is subsequently delivered). Thus, in some implementations, the water circulation system 50 may include at least one sensor 80 positioned to measure at least one characteristic of water being processed in the water circulation system 50 at a location upstream of the cooling tower 62 and at least one characteristic of water being processed in the water circulation system at a location downstream of the cooling tower.

[0042] exist Figure 3 In the example of FIG. 5 , the system 50 is shown to include a sensor 80A that measures a property of the water forming the gravity separated water flow 56, a sensor 80B that measures a property of the water forming the filtered water flow 64, and a sensor 80C that measures a property of the water downstream of the filter 66 and upstream of the nozzle 22. The water circulation system 50 may include sensors 80A and 80B that measure a property of the water forming the filtered water flow 64. Figure 3 Specific examples of different arrangements of processing units and / or different numbers and / or arrangements of sensors 80. In some examples, for example, the water circulation system 50 may include one or more sensors 80D...80Z that measure one or more characteristics of water in the cooling tower 62. For example, one or more sensors may be positioned to measure one or more characteristics of water in the sump of the cooling tower 62 and / or discharged from the cooling tower.

[0043] In some examples, one or more sensors 80 may be implemented using optical sensors to provide measurements indicative of the concentration and / or size of particles in the cooling water. For example, the optical sensor may be used to measure the turbidity and / or light scattering properties of the water in the water circulation system 50. Additionally or alternatively, the optical sensor may measure the total suspended solids in the water.

[0044] Other examples of sensors 80 that may be used in addition to or in place of optical sensors include oxidation reduction potential (ORP) sensors for measuring the ORP of cooling water; pH sensors for measuring the pH of cooling water; conductivity sensors for measuring the conductivity of cooling water; oil-in-water sensors for measuring the concentration of oil in cooling water; fluorometers for directly or indirectly measuring the concentration of one or more chemical additives dosed in the system (e.g., via a fluorescence response proportional to the concentration of the chemical additives); deposit monitors for measuring the rate of fouling deposition in the water system (e.g., biofilm scaling, inorganic deposit scaling, and / or organic deposit scaling); and / or sensors for measuring the rate of corrosion in the water system. Additional or different sensors may be used to measure additional or different properties of water.

[0045] Each sensor 80 can be implemented in the water circulation system 50 in a variety of different ways. For example, one or more sensors can be positioned in line with cooling water that flows through a portion of the water circulation system 50 (e.g., upstream, downstream, and / or within a processing unit of the water circulation system) directly or via a slipstream drawn from the main water flow. Alternatively, one or more sensors can be implemented as an offline monitoring tool that is not in direct fluid communication with the cooling water flowing through the water circulation system 50. In these applications, the cooling water flowing through the water circulation system 50 can be extracted from the system and measured using an offline analysis system. This offline analysis can involve direct evaluation of the sample, such as using one or more sensors, or can involve further processing of the sample, such as wet chemical processing of the sample to generate data related to the sample. In either case, the data generated by each of the one or more sensors 80 and / or otherwise associated with the cooling water being evaluated can be received by the controller 90, such as for storage in a memory and / or further processing. In addition, the discussion of the sensor 80 that analyzes the water sample from the water circulation system 50 is not intended to limit the way the sensor is exposed to water or the amount of water provided to the sensor.

[0046] The specific number of sensors 80 implemented in the water circulation system 50 may vary based on a variety of factors, such as the size and complexity of the water circulation system and the number and configuration of different water treatment units in the water circulation system. In various embodiments, the water circulation system 50 may include at least two sensors 80, such as three, four, five, six or more sensors, that provide measurement data to the controller 90 to determine a composite water quality value. Each sensor 80 may determine the same characteristic of the water being analyzed (e.g., turbidity, pH, conductivity), or at least one sensor 80 may determine that the characteristic of the water being analyzed is different from the characteristic of the water analyzed by one or more other sensors 80. Therefore, the composite water quality value determined for the water circulation system 50 may be based on the same and / or different measured water characteristics in the water circulation system.

[0047] For example, in Figure 3 In the arrangement of, the first sensor 80A can be implemented using an optical sensor that measures the turbidity of water and / or an oil-in-water sensor that measures the concentration of oil in water. The second sensor 80B can also be implemented using an optical sensor that measures the turbidity of water and / or an oil-in-water sensor that measures the concentration of oil in water. The third sensor 80C can also be implemented using an optical sensor that measures the turbidity of water. One or more additional sensors 80D...80Z can measure the conductivity, pH and / or ORP of water.

[0048] It should be understood that although Figure 3 One or more sensors 80 are illustrated and described as discrete sensors, but in other implementations, a single sensor may be implemented to measure the same characteristic from different locations in the water circulation system 50. For example, different conduits may fluidly connect the sensors 80 to different locations in the water circulation system 50 to bring water from different locations to the sensors for analysis. When so configured, the sensors 80 fluidly connected to different locations in the water circulation system 50 may be alternately placed in fluid communication with water from different locations to measure characteristics of water in different sources.

[0049] The water circulation system 50 may include additional and / or different sensors to measure different operating parameters of the water circulation system 50. For example, the system may include one or more flow sensors, temperature sensors, and / or pressure sensors to measure the flow rate, temperature, and / or pressure of cooling water at one or more desired locations in the water circulation system. The water circulation system 50 (including the controller 90 of the water circulation system) may monitor data from one or more sensors online and / or receive data from third-party sources related to the water circulation system. An example of such data that may be received from a third-party source may include data about the flow rate, temperature, and / or pressure of cooling water supplied to and / or discharged from the plurality of nozzles 22, which may be measured by an operator of the casting machine 10 different from the operator controlling the water circulation system 50. The measurement data received by the controller 90 from the third-party source may be used to determine a composite water quality value for the water circulation system. For example, if the measurement data received from the third-party source indicates that the pressure and / or flow rate of the cooling water supplied by the nozzle 22 has dropped, such information may indicate that contaminants in the cooling water are blocking or restricting the flow through the nozzle.

[0050] Figure 3 The water circulation system 50 in the example of includes a controller 90. The controller 90 is communicatively connected to a plurality of sensors 80 and controllable components of the water circulation system to manage the overall operation of the system. For example, the controller 90 is communicatively connected to each of the sensors 80, the pump 68, and / or other controllable components in the water circulation system.

[0051] The controller 90 includes a processor 92 and a memory 94. The controller 90 may communicate with communicatively connected components via a wired or wireless connection, which components are not shown in the figure for simplicity. Figure 3 . The control signals sent from the controller 90 and received by the controller may be propagated through the connection. The memory 94 stores software for running the controller 90, and may also store data generated or received by the processor 92, for example, from the sensor 80. The processor 92 runs the software stored in the memory 94 to manage the operation of the water circulation system 50.

[0052] The controller 90 may be implemented using one or more controllers that may be located on-site at a facility containing a processing unit defining the water circulation system 50. The controller 90 may communicate with one or more remote computing devices 96 via a network 98. For example, the controller 90 may communicate with a geographically distributed cloud computing network that may perform any or all of the functions attributed to the controller 90 in the present disclosure. Data generated and / or received by the controller 90 and / or the remote computing device 96 may be displayed on one or more electronic displays 100 visible to an operator of the water circulation system 50.

[0053] The network 98 can be configured to connect one computing device to another computing device so that the devices can communicate together. The network 98 can enable the use of any form of computer-readable media to transmit information from one electronic device to another electronic device. In addition, in addition to a local area network (LAN), a wide area network (WAN), a direct connection (such as through a universal serial bus (USB) port), other forms of computer-readable media or any combination thereof, the network 98 may also include a wireless interface and / or a wired interface (such as the Internet). On a group of interconnected LANs (including those based on different architectures and protocols), a router can serve as a link between LANs so that messages can be sent from one LAN to another LAN. The communication link within the LAN may include a twisted pair or coaxial cable, and the communication link between the networks may utilize an analog telephone line, a dedicated digital line in whole or in part, an integrated services digital network (ISDNs), a digital subscriber line (DSL), a wireless link including a cellular and satellite link, or other communication links. In addition, remote computers and other related electronic devices can be remotely connected to a LAN or WAN via a modem and a temporary telephone link.

[0054] The display 100 may display information indicating the water characteristics measured by each of the individual sensors 80, the composite water quality value determined for the water circulation system 50, and / or the control of one or more chemical additives added to the water being processed in the water circulation system. The information may be displayed to the operator of the water circulation system 50 in any suitable format, including in text and graphical display. In some examples, the display 100 is controlled to display information indicating the composite water quality value determined for the water circulation system 50. Such information may be displayed in the form of a numerical output, which may be an absolute value or a proportional value of the composite water quality value (e.g., as a fraction of 1.0 or a percentage of 100%). In addition or alternatively, information associated with the determined composite water quality value may be displayed together with a corresponding indication of the risk or desirability of taking a control action. For example, a color coding (e.g., red, yellow, green) associated with the composite water quality value may be determined by the controller 90 and displayed on the display 100 to indicate the relative risk associated with the determined composite water quality value.

[0055] In operation, the plurality of sensors 80 may generate data indicative of one or more characteristics of water in the water circulation system 50. In addition, when implemented with additional sensors such as temperature, flow rate, and / or pressure sensors, such sensors may generate data indicative of corresponding measured characteristics. The controller 90 may receive data from sensors deployed in the water circulation system 50 (in addition to or in lieu of receiving data from external sources, such as data indicative of the operation of the casting machine 10 and / or cooling tower 62), and use the received data to determine a composite water quality value for the water circulation system 50. The composite water quality value may provide a single parameter that aggregates different measurements and / or data streams on the water circulation system 50. This may coordinate and aggregate different discrete measurements for analysis and system control, resulting in more consistent, predictable, and efficient control of the water circulation system 50 in the water flowing through the system.

[0056] The controller 90 may receive data from sensors in the water circulation system 50 and determine the composite water quality value continuously or periodically. For example, the controller 90 may determine the composite water quality value at least once a day, such as at least once an hour, at least once a minute, or at least once a second. The frequency at which the controller 90 calculates the composite water quality value may vary depending on the sampling rate of the sensors in the water circulation system 50, the processing power of the controller 90, and / or operator input selecting the frequency at which the composite water quality value should be calculated.

[0057] In some examples, the controller 90 processes the data received from the sensor 80 before calculating the composite water quality value. For example, the controller 90 may use a statistical smoothing algorithm to smooth the data to remove noise and outliers from the data. The controller 90 may then use the smoothed data to determine the composite water quality value. Alternatively, the controller 90 may calculate the composite water quality value of the raw data and apply the smoothing algorithm to the calculated value.

[0058] In general, the controller 90 may determine a composite water quality value of the water circulation system 50 based on data received from a plurality of sensors 80 and / or based on data received from sources other than the sensors 80. The controller 90 may aggregate data from different sensors using a variety of different computational and / or sensor fusion techniques. In some examples, the controller 90 applies a weighting factor to the measured characteristics from each sensor 80. Each weighting factor may correspond to the predictive strength and test value of a particular measurement of water quality in the water circulation system 50. A particular weighting factor may be determined based on a causal analysis of experimental data that associates a particular measured water characteristic at a particular location in the water circulation system 50 with the water quality in the water circulation system. The weighting factor may also be adjusted up or down based on specific application factors associated with the particular water circulation system 50 being monitored and controlled. The weighting factor may be programmed into a memory associated with the controller 90 and used by the controller to determine a predicted scaling cause associated with a detected change in the heat transfer efficiency trend.

[0059] In some implementations, the weighting factors applied to different measured water properties from different locations in the water circulation system 50 may be scaled to fractions of 1.0 or percentages of 100%. For example, multiple weighting factors corresponding to the number of parameters included in the calculation of the composite water quality value may be assigned. The individual weighting factors may add up to 1.0 or 100%. Parameters that are relatively highly correlated with the water quality in the circulation system 50 may receive relatively high weighting (e.g., a weighting factor of 15% or greater, such as 20% or greater, or 25% or greater). Parameters that are moderately correlated with the water quality in the water circulation system 50 may receive relatively moderate weighting (e.g., a weighting factor of 7% to 15%). Parameters that are less correlated with the water quality in the circulation system 50 may receive relatively low weighting (e.g., a weighting factor of less than 7%, such as 5% or less, or 3% or less, or 2% or less). The weighting factors applied to different measured water properties may include a combination of high weighting, medium weighting, and / or low weighting.

[0060] The controller 90 may apply the weighting factors by multiplying the respective data parameters by their corresponding weighting factors. Depending on the number of data points available for a particular parameter, the controller 90 may average multiple measurements of the parameter and apply the weighting factors to the average of the parameter. For example, the controller 90 may determine the average, median, or mode of multiple data points to provide an average of the parameter and then apply the weighting factors to the average parameter.

[0061] The controller 90 may apply the weighting factors to the individually measured parameters (e.g., turbidity values, pH values, conductivity values, oil concentration values, ORP values, pressure values) by multiplying the weighting factors by the parameters. Additionally or alternatively, the controller 90 may normalize the different individual measured parameters to a uniform numerical scale and apply the weighting factors to each normalized parameter. Normalizing the different individual measured parameters may be helpful when determining a composite water quality value based on different measured characteristics of the water, each of which may be scaled differently and / or within different numerical ranges.

[0062] For example, the controller 90 may compare each parameter included in the calculation of the composite water quality value (e.g., each measured water characteristic from the plurality of sensors 80) with a pre-established risk category stored in the memory 94 of the controller 90. Each risk category may have a plurality of corresponding thresholds (e.g., high, medium, and / or low thresholds) for the parameter, with different categories covering different ranges for the relevant parameter. For example, the memory 94 of the controller 90 may store a low risk category associated with a first numerical range or value of a particular parameter, a medium risk category associated with a second numerical range or value of the particular parameter different from the first numerical range, and / or a high risk category associated with a third numerical range or value of the particular parameter different from the first and second numerical ranges. The third numerical range or value may be greater than or less than the second numerical range or value, which in turn may be greater than or less than the first numerical range or value. Any number of different categories may be stored in the memory 94 of the controller 90, each category may be defined by a numerical range of the relevant parameter, such as two, three, four, or more categories for each parameter.

[0063] The controller 90 may compare the measured and / or received values ​​of a particular parameter (measured values ​​of water characteristics for each of the plurality of sensors 80) and compare the actual value with the corresponding ranges of values ​​associated with different categories stored in the memory 94. The controller 90 may determine which range the measured and / or received value falls within and assign the measured and / or received value to the category associated with the range.

[0064] The memory 94 of the controller 90 may store normalized values ​​associated with each risk category, where different parameters have the same normalized values ​​for each risk category associated with the parameter. The normalized value for each category designated as having a relatively higher risk may be higher (or lower, depending on the scaling) than the normalized value for each category designated as having a relatively lower risk. The controller 90 may then apply the weighting factor for the normalized value associated with each individual measured parameter by multiplying the weighting factor by the normalized value parameter.

[0065] Although the specific weighting factors and normalization values ​​applied by controller 90 may vary based on the application, Table 1 provides exemplary weighting factors and normalization value ranges that may be applied to different parameters.

[0066] Table 1: Example parameters corresponding to example normalization values ​​and weighting factors .

[0067]

[0068]

[0069] To determine the composite water quality value, the controller 90 may sum the individual measured parameters and / or received parameters on which the composite water quality value is based, such as by summing weighted individual measured parameters and / or weighted normalized parameters. For example, the controller 90 may add the individual numerical values ​​associated with each measured parameter and / or received parameter (e.g., processed as described herein) to calculate the numerical composite water quality value. The calculated composite water quality value may be further scaled or normalized by the controller 90.

[0070] In some examples, controller 90 compares the determined composite water quality value to one or more threshold water quality values. Each water quality threshold value may indicate a different quality level of water in water circulation system 50. The particular threshold value against which controller 90 compares the composite water quality value may vary, for example, based on the magnitude of the weighting factor applied.

[0071] Various control actions may be taken in response to the composite water quality value determined by the controller 90 and / or based on a comparison of the composite water quality value to one or more threshold values. As one example, the controller 90 may control one or more pumps 68 to control the addition of one or more chemicals to the cooling water. In some examples, the controller 90 starts the pump 68 or increases the operating rate of the pump 68. Additional control actions that may be taken by the controller 90 and / or an operator of the system 50 include, for example, introducing fresh water into the water circulation system, flushing or controlling a treatment unit (e.g., a filter of the system), or otherwise taking control actions to modify the operation of the water circulation system 50. In addition to or in lieu of taking control actions, information indicating the determined composite water quality value may be displayed on the display 100 for viewing by an operator of the water circulation system 50.

[0072] While the aforementioned remedial actions may be performed by the controller 90, it should be understood that operator intervention may or may not be required to perform some or all of the described actions. For example, in practice, the controller 90 may issue a user alert (e.g., visual text and / or graphics) on a computer user interface that provides control instructions and / or a recommended course of action. An operator may interact with the plant equipment manually or through a controller interface (e.g., a computer) that controls the plant equipment to implement the desired action.

[0073] In applications where there are multiple different chemical additives available for introduction into the cooling water, the controller 90 can select one or more different chemical additives to be introduced into the cooling water by controlling a valve and / or pump that fluidly couples the one or more different chemical additives to the cooling water flow. For example, the controller 90 can vary the type of chemical additive introduced into the cooling water and / or the rate at which the chemical additive is introduced into the cooling water.

[0074] The techniques described herein may be implemented, at least in part, in hardware, software, firmware, or any combination thereof. For example, various aspects of the described techniques may be implemented within one or more processors, including one or more microprocessors, digital signal processors (DSPs), application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), or any other equivalent integrated or discrete logic circuits, and any combination of such components. The term "processor" may generally refer to any of the aforementioned logic circuits, alone or in combination with other logic circuits, or any other equivalent circuits. A control unit including hardware may also perform one or more of the techniques disclosed herein.

[0075] Such hardware, software, and firmware may be implemented within the same device or within separate devices to support the various operations and functions described in this disclosure. In addition, any of the described units, modules, or components may be implemented together or separately as discrete but cooperable logic devices. Describing different features as modules or units is intended to emphasize different functional aspects and does not necessarily imply that such modules or units must be implemented by separate hardware or software components. Rather, the functionality associated with one or more modules or units may be performed by separate hardware or software components, or integrated within common or separate hardware or software components.

[0076] The technology described in the present disclosure may also be embodied or encoded in a computer-readable medium such as a non-transitory computer-readable storage medium containing instructions. The instructions embedded or encoded in the computer-readable storage medium may cause a programmable processor or other processor to perform the method, for example, when the instructions are executed. Non-transitory computer-readable storage media may include volatile and / or non-volatile memory forms, including, for example, random access memory (RAM), read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory, hard disk, CD-ROM, floppy disk, cassette, magnetic media, optical media, or other computer-readable media.

[0077] Various examples have been described. These and other examples are within the scope of the following claims.

Claims

1. A water analysis and chemical control system for a continuous casting process, the system comprising: A continuous casting machine having a cooling zone, the cooling zone including a plurality of nozzles configured to spray water onto metal being cast; A water circulation system, the water circulation system comprising at least a gravity settling tank, a filter and a cooling tower, wherein: the gravity settling tank being fluidly connected to the cooling zone of the continuous casting machine, the gravity settling tank being configured to receive water from the cooling zone of the continuous casting machine after the water contacts the metal being cast and gravity separate the received water to provide a gravity separated water flow; The filter is located downstream of the gravity settling tank and is configured to receive the gravity separated water flow and filter the gravity separated water flow to provide a filtered water flow; and the cooling tower being located downstream of the filter and configured to receive filtered water and reduce the temperature of the filtered water flow by evaporative cooling to provide cooling water, the cooling water being supplied to the plurality of nozzles of the continuous casting machine; a plurality of sensors configured to measure at least one characteristic of a water sample under analysis, each sensor of the plurality of sensors being fluidly connected at a different location in the water circulation system to measure the at least one characteristic of the water sample at each different location; a pump positioned to introduce a chemical additive into water of the water circulation system; and a controller communicatively coupled to the plurality of sensors and the pump, the controller being configured to: receiving, from each of the plurality of sensors, data indicative of the at least one characteristic of the water sample measured by each of the plurality of sensors; determining a composite water quality value based on data received from each of the plurality of sensors; and Based on the determined composite water quality value, the pump is controlled to control the addition of the chemical additive to the water.

2. The system of claim 1, wherein: At least one sensor of the plurality of sensors is positioned to measure the at least one characteristic of the water sample at a location upstream of the cooling tower, and At least one sensor of the plurality of sensors is positioned to measure the at least one characteristic of the water sample at a location downstream of the cooling tower.

3. A system according to claim 1 or 2, wherein: At least one sensor of the plurality of sensors is positioned to measure the at least one characteristic of the water sample from the gravity separated water flow, and At least one sensor of the plurality of sensors is positioned to measure the at least one characteristic of the water sample from the filtered water flow.

4. The system according to any one of claims 1 to 3, further comprising a filter screen, the filter screen being fluidly connected between the cooling water tower and the plurality of nozzles, the filter screen being configured to filter the cooling water before supplying the cooling water to the plurality of nozzles of the continuous casting machine, wherein at least one of the plurality of sensors is positioned to measure the at least one characteristic of the water sample downstream of the filter screen and upstream of the nozzle.

5. The system of any one of claims 1 to 4, wherein the controller is configured to determine the composite water quality value based on the data received from each of the plurality of sensors by applying at least a weighting factor to the data received from each of the plurality of sensors to generate a weighted sensor value. 6 . The system of claim 5 , wherein applying the weighting factor to the data received from each of the plurality of sensors comprises applying different weighting factor values ​​to the data received from different sensors of the plurality of sensors.

7. The system of any one of claims 5 or 6, wherein the controller is configured to determine the composite water quality value based on a sum of the weighted sensor values.

8. The system of any one of claims 1 to 7, wherein the controller is configured to compare the composite water quality value with a threshold water quality value and, if the composite water quality value exceeds the threshold water quality value, control the pump to control the addition of the chemical additive to the water.

9. The system of any one of claims 1 to 8, wherein the plurality of sensors comprises a plurality of optical sensors configured to perform optical measurements of the water sample.

10. The system of any one of claims 1 to 9, wherein at least one water characteristic comprises turbidity.

11. The system of any one of claims 1 to 10, further comprising at least one sensor configured to measure a characteristic of water in the cooling tower, wherein the controller is configured to receive data indicative of the characteristic of the water in the cooling tower from the at least one sensor, and to determine the composite water quality value based on both the data received from each of the plurality of sensors and the data indicative of the characteristic of the water in the cooling tower received from the at least one sensor.

12. The system of claim 11, wherein the property of the water in the cooling tower includes at least one of conductivity, pH, and oxidation reduction potential (ORP).

13. The system of any one of claims 1 to 12, wherein the controller is further configured to receive data indicative of water flow through the plurality of nozzles and to determine the composite water quality value based on both the data received from each of the plurality of sensors and the received data indicative of water flow through the plurality of nozzles.

14. The system of claim 13, wherein the data indicative of water flow through the plurality of nozzles comprises at least one of a flow rate of water supplied to the plurality of nozzles and a pressure of water supplied to the plurality of nozzles.

15. The system of any one of claims 1 to 14, wherein the chemical additive is at least one of a coagulant, a dispersant, a biocide, an anti-corrosion additive, and a pH control agent.

16. The system of any one of claims 1 to 15, wherein the pump is positioned to control the addition of the chemical additive to the gravity settling tank.

17. The system of any one of claims 1 to 16, wherein the pump is positioned to control addition of the chemical additive downstream of the cooling tower.

18. The system of any one of claims 1 to 17, wherein the gravity settling tank comprises a scale pit and the filter comprises a filter bed, and the system further comprises a settling tank located between the gravity settling tank and the filter bed.

19. A method of analyzing water in a continuous casting process and controlling chemical additions to the water, the method comprising: measuring, using a plurality of sensors, at least one characteristic of water in a plurality of different locations of a water circulation system for a continuous casting process having a plurality of nozzles for spraying water onto metal being cast, the water circulation system comprising at least a gravity settling tank, a filter, and a cooling tower; determining, with a processor, a composite water quality value for the water in the water circulation system using at least one characteristic of the water measured from the plurality of sensors; as well as Addition of chemical additives to the water in the water circulation system is controlled based on the determined composite water quality value.

20. The method of claim 19, wherein the plurality of locations includes at least one location upstream of the cooling tower and at least one location downstream of the cooling tower.

21. The method of any one of claims 19 or 20, wherein the plurality of locations comprises a first location providing effluent from the gravity settling tank and a second location providing effluent from the filter.

22. The method of any one of claims 19 to 21, wherein determining the composite water quality value of the water in the water circulation system comprises: applying a weighting factor to the at least one characteristic of the water measured from the plurality of sensors to generate a weighted sensor value; as well as The weighted sensor values ​​are summed.

23. The method of claim 22, wherein applying the weighting factor to data received from each of the plurality of sensors comprises applying different weighting factor values ​​to data received from different sensors of the plurality of sensors.

24. The method of any one of claims 19 to 23, wherein measuring at least one property of the water in the plurality of different locations comprises measuring an optical property.

25. The method of any one of claims 19 to 24, further comprising measuring a property of the water in the cooling tower, wherein determining the composite water quality value of the water in the water circulation system comprises determining the composite water quality value using both the at least one property of the water measured from the plurality of sensors and the property of the water in the cooling tower.

26. The method of any one of claims 19 to 25, further comprising receiving data indicative of water flow through the plurality of nozzles, wherein determining the composite water quality value of the water in the water circulation system comprises determining the composite water quality value using both the at least one characteristic of the water measured from the plurality of sensors and the received data indicative of water flow through the plurality of nozzles.

27. The method of any one of claims 19 to 26, wherein controlling the addition of the chemical additive to the water in the water circulation system based on the determined composite water quality value comprises comparing the composite water quality value with a threshold water quality value and controlling the addition of the chemical additive to the water if the composite water quality value exceeds the threshold water quality value.

28. The method of any one of claims 19 to 27, wherein the chemical additive is at least one of a coagulant, a dispersant, a biocide, an anti-corrosion additive, and a pH control agent.

29. A water analysis system for a continuous casting process, the system comprising: A continuous casting machine having a cooling zone, the cooling zone including a plurality of nozzles configured to spray water onto metal being cast; A water circulation system, the water circulation system comprising at least a gravity settling tank, a filter and a cooling tower, wherein: the gravity settling tank being fluidly connected to the cooling zone of the continuous casting machine, the gravity settling tank being configured to receive water from the cooling zone of the continuous casting machine after the water contacts the metal being cast and gravity separate the received water to provide a gravity separated water flow; The filter is located downstream of the gravity settling tank and is configured to receive the gravity separated water flow and filter the gravity separated water flow to provide a filtered water flow; and the cooling tower being located downstream of the filter and configured to receive the filtered water and reduce the temperature of the filtered water stream by evaporative cooling to provide cooling water, the cooling water being supplied to the plurality of nozzles of the continuous casting machine; a plurality of sensors configured to measure at least one characteristic of a water sample under analysis, each sensor of the plurality of sensors being fluidly connected at a different location in the water circulation system to measure the at least one characteristic of the water sample at each different location; Display; and One or more controllers, the one or more controllers being configured to: receiving data measured from each of the plurality of sensors, the data indicative of the at least one characteristic of the water sample measured by each of the plurality of sensors; determining a composite water quality value based on data received from each of the plurality of sensors; and The display is controlled to display information indicative of the composite water quality value.

30. The system of claim 29, wherein the one or more controllers are configured to compare the determined composite water quality value to a plurality of threshold water quality values ​​and control the display to display different composite water quality classifications based on which the determined composite water quality value exceeds one or more of the plurality of threshold water quality values.

31. The system of claim 30, wherein the different composite water quality classifications include different color codes.

32. The system of any one of claims 29 to 31, wherein the one or more controllers are configured to compare the determined composite water quality value with a threshold water quality value and, if the determined composite water quality value exceeds the threshold water quality value, control the display to issue an alarm.

33. The system of any one of claims 29 to 32, wherein the controller is configured to determine the composite water quality value based on data received from each of the plurality of sensors by applying at least a weighting factor to the data received from each of the plurality of sensors to generate a weighted sensor value.

34. The system of claim 33, wherein applying the weighting factor to data received from each of the plurality of sensors comprises applying different weighting factor values ​​to data received from different sensors of the plurality of sensors.

35. The system of any one of claims 33 or 34, wherein the controller is configured to determine the composite water quality value based on a sum of the weighted sensor values.

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