A dust collection device for reducing carbon black pollution during red copper furnace pouring

Abstract

The utility model discloses a dust extraction device for reducing carbon black pollution during red copper furnace pouring, belongs to copper alloy smelting technical field. The device includes the flexible enclosure that hangs in the bottom of pouring box, and it forms the semi -closed chamber of carbon black diffusion with the top of crystallizer, and the suction end of at least three suction pipes stretches into the chamber and is below pouring hole, and the exhaust end is connected through high temperature resistant hose and connects the main pipe and dust removal system of confluence, and control system is connected with fan frequency converter, is used for controlling fan to constant low frequency timing start -stop during pouring. The utility model combines through physical restraint and near -source low -pressure suction, and the carbon black is collected efficiently from the source, solves the problem of low dust removal efficiency of traditional mode, easy to destroy the process, and the existence hidden danger, has obviously improved the workshop environment, has guaranteed the stable operation of equipment, and can adapt to pouring box tilt, does not influence production rhythm.

Description

Technical Field

[0001] This utility model belongs to the field of copper alloy smelting technology, specifically relating to a dust collection device for reducing carbon black pollution during copper furnace pouring. Background Technology

[0002] Carbon black coating is a necessary step in the copper casting process. Its function is to isolate the copper from air and prevent secondary oxidation, thereby ensuring the surface quality of the ingot and its subsequent rolling performance. The uniformity and stability of the carbon black layer directly affect the quality of the ingot.

[0003] However, for a long time, copper processing enterprises have generally adopted the "open-style manual carbon spreading" method: the casting tank has no surrounding barriers, and carbon black is scattered everywhere under the impact of high-temperature copper flow. These small, lightweight carbon black particles are easily diffused with the hot airflow, seeping into the gaps of electrical control cabinets and operating tables, causing poor contact of PLC contacts, failure of frequency converter heat dissipation, or even sudden short circuits and burnouts, seriously affecting production stability. At the same time, a thick layer of dust can accumulate on the workshop walls, floors, and equipment surfaces in a short time, which not only greatly increases the workload of cleaning and maintenance, but also poses a safety hazard of dust flashover.

[0004] To suppress dust, two methods were tried on site: one was to increase the total air volume of the dust removal system, but this not only increased energy consumption dramatically, but the excessive suction would also damage the necessary carbon black coating at the pouring gate, affecting the quality of the ingot; the other was to use fireproof cloth for simple enclosure, but the fireproof cloth could not be tilted with the pouring box and had poor sealing performance, so the effect was limited and it hindered the operation.

[0005] Therefore, how to achieve integrated governance of carbon black pollution through "source control, efficient collection, and safe treatment" without disrupting the original casting rhythm or weakening the protective function of carbon black has become a technical bottleneck that urgently needs to be overcome in order to achieve green and continuous copper furnace casting processes. Utility Model Content

[0006] The technical problem to be solved by this utility model is to provide a dust collection device that is structurally reasonable, has high efficiency, is safe and reliable, and can adapt to the tilting of the casting box, in order to address the problems of serious unorganized carbon black escape during the casting of copper furnaces, low collection efficiency of traditional dust removal methods which affect the process, and the existence of electrical safety hazards and dust explosion risks.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows:

[0008] A dust collection device for reducing carbon black pollution during copper furnace casting includes a flexible enclosure, a suction assembly, a manifold, and a control system.

[0009] The flexible enclosure is suspended and connected to the bottom outer perimeter of the casting box and surrounds the casting hole of the casting box. Together with the top of the crystallization device below, it forms a semi-enclosed chamber for constraining the diffusion of carbon black. At least one operating port is opened on the front side of the flexible enclosure, directly opposite the casting hole.

[0010] The suction assembly includes at least three suction pipes. The suction end of the suction pipe passes through the flexible enclosure and extends into the semi-enclosed chamber, with its port facing the area below the pouring hole. The exhaust end of the suction pipe is connected to the main manifold via a high-temperature resistant hose. The main manifold is connected to the existing dust removal system in the plant area via a high-temperature resistant hose.

[0011] The control system is electrically connected to the frequency converter of the dust removal system's fan. The control system is configured to control the fan to operate at a constant low frequency during the pouring operation and to start and stop the dust removal operation according to a preset timer program.

[0012] Furthermore, the operating frequency of the fan inverter of the dust removal system is set to 25Hz-35Hz during the pouring process.

[0013] Furthermore, the operating frequency is preferably 30Hz.

[0014] Furthermore, the control system is also interlocked with the pulse cleaning device or explosion-proof valve of the dust removal system. The control system is further configured to: delay the start of the pulse cleaning device for cleaning after the suction stops, or trigger the explosion-proof valve when abnormal pressure or temperature is detected.

[0015] Furthermore, a flared opening is provided at the end of the suction tube that extends into the semi-enclosed chamber.

[0016] Furthermore, there are four suction tubes, which are respectively arranged on the left, right and rear of the two pouring holes.

[0017] Furthermore, the high-temperature resistant hose is a corrugated metal hose with a length allowance to accommodate the tilting motion of the casting box during the casting process.

[0018] Compared with the prior art, the beneficial effects of this utility model are:

[0019] 1. This invention uses a flexible enclosure and the top of the crystallization device to form a semi-enclosed chamber, which physically restricts the diffusion range of carbon black. Combined with multiple suction points arranged near the source, it can capture the carbon black the moment it is lifted. Practical applications show that it can reduce the amount of carbon black escaping without organization by more than 98%, fundamentally improving the workshop environment.

[0020] 2. The flexible enclosure of this utility model can tilt synchronously with the casting box. The suction pipe adopts a high-temperature resistant hose and is reserved with a margin for movement. The whole set of devices does not require any manual intervention or adjustment during the casting process, and does not affect the original casting rhythm and the key carbon black covering process, thus ensuring the stability of the ingot quality.

[0021] 3. This utility model optimizes the dust removal system from "constant resistance control" to "timed control," matching it with the casting process cycle and reducing energy consumption. By integrating control strategies such as low-frequency operation of the frequency converter, timed pulse cleaning, and explosion-proof interlocking in abnormal conditions, it achieves a safe and efficient operation mode integrating "low negative pressure, timed pulse, and explosion-proof interlocking," fundamentally eliminating the risk of electrical faults and dust explosions caused by carbon buildup.

[0022] 4. This utility model makes full use of the existing dust removal system in the factory area, mainly by adding a flexible enclosure, a suction pipe and a control module. The amount of modification work is small, the investment cost is low, the device structure is simple, the flexible enclosure and suction pipe are modular designs, which are easy to replace after damage, convenient to maintain and have a long service life.

[0023] 5. After the application of this utility model, the dust concentration in the workshop has been significantly reduced, the equipment cleaning cycle has been extended, and maintenance costs have been lowered. More importantly, it has completely solved the problem of electrical system failures caused by carbon black intrusion, reducing the related failure rate from several times per month to zero, ensuring the continuity and stability of production, and resulting in significant economic and social benefits. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of this utility model;

[0025] In the diagram: 1-Pouring box; 2-Pouring hole; 3-Flexible enclosure; 4-Suction pipe; 5-Flare mouth; 6-High temperature resistant hose; 7-Main manifold; 8-Operating port. Detailed Implementation

[0026] The present invention will be further described below with reference to the embodiments and accompanying drawings.

[0027] like Figure 1 As shown, this embodiment provides a dust collection device for reducing carbon black pollution during copper furnace casting. The device mainly consists of a flexible enclosure 3, a suction assembly, a main manifold 7, and a control system.

[0028] The flexible enclosure 3 is made of high-temperature resistant aluminum silicate refractory fiber felt and is suspended from the bottom edge of the casting box 1 by detachable connectors such as bolts or hooks. The enclosure 3 covers the left, right, and rear sides of the casting box 1, as well as part of the front side. Two operating ports 8 are provided on the front side, directly opposite the casting hole 2. These ports naturally divide the front enclosure into left and right sections, facilitating the operator's observation of the copper flow and necessary intervention. The lower edge of the flexible enclosure 3 remains in contact with the top of the crystallizer below, together forming a semi-enclosed constraint chamber that encloses the area below the casting hole 2.

[0029] The suction assembly includes four suction pipes 4, made of high-temperature resistant steel. The suction ends of the four suction pipes 4 enter the semi-enclosed chamber from the upper part of the flexible enclosure 3 on the left, right, and rear sides, respectively. The insertion ports are all oriented directly below the pouring hole 2, and a flared end 5 is welded to this end to optimize the airflow field. The external ports of the four suction pipes 4 are connected to the main manifold 7 via a section of high-temperature resistant corrugated metal hose 6. The length of the high-temperature resistant hose 6 is calculated to ensure that it remains slack and is not straightened or twisted when the pouring tank 1 is tilted to its maximum angle.

[0030] The main manifold 7 is connected to the air intake pipe of the workshop's existing dust removal system via a reducer and a pipe.

[0031] The control system is one of the core optimization points of this device. It is based on the original dust collector electrical control cabinet and involves modifications to the PLC program and wiring connections. First, the fan control mode was changed from the original "constant resistance control" (i.e., the fan only starts cleaning and regulating when the pressure difference between the dust collector inlet and outlet reaches a set value) to "timed control." The PLC program is set according to the cycle of the casting process. For example, after the casting start signal is issued, the dust collector fan automatically starts and operates at a fixed low frequency of 30Hz; after casting ends and the furnace body returns to its position, it automatically shuts down after a delay (e.g., 2 minutes). Second, the control system is interlocked with the dust collector's pulse jet cleaning valve, set to only allow pulse cleaning to start after the fan stops running, preventing dust raised during cleaning from forming an explosive mixture in the chamber. Finally, the control system can also be connected to pressure and temperature sensors installed on the main manifold 7. Once an abnormality is detected (such as a sudden pressure increase or excessive temperature), the emergency explosion relief valve can be immediately triggered and an alarm can be sounded.

[0032] Test conditions

[0033] The device described in this embodiment was installed and tested at a copper furnace casting station. Measurements were taken continuously for 30 heats, and the key data were averaged as follows: the dust concentration near the casting port remained stable at 3.8 mg / m³; the ingot surface qualification rate increased to 99.6%; during the same period, no significant dust settling was detected in the PLC cabinet of the casting control area; compared to the high-power fan that was constantly running before the modification, the dust removal fan of this device saves approximately 280 kWh of electricity per day.

[0034] Comparative experiment: Under the same production conditions, removing the flexible enclosure and switching to the traditional top suction mode immediately increased the scrap rate on the ingot surface to 5.2%, and the dust concentration on the operating table to 10.5 mg / m³. This indicates that the overall design scheme of this embodiment plays a crucial role in resolving the contradiction between carbon black pollution and process interference.

[0035] The specific test data is as follows:

[0036]

[0037] The working process of this utility model:

[0038] At the start of the casting operation, the control system activates the dust collector fan at low frequency according to a timed program. Operators use a spoon to scoop carbon black powder and insert it into the operating port 8, evenly spreading the powder onto the surface of the copper liquid container flowing onto the crystallizer. Most of the carbon black that rises is confined within the narrow, semi-enclosed chamber by the flexible enclosure 3. Simultaneously, four suction pipes 4 arranged within the chamber generate a stable low-negative-pressure airflow near the source, rapidly drawing in the diffused carbon black. This black is then transported via the high-temperature resistant hose 6 and the main manifold 7 to the existing dust collector for purification. During the casting process, the casting box 1 slowly tilts, causing the flexible enclosure 3 to sway accordingly. The high-temperature resistant hose 6 compensates for this movement through its own flexible deformation, ensuring the suction pipeline remains unobstructed. After casting, the fan shuts off after a set delay, followed by the pulse cleaning program, which removes the carbon black adhering to the filter bags into the ash hopper, completing one work cycle.

[0039] The above embodiments are for illustrative purposes only and are not intended to limit the scope of the present invention. Although the present invention has been described in detail with reference to the embodiments, those skilled in the art should understand that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and all such changes, modifications, substitutions, and variations should fall within the protection scope defined by the claims of the present invention.

Claims

1. A dust collection device for reducing carbon black pollution during copper casting, characterized in that: Includes a flexible enclosure (3), a suction assembly, a manifold (7), and a control system; The flexible enclosure (3) is suspended and connected to the bottom outer periphery of the casting box (1) and surrounds the casting hole (2) of the casting box (1). Together with the top of the crystallization device below, it forms a semi-closed chamber for constraining the diffusion of carbon black. The flexible enclosure (3) has at least one operating port (8) located on the front side directly opposite the pouring hole (2); The suction assembly includes at least three suction pipes (4). The suction end of the suction pipe (4) passes through the flexible enclosure (3) and extends into the semi-enclosed chamber, with its port facing the area below the casting hole (2). The exhaust end of the suction pipe (4) is connected to the manifold (7) through a high-temperature resistant hose (6). The manifold (7) is connected to the existing dust removal system in the plant area through the high-temperature resistant hose (6). The control system is electrically connected to the frequency converter of the dust removal system's fan. The control system is configured to control the fan to operate at a constant low frequency during the pouring operation and to start and stop the dust removal operation according to a preset timer program.

2. The vacuuming device according to claim 1, characterized in that, The operating frequency of the fan inverter in the dust removal system is set to 25Hz-35Hz during the pouring process.

3. The vacuuming device according to claim 2, characterized in that, The operating frequency is 30Hz.

4. The vacuuming device according to claim 1, characterized in that, The control system is also interlocked with the pulse cleaning device or explosion-proof valve of the dust removal system. The control system is further configured to: delay the start of the pulse cleaning device for cleaning after the suction stops, or trigger the explosion-proof valve when abnormal pressure or temperature is detected.

5. The vacuuming device according to claim 1, characterized in that, A flared mouth (5) is provided at the end of the suction tube (4) that extends into the semi-closed chamber.

6. The vacuuming device according to claim 1, characterized in that: The number of suction pipes (4) is four, which are respectively arranged on the left, right and rear of the two pouring holes (2).

7. The vacuum cleaner according to claim 1, characterized in that: The high-temperature resistant hose (6) is a metal corrugated hose with a length allowance to accommodate the tilting motion of the casting box (1) during the casting process.

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