A casting wheel cleaning method based on spraying and circulation technology

Abstract

The present invention relates to the field of casting wheel cleaning technology, and in particular to a casting wheel cleaning method based on spraying and circulation technology, which is used for the copper crystal casting wheel of the five-wheel continuous casting machine in the SCR continuous casting and rolling equipment, and includes the following steps: dividing the casting wheel working surface into a groove area, a bottom area and an outer area, and constructing a zone monitoring system; setting the cleaning alarm threshold of each area respectively; dynamically determining the need for partial or complete cleaning based on the monitoring data of each area; selecting the corresponding cleaning liquid based on the chemical characteristics of the pollution in the cleaning area; implementing gradient pressure spraying and coordinating with clean water flushing; and recycling the waste liquid formed by flushing after multi-stage treatment. The present invention takes the regional monitoring system as the core, adjusts the cleaning method in real time according to the pollution level of each area, and synchronously completes the differentiated pollution removal and resource recycling of multiple areas in the continuous production process through high-efficiency, low-loss and precise cleaning.

Description

Technical Field

[0001] The present 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. As its service life increases and the water treatment process cannot adapt to changes in the casting process, the degree of scaling in the casting wheel crystallizer (referred to as the casting wheel) is increasing. This seriously affects the thermal conductivity of the casting wheel, resulting in unstable solidification structure of the copper billet, more pores inside the copper billet, more torsional cracks in the copper rod, and reduced tensile properties.

[0003] Casting wheel cleaning technology is a key maintenance step in the foundry industry, particularly for casting wheels used in continuous casting and rolling processes. Efficiently cleaning the wheel surface to remove contaminants such as metal slag, oxides, and crystallized slag directly impacts the wheel's service life and the quality of the copper rod casting. Currently, cleaning technologies primarily include mechanical cleaning, chemical cleaning, and spray cleaning.

[0004] Mechanical cleaning is the removal of surface dirt by manual or mechanical means. It is inefficient, often cannot completely remove attachments, and requires high labor costs. Chemical cleaning is the use of the principle of chemical reaction with dirt to clean. Although it can remove stubborn dirt, this method has problems such as environmental pollution, high cost, chemical corrosion to equipment, and is prone to negative impacts on the environment. Spray cleaning is the use of high-pressure spray cleaning liquid to flush the surface of the casting wheel, which is more common in casting wheel cleaning. Although traditional spray cleaning methods 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, making it difficult to ensure that the cleaning needs of different areas can be met. The efficiency of the spray system usually relies 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 excessive cleaning of some areas, resulting in waste of resources.

[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 an admission or any form of suggestion 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 pollution level of each area. This not only avoids the shortcomings of traditional cleaning that cannot be precisely controlled, but also achieves 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:

[0008] A casting wheel cleaning method based on spraying and circulation technology comprises the following steps:

[0009] Divide the working surface of the casting wheel into groove area, bottom area and outer area, and build a zone monitoring system;

[0010] Set the cleaning alarm threshold for each area separately;

[0011] Dynamically determine partial or complete cleaning needs based on monitoring data from each area;

[0012] Select the appropriate cleaning fluid based on the chemical characteristics of the contamination in the cleaning area;

[0013] Implement gradient pressure spraying and flush with clean water;

[0014] The waste liquid generated by flushing is recycled after multi-stage treatment.

[0015] 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.

[0016] 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.

[0017] 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.

[0018] Specifically, the scale layer in the grooves of the casting wheel crystallizer cavity is composed of a mixture of carbon black, Cu, Cu2O, and CaO. It is formed by a combination of factors such as carbon black enrichment formed by incomplete acetylene combustion, concentrated precipitation of CaCO3 in the slag flushing water, high-temperature decomposition, and high-temperature diffusion of the 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 due to the evaporation of the casting machine cooling water and insufficient water treatment capacity, resulting in high hardness of the casting machine spray water. CaCO3 crystals are supersaturated and precipitated on the high-temperature casting wheel surface. 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.

[0019] Furthermore, the cleaning alarm thresholds for each area are set separately, including:

[0020] Analyze the spatial distribution of pollutant deposition based on each region;

[0021] Determine the critical failure parameters by combining the thermal resistance experiment of the scaling layer;

[0022] Collect historical production process data and use time series analysis to extract sensitive parameters of each area;

[0023] 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.

[0024] 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.

[0025] Furthermore, the need for partial or complete cleaning is dynamically determined based on the monitoring data of each area, including:

[0026] Construct an eigenvalue fusion method using multi-source monitoring parameters;

[0027] Pre-process 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 exceeds the cleaning alarm threshold of the area;

[0028] The weighted pollution degree of each area is calculated by nonlinear superposition to determine the comprehensive anomaly index;

[0029] When the comprehensive anomaly index exceeds the set threshold, a complete cleaning is triggered; otherwise, a hierarchical response is performed based on regional priority.

[0030] Furthermore, the area priorities are, in descending order, the groove area, the bottom area, and the outer area.

[0031] Furthermore, the corresponding cleaning fluid is selected based on the chemical characteristics of the pollution in the cleaning area, which means: for the groove area, a weak acid cleaning fluid (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 fluid supply system adopts an independent pipeline design, and the concentration of the cleaning fluid in each area is precisely controlled by a proportional valve, with an error of ≤±2%, to achieve precise cleaning of each zone.

[0032] Furthermore, gradient pressure spraying and water flushing are implemented, including:

[0033] Multi-stage pressure regulation is used to control the output of the cleaning fluid, and the spray angle is optimized according to the characteristics of the area. After each spray, high-pressure water is used for rinsing. During the rinsing process, the changes in conductivity and turbidity are simultaneously monitored until the cleanliness threshold is reached.

[0034] Furthermore, the waste liquid formed by flushing enters the waste liquid recovery 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 after deep treatment and meets the standards.

[0035] Furthermore, the waste liquid recovery and circulation system has a built-in automatic cleaning function, which maintains treatment efficiency through backwashing and chemical cleaning.

[0036] Compared with the prior art, the present invention has the following beneficial effects:

[0037] The present invention constructs an intelligent, dynamically responsive casting wheel cleaning system to precisely clean different areas during the production process, ensuring optimal cleaning results 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 of 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, reducing unnecessary cleaning time and resource waste, achieving optimization of the cleaning process and efficient recycling of waste liquids. 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.

[0038] This invention achieves precise spatial identification of heterogeneous contamination distribution by dividing the working surface of the casting wheel into a groove zone, a bottom zone, and an outer zone, and constructing an adaptive monitoring system tailored to the functional characteristics of each zone. Compared to traditional monolithic monitoring methods, the partitioned architecture independently captures parameter changes in each zone and dynamically sets cleaning alarm thresholds based on the monitoring data from each zone. By analyzing the correlation between the pollution accumulation rate and equipment operating parameters (such as temperature, speed, and cooling medium flow) in real time, it adaptively adjusts the trigger conditions. This overcomes the cleaning lag or over-cleaning caused by operating condition fluctuations in traditional fixed thresholds, ensuring that the cleaning response precisely matches the critical adhesion state of contaminants.

[0039] The present invention dynamically selects a local cleaning or complete cleaning mode by comprehensively considering the pollution level of each area, the operating status of the equipment, and historical cleaning data. The local cleaning mode is targeted only at areas where the standards are exceeded, while the complete cleaning mode covers the entire area. The decision-making process introduces a pollution spread risk prediction algorithm to prioritize high-risk areas that may cause chain pollution. The cleaning liquid components can be selected based on the chemical properties of the pollutants in the cleaning area to achieve the dual goals of efficient dissolution of pollutants and protection of the substrate. Specifically, a weak 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 on waste liquid treatment caused by excessive use of chemicals.

[0040] This invention utilizes a stepped pressure control strategy, dynamically adjusting the jet pressure according to the spraying stage. The pressure gradient is tailored to the binding intensity distribution characteristics of the pollutant layer. Through a multi-stage physical-chemical treatment process, over 95% of the active ingredients in the wastewater are recovered and reused. Treated reclaimed water is reused in the cleaning system, and residual wastewater is purified and discharged to meet standards. This closed-loop circulation system reduces fresh water consumption by over 90% and reduces the toxicity equivalent of wastewater discharge to less than 5% of that of traditional processes. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. 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 any creative work.

[0042] Figure 1 is a schematic diagram of the connection between the casting wheel and the steel belt;

[0043] Figure 2 A flow chart of the steps of a casting wheel cleaning method based on spraying and circulation technology;

[0044] Reference numerals: 01, groove area; 02, bottom area; 03, outer area; 04, steel belt. DETAILED DESCRIPTION

[0045] To further illustrate the technical means and effectiveness of the present invention in achieving its intended objectives, a detailed description of the specific implementation, features, and effectiveness of a casting wheel cleaning method based on spray and circulation technology is provided below. It should be understood that the specific embodiments described herein are intended only to illustrate the present invention and are not intended to limit the present invention.

[0046] like Figure 1The figure shows the connection between the casting wheel and the steel strip 04. The casting wheel is made of a 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 mold cavity. The cavity rotates continuously with the casting wheel and steel strip 04. Cooling water is sprayed on both sides of the casting wheel and steel strip 04 for rapid cooling. The hot copper liquid flows from the bottom of the ladle into the closed mold cavity. Under the cooling effect of the high-pressure water spray, it quickly solidifies into a billet. Simultaneously, as the crystallization wheel moves clockwise, it is drawn out of the mold cavity through the demolding device, achieving continuous casting of copper.

[0047] 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:

[0048] S1 divides the working surface of the casting wheel into the groove area 01, the bottom area 02 and the outer area 03, and constructs 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.

[0049] S2 sets the cleaning alarm threshold for each area respectively;

[0050] S3 dynamically determines the need for partial or complete cleaning based on monitoring data from each area;

[0051] S4 selects the corresponding cleaning fluid based on the chemical characteristics of the pollution in the cleaning area;

[0052] S5 implements gradient pressure spraying and flushing with clean water;

[0053] The waste liquid generated by S6 flushing is recycled after multi-stage treatment.

[0054] The present invention reduces the use 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, reducing wastewater discharge, realizing the recycling of resources and reducing the environmental burden.

[0055] Specifically, regarding the division of the working surface in S1, groove zone 01 is the axial inner working surface of the casting wheel; bottom zone 02 is the circumferential motion surface of the casting wheel in contact with the cooling medium; and outer zone 03 is the radial heat dissipation surface of the casting wheel. Accurate division improves cleaning targeting and reduces ineffective cleaning areas. The monitoring system is implemented by installing non-contact detection devices on the periphery of the casting wheel, preferably on opposite sides of the detection zones. Zoned monitoring focuses on sensitive production parameters such as cooling water flow rate, casting temperature, and key parameters such as pH and hardness of the cooling water. Sensor data is transmitted in real time to the central control system through Industrial Internet of Things (IIoT) technology, and edge computing technology is used to preprocess the data and extract key feature values.

[0056] This invention divides the working surface of the casting wheel into a groove zone (01), a bottom zone (02), and an outer zone (03), and constructs a monitoring system tailored to the functional characteristics of each zone, achieving precise spatial identification of heterogeneous contamination distribution. Compared to traditional monolithic monitoring methods, this partitioned architecture independently captures parameter changes in each zone and dynamically sets cleaning alarm thresholds based on the monitoring data from each zone. By analyzing the correlation between the pollution accumulation rate and equipment operating parameters (such as temperature, speed, and coolant flow rate) in real time, it adaptively adjusts the trigger conditions. This overcomes the problem of cleaning lag or over-cleaning caused by operating condition fluctuations in traditional fixed thresholds, ensuring precise matching of the cleaning response to the critical contaminant adhesion state.

[0057] The groove area is exposed to high temperatures, and incomplete acetylene combustion leads to localized oxygen deficiency. Copper (Cu) readily oxidizes to form cuprous oxide (Cu2O) in high-temperature, oxygen-restricted environments. Specifically, the scale layer in the groove area 01 is composed of a mixture of carbon black, Cu, Cu2O, and CaO. This is the result of a combination of factors, including carbon black enrichment from incomplete acetylene combustion, concentrated precipitation of CaCO3 in the slag flushing water, high-temperature decomposition, and high-temperature diffusion within the Cu crystallizer and copper billet. Carbon black has a high thermal resistance, which reduces the thermal conductivity of the casting wheel, leading to uneven cooling of the copper liquid and affecting casting quality. Copper scaling can clog the grooves, restricting the flow of the cooling medium and reducing the cooling efficiency of the copper liquid. Scaling of these oxides, such as Cu2O and CaO, increases the surface roughness of the casting wheel, affecting the fluidity of the copper liquid and resulting in a decrease in casting surface quality.

[0058] The scale layers in the bottom zone 02 and outer zone 03 are primarily composed of CaCO3. This is due to the high hardness of the casting machine's spray water caused by evaporation of the casting machine's cooling water and insufficient water treatment capacity. This leads to supersaturation and precipitation of CaCO3 crystals on the high-temperature casting wheel surface. Centrifugal force acts on the CaCO3 particles in the spray water film at the bottom of the casting wheel, accelerating the formation of CaCO3 crystal scale. This CaCO3 scaling forms a hard thermal resistance layer, reducing the heat exchange efficiency between the casting wheel and the cooling medium, resulting in uneven cooling of the copper liquid.

[0059] 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.

[0060] For step S2, the cleaning alarm thresholds for each area are set separately, including:

[0061] The spatial distribution patterns of pollutant deposition are analyzed based on each area; first, a 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 deposits often appear in the groove area 01, while CaCO3 mainly accumulates 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 patterns of pollutants. These 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.

[0062] Critical failure parameters were determined by combining thermal resistance experiments with scaling layers. The formation and thermal resistance characteristics of scaling layers on the wheel surface were simulated under high temperature and high pressure. For example, the effects of the scaling layers on heat conduction were experimentally measured for Cu2O in groove area 01 and CaCO3 in bottom area 02 to determine the critical thermal resistance at which scaling layers in these areas begin to significantly affect the cooling or heating process. Specifically, using groove area 01 as an example, the operating conditions of groove area 01 were simulated, and a carbon black deposit layer was designed and loaded. A simulated thermal cycle experimental platform was constructed according to actual heating power and cooling medium flow rate. The thermal resistance and heat transfer coefficient were measured for different scaling thicknesses. By establishing a thickness-thermal resistance correlation equation, the corresponding thermal resistance and deposit thickness at a 15% drop in heat transfer efficiency were calculated as the corresponding cleaning trigger point. This, in turn, served as the basis for the cleaning alarm. This method ensures that the cleaning signal is automatically triggered before contaminant accumulation reaches a level that affects the function of the wheel.

[0063] 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 changes, etc.) are compared to verify the validity of the sensitive parameters, so as to adjust the cleaning threshold.

[0064] Based on the above analysis results, a 15% drop in heat transfer efficiency was used as the root node for cleaning failure. A process failure path map was constructed to evaluate the role of various sensitive parameters (such as temperature and contaminant concentration) in determining cleaning requirements, and the contribution of each sensitive parameter to cleaning requirements was quantified. For example, in groove area 01, if contaminants (such as Cu2O) accumulate to a certain concentration, significantly affecting the cooling effect of the casting wheel, the cleaning weight of this area is increased. Based on this information, a separate cleaning alarm threshold is set for each area. This threshold is based not only on the accumulation of contaminants in the area but also on their impact on the function of the casting wheel, ensuring a sensitive and accurate alarm system response.

[0065] To adapt to environmental changes and fluctuations in operating parameters during the production process, cleaning alarm thresholds are adaptively adjusted as these parameters change. This is integrated into the online monitoring system to form a closed-loop feedback mechanism. During the cleaning process, the online monitoring system continuously monitors regional pollutant concentrations, temperature, and other parameters, adjusting cleaning parameters (such as spray pressure and spray angle) in real time. This closed-loop feedback mechanism not only allows the system to adjust the cleaning process based on real-time monitoring data but also reversely adjusts alarm thresholds based on historical cleaning data, achieving system self-optimization.

[0066] For example, as production speeds increase, contaminant accumulation may accelerate, necessitating flexible threshold adjustments to ensure timely initiation of the cleaning process. This is achieved by comparing and analyzing real-time monitoring data (such as cleaning fluid conductivity and pressure) with historical cleaning results, and developing a machine learning-based random forest algorithm model. This model leverages real-time feedback from cleaning results to optimize cleaning parameters and alarm thresholds. For groove area 01, due to the complex nature of the contaminants, alarm threshold adjustments are more sensitive; however, for outer area 03, the threshold adjustment is relatively slow.

[0067] During the actual cleaning process, monitoring data (such as contamination levels, temperature, and pressure) is transmitted in real time to the central control system. An algorithm automatically analyzes these data for deviations from historical cleaning data and adjusts the current alarm threshold. Whenever the contamination level in a particular area exceeds the set threshold, the system adjusts the alarm threshold in real time and adjusts the thresholds for other areas accordingly. For example, if the contamination accumulation rate in groove area 01 suddenly increases, the system will raise the alarm threshold for that area, trigger an alarm, and initiate emergency cleaning. The thresholds for bottom area 02 and outer area 03, however, remain relatively stable.

[0068] In step S3, the need for partial or complete cleaning is dynamically determined based on the monitoring data of each area, including:

[0069] A feature value fusion method was developed using multi-source monitoring parameters, including temperature, conductivity, pressure, and flow. By integrating these different monitoring parameters, the pollution level in each area was more comprehensively assessed. Data dimensionality reduction techniques, such as principal component analysis (PCA), were used to synthesize multiple monitoring data into a single feature vector, enabling a comprehensive assessment of pollutant accumulation.

[0070] For example, the contaminants in groove area 01 are primarily carbon black, Cu, Cu2O, and CaO. Combining temperature and conductivity monitoring data can help determine the extent of contaminant accumulation and its impact. For bottom area 02 and outer area 03, conductivity changes are more sensitive, and this data can be used to deduce the distribution of specific contaminants.

[0071] A filtering algorithm is used to remove noise from the monitoring data to ensure the accuracy of the collected data. The time-domain-frequency-domain composite feature vector representing the degree of pollution is extracted. The composite feature vector of the time and frequency domains 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 exceeds the cleaning alarm threshold of the area.

[0072] The weighted pollution levels of each area are nonlinearly superimposed to determine a comprehensive anomaly index. This calculation method accurately reflects the cumulative effects of pollution across multiple areas, allowing for early identification of potential pollution issues. This mechanism allows for selective cleaning of specific areas based on actual conditions, rather than a comprehensive cleanup, significantly saving cleaning resources and improving efficiency.

[0073] When the comprehensive anomaly index exceeds the set threshold, a complete cleaning is triggered; otherwise, a hierarchical response is performed based on regional priority.

[0074] The regional priorities, from highest to lowest, are groove zone 01, bottom zone 02, and outer zone 03. Regional priorities are determined based on the rate of contaminant accumulation in each zone and its impact on wheel performance. Groove zone 01 is considered the most critical area, as contaminant deposits within it can lead to serious functional failures, and therefore requires cleaning first. Bottom zone 02 and outer zone 03 are relatively resistant to contamination, experiencing slower contamination accumulation and therefore have a lower cleaning priority. However, scaling in bottom zone 02 can lead to a surge in thermal resistance at the wheel-steel belt 04 interface, triggering mechanical vibration (measured equipment failure rates increase by 82% when amplitude > 0.3mm), causing cooling water film rupture and, in turn, inducing localized remelting. The outer cooling water flow can be temporarily increased by 15-20% to compensate for heat loss. Therefore, bottom zone 02 has a higher priority than outer zone 03. This prioritization ensures a rational cleaning process, avoids resource waste from excessive cleaning, and ensures long-term, efficient operation of the wheel. This priority setting ensures effective cleaning while reducing unnecessary energy and chemical consumption, thereby maximizing cost-effectiveness.

[0075] The present invention dynamically selects a local cleaning or complete cleaning mode by comprehensively considering the pollution level of each area, the operating status of the equipment, and historical cleaning data. The local cleaning mode is targeted only at areas where the standards are exceeded, while the complete cleaning mode covers the entire area. The decision-making process introduces a pollution spread risk prediction algorithm to prioritize high-risk areas that may cause chain pollution. The cleaning liquid components can be selected based on the chemical properties of the pollutants in the cleaning area to achieve the dual goals of efficient dissolution of pollutants and protection of the substrate. Specifically, a weak 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 on waste liquid treatment caused by excessive use of chemicals.

[0076] Specifically for step S4, the corresponding cleaning fluid is selected based on the chemical characteristics of the pollution in the cleaning area. This means: for the groove area 01, a weak acidic cleaning fluid (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 fluid supply system adopts an independent pipeline design, and the concentration of the cleaning fluid in each area is precisely controlled by a proportional valve, with an error of ≤±2%, to achieve precise cleaning of each area.

[0077] Among them, the implementation of gradient pressure spraying and water flushing includes:

[0078] Multi-stage pressure regulation is used to control the output of the cleaning fluid, and the spray angle is optimized according to the characteristics of the area. After each spray, high-pressure water is used for rinsing. During the rinsing process, the changes in conductivity and turbidity are simultaneously monitored until the cleanliness threshold is reached.

[0079] The multi-stage pressure and spray angle adjustment design allows optimization based on the pollution characteristics of different areas. In the groove area 01, due to its complex structure and difficult-to-remove contaminants, high-pressure spraying and a narrow-angle jet pattern are used to concentrate cleaning power on these difficult-to-remove contaminants. In the bottom area 02, due to its smoother surface and more evenly contaminated surface, a medium-pressure and moderate-angle spray pattern is used to remove accumulated contaminants without damaging the surface. In the outer area 03, lower pressure and a wider-angle spray pattern are used to avoid damage to the cast wheel surface caused by excessive cleaning and impact. This flexible adjustment method not only improves cleaning efficiency but also significantly reduces the risk of equipment damage.

[0080] For example, based on the critical pressure required to break the carbon black adhesion layer at 2.5 MPa and the requirement for CaCO3 dissolution kinetics at 1.8 MPa, a 20° tilted spray head can be set for groove area 01 to match the trapezoidal groove geometric features, and a spray pressure of 1.5~3.0 MPa can be used. During cleaning, 2.5 MPa is used to break the surface scaling layer in the initial stage, 1.5 MPa is used to continuously dissolve pollutants in the maintenance stage, and 3.0 MPa is used for pulse flushing to remove residues in the final stage. The spray pressure of bottom area 02 and outer area 03 is set to 1.5~2.0 MPa. During cleaning, 1.8 MPa is used to break the surface scaling layer in the initial stage, 1.5 MPa is used to continuously dissolve pollutants in the maintenance stage, and 2.0 MPa is used for pulse flushing to remove residues in the final stage. A ring distributor is installed in bottom area 02 to achieve 360° full coverage cleaning, and a fan-shaped nozzle is used to cover the radial structure in outer area 03. The matching degree of spray angle and regional characteristics can increase the residence time of the cleaning liquid and improve the coverage rate of 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.

[0081] 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 deep treatment and meets the standards.

[0082] Specifically, the waste liquid recycling system consists of: first stage filtration to remove macromolecular impurities, then using a 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 recycled 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 with a citric acid solution with a pH of 2 for cleaning. The acid washing environment is used to dissolve calcium salt deposits, restore membrane flux, and stabilize the system pressure difference below 0.15MPa to avoid attenuation of treatment efficiency.

[0083] The waste liquid recovery and 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 waste liquid treatment in each area, different treatment strategies are adopted according to the different pollutants to ensure that the recovery and reuse of waste liquids can meet environmental protection standards and can be reused in the cleaning system. Through the recycling and reuse of waste liquids, 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.

[0084] Those skilled in the art will appreciate that the present invention is not limited to the foregoing embodiments. The foregoing embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of the present invention is defined by the appended 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 groove area, bottom area and outer area, and build a zone monitoring system; Set cleaning alarm thresholds for each area 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 of 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; 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; Pre-process 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 exceeds the cleaning alarm threshold of the area; The weighted pollution degree of each area is calculated by nonlinear superposition to determine the comprehensive anomaly index; When the comprehensive anomaly index exceeds the set threshold, a complete cleaning is triggered, otherwise a hierarchical response is performed based on the regional priorities of the groove area, bottom area, and outer area in descending order; 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. The casting wheel cleaning method based on spraying and circulation technology according to claim 1 is 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 where the casting wheel contacts 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 threshold is adaptively adjusted as the operating parameters change, and is embedded in the online monitoring system to form a closed-loop feedback mechanism.

5. 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, and the spray angle is optimized according to the characteristics of the area. After each spray, high-pressure water is used for rinsing. During the rinsing process, the changes in conductivity and turbidity are simultaneously monitored until the cleanliness threshold is reached.

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

7. The casting wheel cleaning method based on spraying and circulation technology according to claim 6 is characterized in that: The waste liquid recovery and circulation system has a built-in automatic cleaning function, which maintains the processing efficiency through backwashing and chemical cleaning.

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