A smelting charge pack gas supply system and method for an electric arc furnace

Abstract

This invention discloses a gas supply system and method for a molten ladle used in submerged arc furnace smelting. The molten ladle gas supply system includes a ladle car, a reel device for automatically extending and retracting the gas supply hose, a car-mounted rotating device, a flat-plate automatic docking device, a cylinder-type automatic docking device, a gas pipe planetary guide wheel assembly, and an electrical control module. The flat-plate automatic docking device automatically connects the air passage between the car-mounted rotating device and the bottom of the ladle when the ladle is positioned on the ladle car. The cylinder-type automatic docking device automatically connects an external gas source to the air passage between the side or bottom of the ladle after it is lifted by a tilting machine. The gas pipe planetary guide wheel assembly guides and supports the gas supply hose to change direction during furnace rotation. The input end of the car-mounted rotating device is connected to the end of the gas supply hose, and its output end can rotate freely relative to the ladle car. This invention can achieve automatic gas supply following, automatic docking, switching between docking modes, high control precision, and adaptability to complex operating trajectories.

Description

Technical Field

[0001] This invention relates to the field of submerged arc furnace smelting technology, and in particular to a gas supply system and method for a molten charge ladle in submerged arc furnace smelting. Background Technology

[0002] In the smelting production of submerged arc furnaces (such as industrial silicon furnaces and calcium-iron alloy furnaces), the molten material after exiting the furnace needs to be received, transferred, and then subjected to subsequent refining and casting processes via a molten material ladle. To improve product quality and process efficiency, a mixture of oxygen and compressed air is usually introduced into the bottom of the molten material ladle for blowing during the receiving or refining process. Traditional gas supply methods have the following drawbacks: First, the gas supply pipes require manual connection and disconnection, and are dragged along with the molten material ladle cart. Due to the complex trajectory of the molten material ladle cart, including circular motion around the furnace, long-distance straight-line motion, and cross-track rotational motion, if the pipe is too long, multiple people are required to drag it in sections. The environment around the furnace is hot and dusty, posing a risk of silicon molten material splashing, and the furnace is electrically charged, making manual operation extremely dangerous and labor-intensive. Second, gas ratio control relies on manual adjustment of valve openings, adjusting by observing the flow meter based on experience. This requires a high level of operator experience, resulting in unstable production quality and difficulty in achieving precise process control. Therefore, how to provide a gas supply system for molten material ladles that can achieve automatic gas supply following, automatic docking, precise proportioning, and adaptability to harsh environments is a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0003] To solve the above-mentioned technical problems, the present invention provides a gas supply system and method for molten charge ladle in smelting of electric arc furnaces. It can realize automatic gas supply following, automatic docking, mutual switching of docking modes, high control precision, and adaptability to complex operating trajectories.

[0004] The technical solution provided by this invention is as follows: A gas supply system for a molten charge ladle in an electric arc furnace includes: A molten charge carriage is used to carry molten charge packages and run them on a pre-set track. A reel device, installed in a fixed position or on a molten material ladle car, is used to automatically reel in and unwind the gas supply hose; The vehicle-mounted rotating device is fixedly installed on the molten ladle car. Its input end is connected to the end of the air supply hose, and its output end can rotate freely relative to the molten ladle car. A flat-plate automatic docking device is installed between the bottom contact surfaces of the molten ladle car and the molten ladle. It is used to automatically connect the air passage between the on-board rotating device and the bottom of the molten ladle when the molten ladle is placed on the molten ladle car. The cylinder-type automatic docking device is installed on the tilting machine and is used to automatically connect the external air source with the air passage of the side or bottom of the molten material bag after the molten material bag is lifted by the tilting machine. The gas tube planetary guide wheel assembly is used to guide and support the gas supply hose to change direction during furnace operation; The electrical control module is used to precisely control the flow rate and ratio of oxygen and compressed air introduced into the molten charge.

[0005] Preferably, the gas tube planetary guide wheel assembly consists of multiple sets, which are distributed at intervals along the circumference of the furnace body of the electric arc furnace.

[0006] Preferably, the tracheal planetary guide wheel assembly includes a vertical planetary roller, an upper horizontal planetary roller, and a lower horizontal planetary roller. The vertical planetary roller, upper horizontal planetary roller, and lower horizontal planetary roller are arranged in a planetary pattern, together forming a limiting space through which the air supply hose passes.

[0007] Preferably, the tracheal planetary guide wheel assembly is supported by an adjustable height bracket rod so that the air supply hose is suspended at a height of not less than 2 meters (the height is designed according to the actual site conditions; a low-position arrangement uses rollers to support the tracheal hose to avoid dragging and rubbing the tracheal hose on the ground, requiring a relatively dense arrangement of rollers, which makes replacement and maintenance more convenient and safer; an overhead arrangement allows for a slightly longer support distance and does not affect personnel passage, but replacement and maintenance are slightly more difficult and require high-altitude operations).

[0008] Preferably, the vehicle-mounted rotating device includes a rotary joint and a roller assembly; The rotary joint is used to connect the air supply hose to the flat-plate automatic docking device and allows 360° rotation. The roller assembly is used to support the gas supply hose as the gas supply hose rotates with the molten ladle car, preventing it from getting tangled.

[0009] Preferably, the electrical control module is equipped with a mass flow controller for individually and precisely controlling the flow rates of oxygen and compressed air.

[0010] Preferably, the gas supply system for the molten charge ladle in the submerged arc furnace further includes a tensioning device. The tensioning device is located at the end or middle of the gas supply hose to maintain appropriate tension in the gas supply hose as it travels with the molten material ladle.

[0011] Preferably, the gas supply system for the molten charge ladle in the submerged arc furnace further includes a gas pipe guide column assembly. The tracheal guide column assembly includes an upper baffle, a guide roller, a column, and a drop-proof roller. The upper baffle and the anti-drop roller are respectively installed at different heights on the column to restrict the air supply hose along a specific path to prevent it from dragging on the ground; The guide roller is rolled on one side of the column and located below the upper baffle via a vertical ball bearing.

[0012] A method for supplying gas to a molten charge ladle in submerged arc furnace smelting, employing the aforementioned gas supply system for a molten charge ladle in submerged arc furnace smelting, includes the following operational steps: S1. The molten material ladle is placed on the molten material ladle car, triggering the flat-plate automatic docking device to start bottom air supply; S2. The molten charge ladle car carries the molten charge ladle through the furnace arc track, straight track and track changing turntable in sequence. During this process, the reel device automatically retracts and extends the gas supply hose according to the distance of the molten charge ladle car. When the gas supply hose travels around the submerged arc furnace, it is automatically attached to the gas pipe planetary guide wheel assembly, and when the track changing turntable rotates, it can rotate freely without getting tangled through the on-board rotating device. S3. When the molten material ladle car reaches the tilting machine position, the tilting machine lifts the molten material ladle, and the flat-plate automatic docking device automatically disconnects and shuts off the air supply. S4. The cylinder-type automatic docking device extends and connects automatically to continuously supply air to the molten ladle during tilting, pouring and slag removal. S5. After the pouring and slag removal are completed, the cylinder-type automatic docking device closes and retracts, and the empty molten material ladle falls back into the molten material ladle car, repeating the next cycle.

[0013] Preferably, in step S2, the electrical control module automatically adjusts the real-time ratio of oxygen and compressed air according to the preset process flow curve.

[0014] The present invention has the following advantages over the prior art: 1. The gas supply system for molten ladle in the smelting of the electric arc furnace of the present invention, through the structural arrangement of molten ladle car, reel device, vehicle-mounted rotating device, flat plate automatic docking device, cylinder automatic docking device, gas pipe planetary guide wheel assembly and electrical control module, can realize unmanned automated gas supply throughout the entire process from receiving silicon water, refining, transfer, tilting and pouring to slag removal, with high control precision and adaptability to complex operating trajectories. 2. In the gas supply system for the molten charge ladle in the electric arc furnace smelting of the present invention, the molten charge ladle is placed on the molten charge ladle car. The placement accuracy does not need to be too high. Within a deviation of ±50MM, the flat plate automatic docking device can be triggered to conduct bottom gas supply. The weight of the molten charge ladle itself is the clamping force, and no additional power is required. When the molten charge ladle car carries the molten charge ladle on complex tracks (including circular tracks, straight tracks and track changing turntables), the reel device automatically retracts and extends the gas supply hose according to the distance of the molten charge ladle car, and the gas supply hose will not get tangled in the molten charge ladle. The molten charge ladle car moves the molten charge ladle to the tilting machine position, and the tilting machine lifts the molten charge ladle. The cylinder-type automatic docking device does not need to have too high docking accuracy. Within a deviation of ±30MM, it automatically extends and conducts, and simultaneously aligns with the molten charge ladle. In the relatively static state, the molten charge ladle is continuously supplied with gas during the tilting, pouring and slag removal process. The gas pipe guide column assembly limits the gas supply hose on complex paths and can prevent the gas supply hose from dragging on the ground, which is safe and reliable. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the gas supply system for the molten charge ladle in an embodiment of the present invention. Figure 2 This is a schematic diagram of the tracheal guide column assembly in an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of the tracheal planetary guide wheel assembly in an embodiment of the present invention; Figure 4 This is a schematic diagram of the reel device in an embodiment of the present invention; Figure 5 This is a schematic diagram of the tilting machine in an embodiment of the present invention; Figure 6 This is a schematic diagram of the tilting machine in its tilted state according to an embodiment of the present invention.

[0017] Figure label: 1. Melting ladle car; 2. Reel device; 3. Onboard rotating device; 31. Rotary joint; 32. Roller assembly; 4. Flatbed automatic docking device; 5. Air pipe planetary guide wheel assembly; 51. Vertical planetary roller; 52. Upper horizontal planetary roller; 53. Lower horizontal planetary roller; 54. Support rod; 6. Cylinder-type automatic docking device; 7. Electrical control module; 8. Tilting machine; 9. Submerged arc furnace; 10. Rail changing turntable; 11. Circular arc track; 12. Straight track; 13. Tensioning device; 14. Air pipe guide column assembly; 141. Upper baffle; 142. Guide roller; 143. Anti-fall roller; 144. Column; 145. With vertical ball bearing seat; 15. Melting ladle; 16. Air supply hose. Detailed Implementation

[0018] To enable those skilled in the art to better understand the technical solutions of this invention, the technical solutions in the embodiments of this invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0019] Example 1: like Figure 1 , 3 As shown in Figure 6, this embodiment of the invention provides a gas supply system for a molten charge ladle used in smelting of an electric arc furnace, including a molten charge ladle car 1, a reel device 2, a car-mounted rotating device 3, a flat-plate automatic docking device 4, a gas pipe planetary guide wheel assembly 5, a cylinder-type automatic docking device 6, and an electrical control module 7.

[0020] In this embodiment, the gas supply system for the molten ladle used in smelting of an electric arc furnace adopts two methods of automatic docking: flat plate type and cylinder type. When the molten ladle is placed on the molten ladle car 1, the flat plate type automatic docking is used. When the molten ladle enters the tilting machine 8 and is ready to be tilted for casting, the system switches to cylinder type automatic docking. The entire process of refining and casting of the molten ladle can be carried out without human intervention in inserting or removing gas pipes.

[0021] In this embodiment, the gas pipe planetary guide wheel assembly 5 consists of multiple sets, which are spaced apart along the circumference of the furnace body 9 of the electric arc furnace. For example... Figure 3 As shown, the tracheal planetary guide wheel assembly 5 includes a vertical planetary roller 51, an upper horizontal planetary roller 52, and a lower horizontal planetary roller 53. These three rollers are arranged in a planetary configuration, collectively forming a limiting space (a "planetary" channel) through which the air supply hose 16 passes, supporting the hose in a relaxed state and preventing it from detaching. The tracheal planetary guide wheel assembly 5 is supported by an adjustable-height bracket 54, ensuring the air supply hose 16 is 2.5 meters off the ground, guaranteeing safe passage for personnel and preventing interference with ground obstacles.

[0022] In this embodiment, the gas pipe planetary guide wheel assembly 5, combined with the vehicle-mounted rotating device 3 on the molten ladle car 1, enables the gas supply hose 16 to easily move around the furnace, with a furnace-circling angle exceeding 180° to 270°. When the molten ladle car 1 travels around the submerged arc furnace 9, the gas supply hose, under the unwinding action of the reel device 2, smoothly enters and passes between the rollers of each gas pipe planetary guide wheel assembly 5, and is guided by the rollers to change its linear motion into an arc motion, avoiding friction with the furnace body or other equipment. When the molten ladle car 1 needs to enter the track-changing turntable 10 for in-situ rotation track changing, the molten ladle car 1 itself will rotate at a large angle. At this time, the rotary joint inside the vehicle-mounted rotating device 3 rotates freely, and the gas supply hose 16 is supported and moves with the gas pipe planetary guide wheel assembly 5, thereby effectively preventing the gas supply hose from getting tangled on the molten ladle 15 or the molten ladle car 1.

[0023] In this embodiment, the gas tube planetary guide wheel assembly 5 adopts a planetary arrangement. In a limited space, multiple sets of small planetary rollers can be arranged in an arc to improve the turning radius of the air supply hose 16 and extend its service life. The rollers in the vertical planetary roller 51, the upper horizontal planetary roller 52, and the lower horizontal planetary roller 53 are made of non-metallic wear-resistant materials, which can effectively protect the air supply hose 16.

[0024] In this embodiment, the vehicle-mounted rotating device 3 includes a rotary joint 31 and a roller assembly 32; the rotary joint 31 is used to realize the air passage connection between the air supply hose 16 and the flat automatic docking device 4, and allows 360° rotation; the roller assembly 32 is used to support the air supply hose 16 when the air supply hose rotates with the molten material ladle car 1, so as to realize the air passage connection and prevent the air supply hose 16 from wrapping around the molten material ladle 15 when the molten material ladle car 1 rotates at a large angle.

[0025] In this embodiment, the electrical control module 7 specifically includes an electrical control unit and a pneumatic control unit. The electrical control module 7 is equipped with a high-precision mass flow controller (existing products can be used, such as imported brands like Bronkhorst from the Netherlands and E+H from Switzerland, or domestic brands like Beijing Qixing Huachuang and Chongqing Chuanyi). This controller has both flow measurement and flow control functions, and can independently and precisely control the flow rates of oxygen and compressed air. If the process parameters are fixed, the electrical control module 7 can automatically adjust the oxygen and compressed air ratio according to the process flow curve requirements, reducing reliance on manual experience and stabilizing production quality. Furthermore, the electrical control module 7 performs logical judgments based on the collected gas medium pressure, flow rate, and valve status parameters before and after the valves to determine the blockage or leakage in the gas supply pipeline. It can also evaluate and predict the performance of the permeable bricks embedded at the bottom of the molten material package 15, prompting for replacement when the permeability fails to meet production requirements.

[0026] A method for supplying gas to a molten charge ladle in submerged arc furnace smelting, employing the aforementioned gas supply system for a molten charge ladle in submerged arc furnace smelting, includes the following operational steps: S1, the molten material bag 15 is placed on the molten material bag car 1, triggering the flat plate automatic docking device 4 to conduct and start bottom air supply; S2. The molten charge car 1 carries the molten charge 15 and passes through the furnace arc track 11, the straight track 12 and the track changing turntable 10 in sequence. During this process, the reel device 2 automatically retracts and extends the gas supply hose 16 according to the distance of the molten charge car 1. When the gas supply hose 16 travels around the submerged arc furnace, it is automatically attached to the gas pipe planetary guide wheel assembly 5, and when the track changing turntable 9 rotates, it can rotate freely without getting tangled through the on-board rotating device 3. S3. The molten material bag 1 moves to the tilting machine position, the tilting machine 7 lifts the molten material bag 15, and the flat plate automatic docking device 4 automatically disconnects and shuts off the air source. S4. The cylinder-type automatic docking device 6 extends and connects automatically to continuously supply air to the molten material ladle 15 during the tilting, pouring and slag removal process. S5. After the pouring and slag removal are completed, the cylinder-type automatic docking device 6 closes and retracts, and the empty molten material bag 15 falls back into the molten material bag car 1, repeating the next cycle.

[0027] Example 2: The difference between this embodiment and Embodiment 1 is that, in order to prevent the gas supply hose 16 from becoming too long and dragging on the ground, a tensioning device 13 is installed at the end (near the molten ladle car 1) or in the middle of the gas supply hose 16. This tensioning device 13 can be a spring-loaded pulley system or a gravity hammer tensioner, used to maintain appropriate tension on the hose 16, keeping it suspended and further preventing friction with the ground. The tensioning device 13 also acts as a buffer. Because the molten ladle car 1 frequently starts and stops during operation, it has significant inertia, resulting in a large impact on the gas supply hose 16. The tensioning device 13 can eliminate this impact, preventing the gas supply hose 16 from breaking.

[0028] In addition, on certain straight track sections, features such as Figure 2 The air tube guide column assembly 14 shown includes an upper baffle 141, a guide roller 142, a ground-resistant roller 143, and a column 144. The upper baffle 141 and the ground-resistant roller 143 are respectively set at different heights on the column 144 to confine the air supply hose 16 between the upper baffle 141 and the ground-resistant roller 143 to prevent it from dragging on the ground and to ensure that it does not fall to the ground and operates smoothly. The guide roller 142 is rolled on one side of the column 144 and located below the upper baffle 141 via a vertical ball bearing 145.

[0029] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A gas supply system for a molten charge ladle used in submerged arc furnace smelting, characterized in that, include: A molten charge carriage is used to carry molten charge packages and run them on a pre-set track. A reel device, installed in a fixed position or on a molten material ladle car, is used to automatically reel in and unwind the gas supply hose; The vehicle-mounted rotating device is fixedly installed on the molten ladle car. Its input end is connected to the end of the air supply hose, and its output end can rotate freely relative to the molten ladle car. A flat-plate automatic docking device is installed between the bottom contact surfaces of the molten ladle car and the molten ladle. It is used to automatically connect the air passage between the on-board rotating device and the bottom of the molten ladle when the molten ladle is placed on the molten ladle car. The cylinder-type automatic docking device is installed on the tilting machine and is used to automatically connect the external air source with the air passage of the side or bottom of the molten material bag after the molten material bag is lifted by the tilting machine. The gas tube planetary guide wheel assembly is used to guide and support the gas supply hose to change direction during furnace operation; The electrical control module is used to precisely control the flow rate and ratio of oxygen and compressed air introduced into the molten charge.

2. The gas supply system for the molten charge ladle in submerged arc furnace smelting according to claim 1, characterized in that, The gas tube planetary guide wheel assembly consists of multiple sets, which are distributed at intervals along the circumference of the submerged arc furnace.

3. The gas supply system for the molten charge ladle in submerged arc furnace smelting according to claim 2, characterized in that, The tracheal planetary guide wheel assembly includes a vertical planetary roller, an upper horizontal planetary roller, and a lower horizontal planetary roller. The vertical planetary roller, upper horizontal planetary roller, and lower horizontal planetary roller are arranged in a planetary pattern, together forming a limiting space through which the air supply hose passes.

4. The gas supply system for the molten charge ladle in submerged arc furnace smelting according to claim 2, characterized in that, The tracheal planetary guide wheel assembly is supported by an adjustable height bracket rod to ensure that the air supply hose is suspended at a height of not less than 2 meters.

5. The gas supply system for the molten charge ladle in submerged arc furnace smelting according to any one of claims 1-4, characterized in that, The vehicle-mounted rotating device includes a rotary joint and a roller assembly; The rotary joint is used to connect the air supply hose to the flat-plate automatic docking device and allows 360° rotation. The roller assembly is used to support the gas supply hose as it rotates with the molten ladle car, preventing it from getting tangled.

6. The gas supply system for the molten charge ladle in submerged arc furnace smelting according to any one of claims 1-4, characterized in that, The electrical control module is equipped with a mass flow controller for individually and precisely controlling the flow rates of oxygen and compressed air.

7. The gas supply system for the molten charge ladle in submerged arc furnace smelting according to any one of claims 1-4, characterized in that, The gas supply system for the molten charge ladle used in the electric arc furnace smelting also includes a tensioning device. The tensioning device is located at the end or middle of the gas supply hose to maintain appropriate tension in the gas supply hose as it travels with the molten material ladle.

8. The gas supply system for the molten charge ladle in submerged arc furnace smelting according to any one of claims 1-4, characterized in that, The gas supply system for the molten charge ladle used in the submerged arc furnace smelting also includes a gas pipe guide column assembly. The tracheal guide column assembly includes an upper baffle, a guide roller, a column, and a drop-proof roller. The upper baffle and the anti-drop roller are respectively installed at different heights on the column to restrict the air supply hose along a specific path to prevent it from dragging on the ground; The guide roller is rolled on one side of the column and located below the upper baffle via a vertical ball bearing.

9. A method for supplying gas to a molten charge ladle for smelting in a submerged arc furnace, characterized in that, The gas supply system for the molten charge ladle used in any one of claims 1-8 of the above-mentioned claims includes the following operating steps: S1. The molten material ladle is placed on the molten material ladle car, triggering the flat-plate automatic docking device to start bottom air supply; S2. The molten charge ladle car carries the molten charge ladle through the furnace arc track, straight track and track changing turntable in sequence. During this process, the reel device automatically retracts and extends the gas supply hose according to the distance of the molten charge ladle car. When the gas supply hose travels around the submerged arc furnace, it is automatically attached to the gas pipe planetary guide wheel assembly, and when the track changing turntable rotates, it can rotate freely without getting tangled through the on-board rotating device. S3. When the molten material ladle car reaches the tilting machine position, the tilting machine lifts the molten material ladle, and the flat-plate automatic docking device automatically disconnects and shuts off the air supply. S4. The cylinder-type automatic docking device extends and connects automatically to continuously supply air to the molten ladle during tilting, pouring and slag removal. S5. After the pouring and slag removal are completed, the cylinder-type automatic docking device closes and retracts, and the empty molten material ladle falls back into the molten material ladle car, repeating the next cycle.

10. The gas supply method for the molten charge ladle in submerged arc furnace smelting according to claim 9, characterized in that, In step S2, the electrical control module automatically adjusts the real-time ratio of oxygen and compressed air according to the preset process flow curve.

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