Cast wheel cleaning method based on spraying and circulating technology

Abstract

The invention relates to the technical field of cast wheel cleaning, in particular to a cast wheel cleaning method based on a spraying and circulating technology, and the cast wheel cleaning method is used for a copper crystallization cast wheel of a five-wheel continuous casting machine in SCR continuous casting and rolling equipment and comprises the following steps that the working surface of the cast wheel is divided into a groove area, a bottom area and an outer side area, and a partition monitoring system is constructed; respectively setting a cleaning alarm threshold value of each area; dynamically judging local or complete cleaning requirements based on monitoring data of each region; corresponding cleaning fluid is selected based on pollution chemical characteristics of the cleaning area; gradient pressure spraying is carried out, and clean water flushing is matched; waste liquid formed by flushing is recycled after being subjected to multi-stage treatment. According to the method, the regional monitoring system is taken as a core, the cleaning mode is adjusted in real time according to the pollution degree of each region, and multi-region differentiated pollution removal and resource recycling are synchronously completed in the continuous production process through high-efficiency and low-loss precise cleaning.

Description

Technical Field

[0001] The invention relates to the technical field of casting wheel cleaning, and in particular to a casting wheel cleaning method based on spraying and circulation technology. Background Art

[0002] The five-wheel continuous casting machine is the core equipment for the efficient and stable operation of the SCR production line and the quality control of copper rods. With the increase of service life and the inability of the water treatment process to adapt to the changes in the casting process, the scaling degree of the casting wheel crystallizer (referred to as the casting wheel) has increased day by day, which has seriously affected the thermal conductivity of the casting wheel, resulting in unstable solidification structure of the copper billet, many pores inside the copper billet, increased torsional cracks in the copper rod, and decreased tensile properties.

[0003] Casting wheel cleaning technology is one of the key maintenance links in the foundry industry, especially for casting wheels using continuous casting and rolling processes. How to efficiently clean the casting wheel surface and remove attached metal slag, oxides, crystal slag and other dirt directly affects the service life of the casting wheel and the casting quality of the copper rod. At present, cleaning technologies mainly include mechanical cleaning, chemical cleaning and spray cleaning.

[0004] Mechanical cleaning is to remove surface dirt by manual or machine physical means, which is inefficient, often cannot completely remove attachments, and requires high labor costs. Chemical cleaning is to use the principle of chemical agent and dirt reaction for cleaning. Although it can remove stubborn dirt, this method has problems such as environmental pollution, high cost, chemical corrosion equipment, and is easy to have a negative impact on the environment. Spray cleaning is to flush the surface of the casting wheel with high-pressure spray cleaning liquid, which is more common in casting wheel cleaning. Although the traditional spray cleaning method can remove dirt to a certain extent, factors such as the pressure, flow rate, and temperature of the spray liquid are difficult to achieve precise control in actual operation, so it is difficult to ensure that the cleaning needs of different areas can be met. The efficiency of the spray system usually depends on manual settings, and does not fully utilize the differences in the surface areas of the casting wheel for customized cleaning, resulting in incomplete cleaning of some areas, and some areas may cause waste of resources due to excessive cleaning.

[0005] The information disclosed in this background technology section is only intended to deepen the understanding of the overall background technology of the present invention, and should not be regarded as acknowledging or suggesting in any form that the information constitutes the prior art known to those skilled in the art. Summary of the invention

[0006] The purpose of the present invention is to provide a casting wheel cleaning method based on spraying and circulation technology. By establishing an intelligent and dynamic cleaning management system with a regional monitoring system as the core, the cleaning method is adjusted in real time according to the degree of pollution in each area, which not only avoids the shortcomings of traditional cleaning that cannot be accurately controlled, but also realizes efficient resource utilization in the cleaning process; through high-efficiency, low-loss precision cleaning, differentiated pollution removal and resource recycling in multiple areas are simultaneously completed in the continuous production process.

[0007] The above technical objectives of the present invention are achieved through the following technical solutions: A casting wheel cleaning method based on spraying and circulation technology comprises the following steps: Divide the working surface of the casting wheel into the groove area, bottom area and outer area, and build a zone monitoring system; Set the cleaning alarm threshold for each area separately; Dynamically determine partial or complete cleaning needs based on monitoring data from each area; Select the appropriate cleaning fluid based on the chemical characteristics of the contamination in the cleaning area; Implement gradient pressure spraying and flush with clean water; The waste liquid generated by flushing is recycled after multi-stage treatment.

[0008] Furthermore, the groove area is the axial inner cavity working surface of the casting wheel; the bottom area is the circumferential motion surface of the casting wheel in contact with the cooling medium; and the outer area is the radial heat dissipation surface of the casting wheel.

[0009] Furthermore, the construction of the monitoring system is achieved by arranging a non-contact detection device on the periphery of the casting wheel, preferably on the opposite side of the detection area.

[0010] Furthermore, the contaminants in the groove region include carbon black, Cu, Cu2O and CaO, and the contaminants in the bottom region and the outer region include CaCO3.

[0011] Specifically, the scale layer in the inner groove of the casting wheel crystallizer is composed of a mixture of carbon black, Cu, Cu2O and CaO, which is formed by the carbon black enrichment formed by incomplete combustion of acetylene, the concentrated precipitation of CaCO3 in the slag flushing water, high-temperature decomposition, and the high-temperature diffusion of Cu crystallizer and copper billet. The scale layer at the bottom and outside of the casting wheel crystallizer is mainly composed of CaCO3. This is because the evaporation of the casting machine cooling water and the insufficient water treatment capacity lead to the high hardness of the casting machine spray water, and the supersaturated precipitation of CaCO3 crystals on the surface of the high-temperature casting wheel. Among them, the CaCO3 particles in the spray water film at the bottom of the casting wheel are subject to centrifugal force, which accelerates the formation of CaCO3 crystal scale.

[0012] Furthermore, the cleaning alarm thresholds of each area are set separately, including: Analyze the spatial distribution of pollutant deposition based on each region; Determine the critical failure parameters by combining the thermal resistance experiment of the scaling layer; Collect historical production process data and use time series analysis to extract sensitive parameters in each area; Construct a process failure path map, quantify the contribution weight of different sensitive parameters to the cleaning requirements of each area, and set independent cleaning alarm thresholds for each area.

[0013] Furthermore, the cleaning alarm threshold is adaptively adjusted as the operating parameters change, and is embedded in the online monitoring system to form a closed-loop feedback mechanism.

[0014] Furthermore, the need for partial or complete cleaning is dynamically determined based on the monitoring data of each area, including: Construct an eigenvalue fusion method using multi-source monitoring parameters; Preprocess the monitoring data, extract the time-domain-frequency-domain composite feature vector representing the pollution degree, calculate the pollution degree of each area in real time, and mark the area with a primary alarm if the pollution degree is greater than the cleaning alarm threshold of the area; The weighted pollution degree of each area is calculated by nonlinear superposition to determine the comprehensive abnormal index; When the comprehensive anomaly index exceeds the set threshold, full cleaning is triggered, otherwise a hierarchical response is performed based on regional priority.

[0015] Furthermore, the area priorities are, in descending order, the groove area, the bottom area, and the outer area.

[0016] Furthermore, the corresponding cleaning liquid is selected based on the chemical characteristics of the pollution in the cleaning area, which means: for the groove area, a weak acid cleaning liquid (pH 4.5-5.5) is used to dissolve copper oxides, and corrosion inhibitors are added to protect the substrate; for the bottom area and the outer area, a chelating cleaning agent (EDTA concentration 8%-12%) is used to remove scale, and a surfactant is used to improve permeability; the cleaning liquid supply system adopts an independent pipeline design, and the concentration of the cleaning liquid in each area is accurately controlled by a proportional valve, with an error of ≤±2%, to achieve precise cleaning of each area.

[0017] Furthermore, gradient pressure spraying and water flushing are implemented, including: Multi-stage pressure regulation is used to control the output of the cleaning fluid. The spray angle is optimized according to the characteristics of the area. High-pressure water is used for flushing after each spray. During the flushing process, the changes in conductivity and turbidity are monitored simultaneously until the cleanliness threshold is reached.

[0018] Furthermore, the waste liquid formed by flushing enters the waste liquid recovery and circulation system, and the recycled water after multi-stage treatment is returned to the cleaning system after being qualified by online monitoring, and the remaining waste water is discharged in compliance with the standards after deep treatment.

[0019] Furthermore, the waste liquid recovery and circulation system has a built-in automatic cleaning function to maintain processing efficiency through backwashing and chemical cleaning.

[0020] Compared with the prior art, the present invention has the following beneficial effects: The present invention constructs an intelligent, dynamically responsive casting wheel cleaning system to accurately clean different areas during the production process, ensuring the best cleaning effect with minimal resource consumption. By implementing regional division and pollution monitoring, the degree of pollution can be fed back in real time and the cleaning mode can be automatically adjusted. This cleaning system based on dynamic monitoring and adaptive adjustment can optimize the parameters in the spraying and flushing process according to the degree of pollution on the working surface of the casting wheel, the type of pollutants and the accumulation rate, reduce unnecessary cleaning time and resource waste, and achieve optimization of the cleaning process and efficient recycling of waste liquid. Compared with traditional cleaning methods, this technical solution greatly improves cleaning efficiency, reduces energy consumption and the use of chemicals, thereby achieving dual optimization of environmental protection and economic benefits.

[0021] The present invention divides the working surface of the casting wheel into a groove area, a bottom area and an outer area, and constructs an adaptive monitoring system for the functional characteristics of each area, thereby realizing accurate spatial identification of heterogeneous pollution distribution. Compared with the traditional integrated monitoring method, the partition architecture can independently capture the parameter changes of each area and dynamically set the cleaning alarm threshold based on the monitoring data of each area. By analyzing the correlation between the pollution accumulation rate and the equipment operating parameters (such as temperature, speed, and cooling medium flow) in real time, the trigger conditions are adaptively adjusted, overcoming the cleaning lag or over-cleaning problem caused by the fluctuation of the working conditions of the traditional fixed threshold, so that the cleaning response is accurately matched with the critical adhesion state of the pollutant.

[0022] The present invention dynamically selects local cleaning or complete cleaning mode by comprehensively considering the pollution degree of each area, the operating status of the equipment and the historical cleaning data. The local cleaning mode is only targeted at the area where the standard is exceeded, while the complete cleaning mode covers the entire area; the decision-making process introduces a pollution diffusion risk prediction algorithm to give priority to high-risk areas that may cause chain pollution. The cleaning liquid components can be selected according to the chemical characteristics of the pollutants in the cleaning area to achieve the dual goals of efficient dissolution of pollutants and protection of the substrate. Specifically, a weakly acidic medium is used for selective dissolution of areas dominated by metal oxides, while a chelating agent is used for targeted removal of inorganic salt scaling areas. Compared with general-purpose cleaning agents, it can reduce the annual corrosion loss of the substrate and reduce the pressure of waste liquid treatment caused by excessive use of agents.

[0023] The present invention adopts a step-by-step pressure control strategy to dynamically adjust the jet pressure according to the spraying stage, and its pressure gradient is adapted to the distribution characteristics of the binding strength of the pollutant layer. Through a multi-stage physical-chemical treatment process, more than 95% of the effective components in the waste liquid are recycled. The treated recycled water is reused in the cleaning system, and the residual wastewater is purified and discharged in compliance with the standards. The closed-loop circulation system reduces the consumption of new water by more than 90%, and the toxic equivalent of wastewater discharge is reduced to less than 5% of that of the traditional process. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0025] Figure 1 is a schematic diagram of the connection between the casting wheel and the steel belt; Figure 2 A flow chart of the steps of a casting wheel cleaning method based on spraying and circulation technology; Figure numerals: 01, groove area; 02, bottom area; 03, outer area; 04, steel belt. DETAILED DESCRIPTION

[0026] In order to further explain the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, a casting wheel cleaning method based on spraying and circulation technology proposed by the present invention, its specific implementation method, features and effects are described in detail as follows. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0027] like Figure 1 The figure shows the connection diagram of the casting wheel and the steel strip 04. The casting wheel is made of CuCrZr alloy, and the steel strip 04 is made of 430 stainless steel. The casting wheel groove area 01 and the steel strip 04 form a closed area with a trapezoidal cross section, which is the cavity. The cavity can rotate continuously with the casting wheel and the steel strip 04. Cooling water is sprayed on both sides of the casting wheel and the steel strip 04 for rapid cooling. The high-temperature molten copper flows out from the bottom of the ladle and enters the closed cavity. It is rapidly solidified into a billet under the cooling effect of the spraying of high-pressure water. At the same time, it moves clockwise with the crystallization wheel and is led out of the cavity through the demoulding device to achieve continuous casting of copper.

[0028] The present invention is directed to cleaning the above casting wheel, specifically using the following method: Figure 2 A casting wheel cleaning method based on spraying and circulation technology is shown, comprising the following steps: S1 divides the working surface of the casting wheel into groove area 01, bottom area 02 and outer area 03 to build a zoning monitoring system; with the regional monitoring system as the core, it can accurately identify the degree of contamination in each area, thereby implementing targeted cleaning, avoiding unnecessary cleaning operations and improving cleaning efficiency.

[0029] S2 sets the cleaning alarm threshold for each area respectively; S3 dynamically determines the need for partial or complete cleaning based on monitoring data from each area; S4 selects the corresponding cleaning fluid based on the chemical characteristics of the pollution in the cleaning area; S5 implements gradient pressure spraying and flushing with clean water; The waste liquid generated by S6 flushing is recycled after multi-stage treatment.

[0030] The present invention reduces the usage of cleaning liquid and water and reduces resource loss by selecting the corresponding cleaning liquid based on the chemical characteristics of the pollution in the cleaning area and combining gradient pressure spraying and clean water flushing. The waste liquid formed by flushing is recycled after multi-stage treatment, which reduces wastewater discharge, realizes the recycling of resources and reduces the environmental burden.

[0031] Specifically for the division of the working surface in S1, the groove area 01 is the axial inner cavity working surface of the casting wheel; the bottom area 02 is the circumferential motion surface of the casting wheel in contact with the cooling medium; the outer area 03 is the radial heat dissipation surface of the casting wheel. Accurate division can improve the cleaning targeting and reduce the ineffective cleaning area. The construction of the monitoring system is achieved by setting a non-contact detection device on the periphery of the casting wheel, preferably on the opposite side of the detection area. The focus of the partition monitoring is to monitor sensitive production parameters, such as production parameters such as cooling water flow rate and casting liquid temperature, and key parameters such as pH value and hardness of cooling water. The sensor data is transmitted to the central control system in real time through the Industrial Internet of Things (IIoT) technology, and the edge computing technology is used to pre-process the data and extract key feature values.

[0032] The present invention divides the working surface of the casting wheel into the groove area 01, the bottom area 02 and the outer area 03, and constructs an adaptive monitoring system according to the functional characteristics of each area, thereby realizing the spatial accurate identification of heterogeneous pollution distribution. Compared with the traditional integrated monitoring method, the partition architecture can independently capture the parameter changes of each area and dynamically set the cleaning alarm threshold based on the monitoring data of each area. By analyzing the correlation between the pollution accumulation rate and the equipment operating parameters (such as temperature, rotation speed, and cooling medium flow) in real time, the trigger conditions are adaptively adjusted. It overcomes the problem of cleaning lag or over-cleaning caused by fluctuations in working conditions of the traditional fixed threshold, and makes the cleaning response accurately match the critical adhesion state of the pollutant.

[0033] The groove area is in a high temperature environment, and incomplete acetylene combustion will lead to local hypoxia. Copper (Cu) is easily oxidized to form cuprous oxide Cu2O in a high temperature and oxygen-restricted environment. Specifically, the scale layer in the groove area 01 is composed of a mixture of carbon black, Cu, Cu2O and CaO. It is a composite of carbon black enrichment formed by incomplete acetylene combustion, CaCO3 concentration and precipitation in slag flushing water, high-temperature decomposition, and high-temperature diffusion of Cu crystallizer and copper billet. The thermal resistance of carbon black is high, which will reduce the thermal conductivity of the casting wheel, resulting in uneven cooling of the copper liquid and affecting the quality of the casting wheel. The scaling of copper will block the groove, affect the flow of the cooling medium, and reduce the cooling effect of the copper liquid. The scaling of oxides such as Cu2O and CaO will increase the surface roughness of the casting wheel, affect the fluidity of the copper liquid, and reduce the surface quality of the casting wheel.

[0034] The scale layer in the bottom area 02 and the outer area 03 is mainly composed of CaCO3. This is because the casting machine cooling water evaporates and the water treatment capacity is insufficient, resulting in high hardness of the casting machine spray water. CaCO3 crystals are supersaturated and precipitated on the surface of the high-temperature casting wheel. Among them, the CaCO3 particles in the spray water film at the bottom of the casting wheel are subjected to centrifugal force, which accelerates the formation of CaCO3 crystal scale. The scaling of CaCO3 will form a hard thermal resistance layer, reduce the heat exchange efficiency between the casting wheel and the cooling medium, and cause uneven cooling of the copper liquid.

[0035] The present invention uses zoned cleaning to select the most suitable cleaning liquid and cleaning method according to the characteristics of pollutants in different areas, thereby improving the cleaning effect, reducing the amount of cleaning liquid used, and extending the service life of the casting wheel.

[0036] For step S2, the cleaning alarm thresholds of each area are set respectively, including: The spatial distribution of pollutant deposition is analyzed based on each area; first, the spatial distribution map of pollutant accumulation in each area is collected and constructed based on historical data. The deposition speed, distribution form and type of pollutants are different in the groove area 01, the bottom area 02 and the outer area 03. For example, Cu and Cu2O deposition often occur in the groove area 01, while CaCO3 is mainly accumulated in the bottom area 02 and the outer area 03. Data is collected in real time through sensors such as temperature sensors, pressure sensors, and humidity sensors to establish the spatial distribution law of pollutants. The data are analyzed using a multidimensional spatial model, and the deposition characteristics and influencing factors of pollutants in each area are derived by combining the existing physical properties of pollutants with the chemical reaction mechanism. This analysis helps to identify areas where pollutants accumulate faster in the subsequent cleaning process, so that they can be treated first.

[0037] Combined with the thermal resistance experiment of the scaling layer, the critical failure parameters are determined; the formation and thermal resistance characteristics of the scaling layer on the surface of the casting wheel are simulated under high temperature and high pressure environment. For example, for Cu2O in groove area 01 and CaCO3 in bottom area 02, the effect of the scaling layer on heat conduction is measured experimentally to determine the critical thermal resistance value at which the scaling layer in these areas begins to significantly affect the cooling or heating process. Taking groove area 01 as an example, by simulating the working conditions of groove area 01 and designing a carbon black deposition layer, a simulated thermal cycle experimental platform is built according to the actual heating power and cooling medium flow rate, and the thermal resistance and heat transfer coefficient under different scaling thicknesses are measured. By establishing a thickness-thermal resistance correlation equation, the corresponding thermal resistance and deposition thickness are calculated as the corresponding cleaning trigger point when the heat transfer efficiency drops by 15%. And then it serves as the basis for the cleaning alarm. This method can ensure that the cleaning signal is automatically triggered before the contaminants accumulate to the extent that they affect the function of the casting wheel.

[0038] By collecting historical production data (for example, production cycle, pollutant accumulation rate, casting pressure, cooling water flow, mold temperature, etc.), the abnormal events of deposition thickness corresponding to the cleaning trigger point are traced back, and the sensitive parameters of each area are extracted using time series analysis; that is, the sensitive parameters in actual production corresponding to the corresponding deposition thickness threshold are obtained, and different monitoring data (such as conductivity, turbidity, pressure change, etc.) are compared to verify the effectiveness of the sensitive parameters, so as to adjust the cleaning threshold.

[0039] Combined with the above analysis results, the 15% decrease in heat transfer efficiency is used as the root node of cleaning failure, and a process failure path map is constructed to evaluate the role of various sensitive parameters (such as temperature and pollutant concentration) in the judgment of cleaning needs, and quantify the contribution weight of each sensitive parameter to the cleaning needs. Taking groove area 01 as an example, if the accumulation of pollutants (such as Cu2O) reaches a certain concentration, it will significantly affect the cooling effect of the casting wheel, and the cleaning weight of this area will be greater; based on this information, an independent cleaning alarm threshold is set for each area. This threshold is not only based on the accumulation of regional pollutants, but also takes into account the impact of pollutants on the function of the casting wheel, ensuring that the alarm system responds sensitively and accurately.

[0040] In order to adapt to environmental changes and fluctuations in operating parameters during the production process, the cleaning alarm threshold is adaptively adjusted as the operating parameters change, and is embedded in the online monitoring system to form a closed-loop feedback mechanism. During the cleaning process, the concentration, temperature and other parameters of regional pollutants are continuously monitored through the online monitoring system, and the cleaning parameters (such as spray pressure, spray angle, etc.) are adjusted in real time. Based on the closed-loop feedback mechanism, the system can not only adjust the cleaning process according to real-time monitoring data, but also reversely adjust the alarm threshold according to historical cleaning data, thereby achieving system self-optimization.

[0041] For example, as production speed increases, the accumulation of pollutants may accelerate, so the threshold needs to be flexibly adjusted to ensure that the cleaning process is started in a timely manner. Specifically, real-time monitoring data (such as conductivity and pressure of the cleaning fluid) is used to compare and analyze historical cleaning effects, and a random forest algorithm model based on machine learning is established. The model is used to learn feedback information on cleaning effects in real time to optimize cleaning parameters and alarm thresholds. For groove area 01, the alarm threshold adjustment is more sensitive because of its complex types of pollutants; while for outer area 03, the alarm threshold adjustment is relatively slow.

[0042] During the actual cleaning process, monitoring data (such as contamination, temperature, pressure, etc.) will be transmitted to the central control system in real time. The algorithm model automatically analyzes the deviation between the data and the historical cleaning data and adjusts the current alarm threshold. Whenever the contamination level in a certain area exceeds the set threshold, the system will correct the alarm threshold in real time and adjust the thresholds of other areas accordingly. For example, when the pollution accumulation rate in groove area 01 suddenly increases, the system will increase the alarm threshold of the area accordingly, trigger an alarm, and start emergency cleaning. The thresholds of bottom area 02 and outer area 03 remain relatively stable.

[0043] For step S3, the need for partial or complete cleaning is dynamically determined based on the monitoring data of each area, including: Construct a eigenvalue fusion method using multi-source monitoring parameters; the multi-source monitoring parameters used include physical quantities such as temperature, conductivity, pressure and flow, and the pollution level of each area is more comprehensively evaluated by fusing different monitoring parameters. Use data dimensionality reduction techniques such as principal component analysis (PCA) to synthesize multiple monitoring data into a eigenvector to comprehensively judge the accumulation of pollutants.

[0044] For example, the pollutants in the groove area 01 are mainly carbon black, Cu, Cu2O and CaO. Combined with the monitoring data of temperature and conductivity, the accumulation degree of pollutants and their impact can be judged. For the bottom area 02 and the outer area 03, the conductivity changes are more sensitive, and these data can be used to deduce the distribution of specific pollutants.

[0045] For the monitoring data, a filtering algorithm is used for denoising to ensure the accuracy of the collected data, and the time domain-frequency domain composite feature vector representing the degree of pollution is extracted. The composite feature vector of the time domain and frequency domain can more accurately reflect the accumulation of pollutants, calculate the pollution degree of each area in real time, and mark the area with a primary alarm if the pollution degree is greater than the cleaning alarm threshold of the area; The weighted pollution degree of each area is nonlinearly superimposed to determine the comprehensive abnormal index; the calculation method of the comprehensive abnormal index can accurately reflect the pollution accumulation effect of multiple areas and identify potential pollution problems in advance. Through this mechanism, certain areas can be selectively cleaned according to actual conditions instead of cleaning the whole area, thereby greatly saving cleaning resources and improving efficiency.

[0046] When the comprehensive anomaly index exceeds the set threshold, full cleaning is triggered, otherwise a hierarchical response is performed based on regional priority.

[0047] The regional priorities are groove area 01, bottom area 02 and outer area 03 in descending order. The regional priorities are set based on the pollutant accumulation rate of each area and its influence on the performance of the casting wheel. Groove area 01 is considered to be the most critical area because the deposition of pollutants inside it may cause serious functional failure, so it needs to be cleaned first. Bottom area 02 and outer area 03 are relatively resistant to pollution, and their pollution accumulation rate is slow, so the cleaning priority is low. However, scaling in bottom area 02 will cause a surge in thermal resistance of the contact surface between the casting wheel and the steel belt 04, causing mechanical vibration (the equipment failure rate increases by 82% when the measured amplitude is greater than 0.3mm), causing the cooling water film to rupture, and then inducing local remelting. The outer cooling water flow rate can be temporarily increased by 15-20% to compensate for the heat dissipation loss. Therefore, the priority of bottom area 02 is greater than that of outer area 03. The present invention can ensure the rationality of the cleaning process through priority sorting, avoid the waste of resources caused by excessive cleaning, and also ensure the long-term and efficient operation of the casting wheel. This priority setting can reduce unnecessary energy consumption and chemical use while ensuring the cleaning effect, thereby maximizing cost-effectiveness.

[0048] The present invention dynamically selects local cleaning or complete cleaning mode by comprehensively considering the pollution degree of each area, the operating status of the equipment and the historical cleaning data. The local cleaning mode is only targeted at the area where the standard is exceeded, while the complete cleaning mode covers the entire area; the decision-making process introduces a pollution diffusion risk prediction algorithm to give priority to high-risk areas that may cause chain pollution. The cleaning liquid components can be selected according to the chemical characteristics of the pollutants in the cleaning area to achieve the dual goals of efficient dissolution of pollutants and protection of the substrate. Specifically, a weakly acidic medium is used for selective dissolution of areas dominated by metal oxides, while a chelating agent is used for targeted removal of inorganic salt scaling areas. Compared with general-purpose cleaning agents, it can reduce the annual corrosion loss of the substrate and reduce the pressure of waste liquid treatment caused by excessive use of agents.

[0049] Specifically for step S4, the corresponding cleaning liquid is selected based on the chemical characteristics of the pollution in the cleaning area, that is: for the groove area 01, a weak acid cleaning liquid (pH 4.5-5.5) is used to dissolve copper oxides, and corrosion inhibitors are added to protect the substrate; for the bottom area 02 and the outer area 03, a chelating cleaning agent (EDTA concentration 8%-12%) is used to remove scale, and a surfactant is used to improve permeability; the cleaning liquid supply system adopts an independent pipeline design, and the cleaning liquid concentration in each area is accurately controlled by a proportional valve, with an error of ≤±2%, to achieve precise cleaning of each area.

[0050] Among them, gradient pressure spraying and water flushing are implemented, including: Multi-stage pressure regulation is used to control the output of the cleaning fluid. The spray angle is optimized according to the characteristics of the area. High-pressure water is used for flushing after each spray. During the flushing process, the changes in conductivity and turbidity are monitored simultaneously until the cleanliness threshold is reached.

[0051] The multi-stage pressure adjustment and spray angle adjustment design can be optimized according to the pollution characteristics of different areas. The groove area 01 has a complex structure and is difficult to remove pollution, so high-pressure spraying and small-angle spraying are used to concentrate the cleaning of difficult-to-remove pollutants; the bottom area 02 has a relatively smooth surface and relatively uniform pollution, so a spray mode with medium pressure and moderate spray angle is used to remove accumulated pollutants without causing surface damage; the outer area 03 uses a lower pressure and a larger angle spraying method to avoid excessive cleaning and impact damage to the casting wheel surface. This flexible adjustment method not only improves the cleaning efficiency, but also greatly reduces the risk of damage to the equipment.

[0052] For example, based on the critical pressure of 2.5MPa for breaking the carbon black adhesion layer and 1.8MPa for satisfying the CaCO3 dissolution kinetics requirements, the groove area 01 can be set to use a 20° tilted spray head, matching the trapezoidal groove geometric features, and using a spray pressure of 1.5~3.0MPa. During cleaning, 2.5MPa is used in the initial stage to break the surface scaling layer, 1.5MPa is used in the maintenance stage to continuously dissolve pollutants, and 3.0MPa is used for pulse flushing to remove residues at the end. The bottom area 02 and the outer area 03 are set to a spray pressure of 1.5~2.0MPa. During cleaning, 1.8MPa is used in the initial stage to break the surface scaling layer, 1.5MPa is used in the maintenance stage to continuously dissolve pollutants, and 2.0MPa is used for pulse flushing to remove residues at the end. An annular distributor is installed in the bottom area 02 to achieve 360° full coverage cleaning, and a fan-shaped nozzle is used in the outer area 03 to cover the radial structure. The matching degree of the spray angle and the regional characteristics can increase the residence time of the cleaning liquid and improve the coverage rate of the groove dead corners. The present invention sets a pressure gradient to match the difference in binding energy of pollutants, thereby preventing the high-pressure area from causing damage to the substrate and ensuring the cleaning economy of the low-pressure area.

[0053] In the present invention, the waste liquid formed by flushing enters the waste liquid recovery circulation system, the regenerated water after multi-stage treatment is returned to the cleaning system after being qualified by online monitoring, and the remaining waste water is discharged after being deeply treated and meeting the discharge standards.

[0054] Specifically, the waste liquid recycling system consists of: first stage filtration to remove macromolecular impurities, then use cyclone separator to remove particles >50μm, second stage electrochemical treatment to decompose organic pollutants, third stage reverse osmosis membrane to achieve desalination treatment, multi-stage treatment to match the physical and chemical characteristics of different pollutants, so that the conductivity of regenerated water is controlled below 50μS / cm, meeting the reuse standard. Furthermore, the waste liquid recycling system has a built-in automatic cleaning function, which cleans the waste liquid every 20m 3 The waste liquid is backwashed once and circulated and cleaned with a citric acid solution with a pH value of 2. The acid washing environment is used to dissolve calcium salt deposits and restore membrane flux, so that the system pressure difference is stabilized below 0.15MPa to avoid attenuation of treatment efficiency.

[0055] The waste liquid recovery circulation system of the present invention first removes most of the solid particles through multi-stage filtration and centrifugal separation to ensure the cleanliness and stability of the system. For waste liquids containing higher pollution concentrations, chemical cleaning and reaction methods are used for further purification. These chemical methods can effectively decompose harmful components in pollutants and reduce pollution to the environment. In the treatment of waste liquid in each area, different treatment strategies are adopted according to different pollutants to ensure that the recovery and reuse of waste liquid can meet environmental protection standards and can be reused in the cleaning system. Through the recycling and reuse of waste liquid, the consumption of water and cleaning agents is reduced, while the negative impact on the environment is reduced, forming an efficient and environmentally friendly closed-loop system.

[0056] Those skilled in the art should understand that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A casting wheel cleaning method based on spraying and circulation technology, characterized in that: The following steps are involved: Divide the working surface of the casting wheel into the groove area, bottom area and outer area, and build a zone monitoring system; Set the cleaning alarm threshold for each area separately; Dynamically determine partial or complete cleaning needs based on monitoring data from each area; Select the appropriate cleaning fluid based on the chemical characteristics of the contamination in the cleaning area; Implement gradient pressure spraying and flush with clean water; The waste liquid generated by flushing is recycled after multi-stage treatment.

2. A casting wheel cleaning method based on spraying and circulation technology according to claim 1, characterized in that: The groove area is the axial inner cavity working surface of the casting wheel; the bottom area is the circumferential motion surface of the casting wheel in contact with the cooling medium; and the outer area is the radial heat dissipation surface of the casting wheel.

3. The casting wheel cleaning method based on spraying and circulation technology according to claim 1 is characterized in that: The contaminants in the groove region include carbon black, Cu, Cu2O and CaO, and the contaminants in the bottom region and the outer region include CaCO3.

4. The casting wheel cleaning method based on spraying and circulation technology according to claim 1 is characterized in that: The cleaning alarm thresholds of each area are set separately, including: Analyze the spatial distribution of pollutant deposition based on each region; Determine the critical failure parameters by combining the thermal resistance experiment of the scaling layer; Collect historical production process data and use time series analysis to extract sensitive parameters in each area; Construct a process failure path map, quantify the contribution weight of different sensitive parameters to the cleaning requirements of each area, and set independent cleaning alarm thresholds for each area.

5. A casting wheel cleaning method based on spraying and circulation technology according to claim 4, characterized in that: The cleaning alarm threshold is adaptively adjusted as the operating parameters change, and is embedded in the online monitoring system to form a closed-loop feedback mechanism.

6. The casting wheel cleaning method based on spraying and circulation technology according to claim 4 is characterized in that: Dynamically determine partial or complete cleaning needs based on monitoring data from each area, including: Construct an eigenvalue fusion method using multi-source monitoring parameters; Preprocess the monitoring data, extract the time-domain-frequency-domain composite feature vector representing the pollution degree, calculate the pollution degree of each area in real time, and mark the area with a primary alarm if the pollution degree is greater than the cleaning alarm threshold of the area; The weighted pollution degree of each area is calculated by nonlinear superposition to determine the comprehensive abnormal index; When the comprehensive anomaly index exceeds the set threshold, full cleaning is triggered, otherwise a hierarchical response is performed based on regional priority.

7. A casting wheel cleaning method based on spraying and circulation technology according to claim 6, characterized in that: The area priorities are, in descending order, the groove area, the bottom area, and the outer area.

8. The casting wheel cleaning method based on spraying and circulation technology according to claim 1 is characterized in that: Implement gradient pressure spraying and flush with clean water, including: Multi-stage pressure regulation is used to control the output of the cleaning fluid. The spray angle is optimized according to the characteristics of the area. High-pressure water is used for flushing after each spray. During the flushing process, the changes in conductivity and turbidity are monitored simultaneously until the cleanliness threshold is reached.

9. The casting wheel cleaning method based on spraying and circulation technology according to claim 1 is characterized in that: The waste liquid formed by flushing enters the waste liquid recovery circulation system. The recycled water after multi-stage treatment is returned to the cleaning system after passing the online monitoring. The remaining waste water meets the discharge standards after deep treatment.

10. The casting wheel cleaning method based on spraying and circulation technology according to claim 1 is characterized in that: The waste liquid recovery circulation system has a built-in automatic cleaning function to maintain processing efficiency through backwashing and chemical cleaning.

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