System and method for steam condensation in an aluminum direct chill casting pit

Abstract

The direct chill (DC) casting system can be used to cast metal ingots from molten metal such as aluminum or aluminum alloys. The above-described DC casting system includes a steam condensation system that condenses the steam generated during the DC casting process into recycled water. The above-described recycled water can be used for subsequent cooling of the metal ingot during the DC casting process.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit of U.S. Provisional Patent Application No. 63 / 367,061, filed on June 27, 2022, entitled "SYSTEMS AND METHODS FOR STEAM CONDENSATION IN ALUMINUM DIRECT CHILL CASTING PIT", the contents of which are hereby incorporated by reference in their entirety.

[0002] This application generally relates to metal processing, and more specifically, but not limited thereto, to metal processing that generates steam, such as direct chill casting.

Background Art

[0003] Steam can be generated during various metal processing operations. As an example, in a casting process such as direct chill (DC) casting, steam can be generated when the system directs water at the ingot being cast for the purpose of cooling the ingot. Some of the water may not turn into steam during such processing, and such liquid - form water can be re - cooled by the cooling system and reused during the casting process. Other water can turn into steam during the cooling of the ingot. Inside the casting pit, such steam can pose a safety hazard by reducing visibility before it is customarily discharged to the environment. Steam can also rise from the casting pit and re - condense on equipment around and / or above the casting pit, which can shorten the life of the equipment and cause product defects at the head of the ingot. To make up for the water lost as steam, new water or makeup water needs to be periodically introduced into the system. Such a need for new water or makeup water is costly both financially and in terms of resources.

Summary of the Invention

[0004] The embodiments to which this patent applies are defined by the following claims, not by the summary of this invention. The summary of this invention is a high-level overview of various embodiments and introduces some of the concepts further described in the section on forms for carrying out the following invention. The summary of this invention is not intended to identify the important or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. The present subject matter is to be understood by reference to the entire specification of this patent, any or all of the drawings, and the appropriate portions of each claim.

[0005] According to various embodiments, a metal processing system for processing a metal substrate includes a vapor condensation system for condensing vapor generated during metal processing of the metal substrate.

[0006] According to a particular embodiment, a DC casting system includes a vapor condensation system for condensing vapor generated during the DC casting process.

[0007] According to some embodiments, a DC casting system includes a cooling system for at least partially cooling a metal ingot during the DC casting process. In a particular embodiment, the cooling system can cool the metal ingot by directing water from a coolant source onto the metal ingot. The cooling system may include a vapor condensation system for condensing vapor generated during the DC casting process.

[0008] According to various embodiments, a method of DC casting a metal ingot includes cooling the metal ingot emerging from a mold by directing water from a coolant source onto the metal ingot and condensing the vapor generated by the cooling of the metal ingot as recycled water. The method includes providing the recycled water to the coolant source.

[0009] According to certain embodiments, a metal processing system for processing a metal substrate includes a vapor condensation system that directs a flow of vapor generated during the metal processing of the metal substrate by spraying water in the direction of the flow of the vapor.

[0010] The various embodiments described herein can include additional systems, methods, features, and advantages, which may not necessarily be explicitly disclosed herein, but will be apparent to those skilled in the art upon examination of the following detailed description and the accompanying drawings. All such systems, methods, features, and advantages are intended to be included within the present disclosure and protected by the appended claims.

[0011] This specification refers to the following accompanying drawings, and when the same reference numerals are used in different figures, it is intended to indicate the same or similar components.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

Figure 4

Modes for Carrying Out the Invention

[0013] Systems and methods for condensing vapor produced by a metal processing system, such as, but not limited to, a casting system such as a DC casting system, are described herein. The systems and methods described herein can condense the vapor into recycled water and, in some embodiments, return the recycled water to a cooling system of the metal processing system for use in cooling a metal substrate. The systems and methods described herein can conventionally reduce the amount of water lost to the environment and thereby reduce the amount of new or makeup water that needs to be introduced into the system. Thus, the systems and methods provided herein can be less costly and resource intensive compared to conventional metal processing systems that discharge vapor produced as a byproduct of metal processing. The systems and methods described herein can also enable the recycled water to be used as a coolant during the casting process by returning the recycled water to the cooling system of the metal casting system. Various other benefits and advantages may be realized by the systems and methods provided herein, and the above advantages should not be considered limiting.

[0014] FIG. 1 shows an example of a metal processing system 100 according to various embodiments. The metal processing system 100 includes one or more metal processing stations 102, a cooling system 104, and a vapor condensation system 106.

[0015] The cooling system 104 provides a coolant, such as liquid water, to the metal processing station 102 (represented by arrow 108). The metal processing station 102 can be various metal processing apparatuses, stations, workplaces, etc. that utilize water from the cooling system 104 to cool a metal substrate as needed. Vapor (represented by arrow 110) is generated during the metal processing performed by the metal processing station 102, and the vapor condensation system 106 condenses the vapor into recycled water. Optionally, as represented by arrow 112, the vapor condensation system 106 can supply the recycled water as liquid water to the metal processing station 102 by returning the recycled water to the cooling system 104. The vapor condensation system 106 can be various systems and apparatuses for condensing the vapor from the metal processing station 102. Non-limiting examples of the vapor condensation system are described in detail below and shown in FIGS. 2 - 4.

[0016] FIG. 2 shows a non-limiting example where the metal processing station 102 is a DC casting system 214. As shown in FIG. 2, the DC casting system 214 generally includes a casting pit with at least one open mold 216 that defines a casting cavity, and molten metal can be introduced into the casting cavity as represented by arrow 218. The mold 216 is initially closed at its lower end by a bottom block 220, and the bottom block 220 remains in a predetermined position until a certain amount of molten metal accumulates in the casting cavity and begins to cool. Next, the bottom block 220 is separated from the mold 216 so that the ingot 222 gradually exits from the lower end of the mold 216. The ingot 222 can be manufactured to a desired length limited only by the space available below the mold 216 by the movement of the bottom block 220 and the corresponding continuous supply of molten aluminum to the mold 216.

[0017] In various embodiments, the cooling system 104 may be in fluid communication with the mold 216 to supply water or other coolant to the mold 216. The mold walls are typically cooled to cool the metal within the casting cavity. The ingot 222 emerging from the lower end of the mold 216 in DC casting is externally solid, but its central core is still molten. To maintain the surroundings of the ingot and promote internal cooling and solidification of the ingot, a coolant such as water 224 is applied directly to the surface 225 of the ingot 222 emerging from the mold 216. In this procedure, the water 224 is directed onto the ingot surface 225. A portion of the water 224 flows downward on the ingot surface 225, and the remaining water turns into vapor 226. As described above, the vapor 226 generated by DC casting is conventionally discharged to the environment.

[0018] As illustrated in FIG. 2, a vapor condensation system 206 is provided for the treatment of the vapor 226. In the embodiment illustrated in FIG. 2, the vapor condensation system 206 includes one or more nozzles or atomizers 228. The atomizer 228 is configured to spray water 230 into the casting pit to interact with the vapor 226, whereby the vapor 226 is condensed as recycled water (represented by arrow 232). In some embodiments, the atomizer 228 can spray the water 230 in various forms. As a non-limiting example, the atomizer 228 optionally sprays the water 230 as fine droplets, but in other embodiments, the atomizer 228 can introduce the water 230 into the casting pit to interact with the vapor 226 as desired. The atomizer 228 may be various types of nozzles as needed and may introduce the water 230 in various spray patterns as desired. As two non-limiting examples, the atomizer 228 may be a nozzle that introduces the water 230 in a flat spray pattern, a hollow cone spray pattern, a full cone spray pattern, and / or other patterns as desired.

[0019] In addition to being various types of nozzles as needed, since the steam condensation system 206 can include any number of atomizers 228 at various positions as needed, the number and position of the atomizers 228 should not be considered limiting. In certain embodiments, one or more of the type of nozzle, the position of the nozzle, and the number of nozzles can be controlled to control the condensation rate and / or amount of steam 226. Additionally or alternatively, other control parameters of the atomizer 228 can be controlled to control the condensation rate and / or amount of steam 226. The control parameters include, but are not limited to, the pressure of the water 230, the flow rate of the water 230 to the atomizer 228, the temperature of the water 230 being distributed, combinations thereof, and / or other control parameters as needed. The control parameters may also be controlled and / or changed during the casting process as the conditions of steam generation change. As a non-limiting example, the casting process may start with a low water flow, transition to a high water flow, and then have a reduced water flow during the casting process.

[0020] As described above, the water 230 distributed by the atomizer 228 then condenses the steam 226 into recycled water 232 (e.g., in liquid form). The water 232 can be collected using a variety of desired devices, mechanisms, or techniques including, but not limited to, various collection tanks 234, drains, suction devices, etc. as needed. The collected recycled water 232 can optionally be returned to the cooling system 204, whereby the recycled water 232 can be re-cooled (if necessary) and / or otherwise processed as needed. Such water 232 can then be supplied to the DC casting system 214 for cooling the ingot 222 and / or for use by the atomizer 228. As described above, by condensing the steam 226 generated by metal processing (e.g., DC casting), the system can reuse the recycled water 232 for subsequent cooling, thereby resulting in cost and resource savings.

[0021] Figure 3 shows another example of a vapor condensation system 306 for a metal processing system according to an embodiment. In one non-limiting example, the vapor condensation system 306 may be used with, or in addition to, the DC casting system 214 in place of the vapor condensation system 206. In the embodiment of Figure 3, the vapor condensation system 306 includes a conduit 336, and vapor 226 condenses into recycled water within the conduit 336.

[0022] In certain embodiments, as shown in Figure 3, the conduit 336 includes one or more inlets 338. In some embodiments, the conduit 336 may be elongated between opposing ends 342, 344, and the one or more inlets 338 may be provided in a sidewall 346 between the ends 342, 344. As represented by arrow 348, vapor 226 may enter the conduit 336 through the one or more inlets 338. The conduit 336 further includes one or more fluid outlets 356 for discharging recycled water 232 after the vapor 226 has condensed within the conduit 336.

[0023] The vapor condensation system 306 includes one or more devices or mechanisms for condensing the vapor 226 within an interior region 352 of the conduit 336.

[0024] In some embodiments, as shown in Figure 3, the vapor condensation system 306 includes one or more sprayers 228 for spraying water 230 into the vapor 226 within the interior region 352. In certain embodiments, the sprayer 228 is within the interior region 352 of the conduit 336, but in other embodiments, the sprayer 228 need not be within the interior region 352, and the sprayer 228 can direct the water 230 into the interior region 352. The number, type, and location of the sprayer 228 within and / or with respect to the conduit 336 should not be considered limiting.

[0025] In some embodiments, the nebulizer 228 and / or the nozzle can be controlled such that the water 230 is directed in various directions relative to the steam and / or air flow. In such embodiments, the nebulizer 228 can also be utilized to assist in controlling the direction of the steam and / or air flow. By way of non-limiting example, the nebulizer 228 and / or the nozzle can be controlled such that the water 230 (e.g., in droplet form or other desired form) is directed parallel to the steam and / or air flow, at a non-zero angle relative to the steam and / or air flow, in a cross-flow direction relative to the steam and / or air flow, in combinations thereof, and / or in other desired directions. In certain embodiments, the angle or orientation of the nebulizer 228 and / or the nozzle can be adjustable such that the angle of the water 230 from the nebulizer 228 and / or the nozzle (and thus the ability to control the steam and / or air flow) can be adjusted as desired. Such control can be achieved automatically (e.g., using a controller (processor and / or memory) communicatively coupled to the nebulizer 228 and / or other actuators as desired) and / or by an operator.

[0026] Additionally or alternatively, the steam condensation system 306 optionally includes one or more chiller conduits 354 within the internal region 352. To reduce the temperature within the internal region 352, a coolant such as cooling water is directed through the chiller conduits 354, thereby condensing the steam 226. As another non-limiting example, a cooling gas such as, but not limited to, cooling air may be used as the coolant. Other devices, materials, and / or mechanisms within the internal region 352 for condensing the steam 226 may be utilized as necessary.

[0027] Similar to the steam condensation system 206, after the steam 226 is condensed to the recycled water 232 by the steam condensation system 306, the recycled water 232 can optionally be provided to the cooling system before being used as part of the cooling in the metal treatment.

[0028] In some embodiments, one or more suction devices, such as blower 350, may optionally be included in conduit 336 to generate a suction force that draws vapor 226 into the conduit 336. By way of non-limiting example, blower 350 can be a blower or fan that draws air and vapor 226 into conduit 336. In the illustrated embodiment, vapor condensation system 306 includes two blowers 350 provided at opposite ends 342, 344 of conduit 336. However, in other embodiments, vapor condensation system 306 can include any number of blowers, including the omission of blower 350, a single blower 350, or two or more blowers 350, as needed. One or more blowers 350 may be provided at any suitable location.

[0029] FIG. 4 shows another example of a vapor condensation system 406 for a metal processing system, according to an embodiment. Similar to vapor condensation system 306, vapor condensation system 406 includes a conduit 436. Vapor 226 is directed into conduit 436 (represented by arrow 458), where vapor 226 is condensed into recycled water. In some embodiments, similar to vapor condensation system 306, vapor condensation system 406 can include one or more blowers 350 to generate a suction force that draws vapor 226 into conduit 436.

[0030] Compared to vapor condensation system 306, which includes an internal cooling device or mechanism for condensing vapor, vapor condensation system 406 includes one or more cooling devices or mechanisms on outer surface 460 of conduit 436 to cool the temperature of conduit 436. The external cooling device or mechanism can be various suitable devices or mechanisms as needed.

[0031] Referring to FIG. 4, in some embodiments, a process gas line or conduit 462 for a metal processing system may be provided on the outer surface 460 to cool the conduit 436. In certain embodiments, since the process gas may be provided at a lower temperature, the conduit 462 may have a reduced temperature and, in that way, by arranging the conduit 462 in contact with the conduit 436, the conduit 436 can be cooled. The process gas line 462 can be various process gas lines as needed and can depend on the particular metal processing system. Non-limiting examples of the process gas line 462 can be an argon gas line, a nitrogen gas line, a carbon dioxide gas line, a chlorine gas line, combinations thereof, and / or one or more of other process gas lines 462 as needed.

[0032] In addition to or instead of the process gas line 462, the conduit 436 may include one or more heat exchanger fins 464 along the conduit 436. In some embodiments, the heat exchanger fins 464 may be circular fins on the conduit 436 and, optionally, may be provided along the length of the conduit 436. However, in other embodiments, the heat exchanger fins 464 may have other shapes or contours as needed and the heat exchanger fins 464 may be provided along the conduit 436 as needed. In other embodiments, other devices or mechanisms suitable for externally cooling the conduit 436 may be used as needed.

[0033] The external cooling device of the steam condensation system 406 cools the conduit 436, thereby reducing the temperature within the internal region of the conduit 436. Such a temperature reduction allows the steam 226 to condense within the conduit as recycled water. The steam 226 condensed into recycled water may optionally be sent to a cooling system or held within the storage tank 434 (represented by arrow 466) before being processed in a desired other way.

[0034] Although the vapor condensation systems 206, 306, 406 are shown separately, in various embodiments, two or more condensation systems may be used in the metal processing system. As a non-limiting example, referring to FIG. 2, the DC casting system 214 may utilize both the vapor condensation system 206 and the vapor condensation system 306, and / or may utilize all of the vapor condensation systems 206, 306, 406. Optionally, various other combinations or sub-combinations of the vapor condensation systems can be utilized. Further, in other embodiments, in addition to or instead of the vapor condensation systems 206, 306, 406, other vapor condensation systems may be utilized.

[0035] Referring back to FIG. 1, a method of processing a metal substrate in a metal processing system 100 having a vapor condensation system 106 includes supplying water to a metal processing station 102 for a cooling process. In one non-limiting example, supplying water to the metal processing station 102 may include supplying water to the DC casting system 214 and cooling the metal ingot 222 exiting the mold 216 by directing the water onto the metal ingot 222.

[0036] This method includes condensing the vapor generated by the cooling process into recycled water using the vapor condensation system 106. In some embodiments, condensing the vapor may include spraying water into the vapor. In certain embodiments, condensing the vapor may include drawing the vapor into a conduit and condensing the vapor using an internal cooling device and / or an external cooling device. Non-limiting examples of the internal cooling device may include a sprayer and / or a chiller conduit(s), and non-limiting examples of the external cooling device may include a process gas line and / or heat exchanger fins.

[0037] In certain embodiments, the method optionally includes providing recycled water from the vapor condensation system 106 to the cooling system 104. The method optionally includes re-cooling and / or otherwise treating the recycled water using the cooling system 104 or, if necessary, another system. The method includes supplying recycled water from the cooling system 104 to the metal treatment station 102 for the cooling process.

[0038] A set of exemplary embodiments is provided below, including at least some that are explicitly listed as "Examples" providing further explanation of various exemplary embodiments according to the concepts described herein. These examples are not intended to be mutually exclusive, exhaustive, or restrictive, and the present disclosure is not limited to these exemplary embodiments, but rather encompasses all possible modifications and variations within the scope of the issued patent claims and their equivalents.

Examples

[0039] Example 1. A DC casting system for casting a metal ingot, the DC casting system including a vapor condensation system for condensing vapor generated during the DC casting process.

[0040] Example 2. The DC casting system according to any preceding or subsequent example or combination of examples, wherein the aforementioned vapor condensation system includes a plurality of sprayers configured to spray water into the casting pit of the aforementioned DC casting system.

[0041] Example 3. The DC casting system according to any preceding or subsequent example or combination of examples, wherein the aforementioned plurality of sprayers includes a plurality of nozzles.

[0042] Example 4. The DC casting system according to any preceding or subsequent example or combination of examples, wherein the aforementioned plurality of sprayers is configured to control the direction of the vapor flow and / or the air flow by spraying water into the aforementioned casting pit.

[0043] Example 5. The plurality of atomizers described above are adjustable so as to be able to adjust the direction of the steam flow and / or the air flow by spraying water into the casting pit described above, and are a DC casting system according to any one of the preceding or subsequent examples or combinations of examples.

[0044] Example 6. The steam condensation system described above includes at least one inlet and at least one outlet, a conduit configured to receive the steam described above, a suction device configured to generate a suction force for drawing the steam described above into the conduit through the at least one inlet described above, and at least one atomizer in the conduit described above for spraying water into the conduit described above, and is a DC casting system according to any one of the preceding or subsequent examples or combinations of examples.

[0045] Example 7. The conduit described above includes a first end portion, a second end portion, and a side wall extending from the first end portion to the second end portion described above, the suction device described above is provided at the first end portion described above, and the at least one inlet described above and the at least one outlet described above are provided on the side wall of the conduit described above, and is a DC casting system according to any one of the preceding or subsequent examples or combinations of examples.

[0046] Example 8. The suction device described above is a first suction device, and the steam condensation system described above further includes a second suction device at the second end portion of the conduit described above for drawing steam into the conduit described above, and is a DC casting system according to any one of the preceding or subsequent examples or combinations of examples.

[0047] Example 9. The steam condensation system described above includes a conduit for receiving the steam described above and a cooling device on the outer surface of the conduit described above for cooling the conduit described above, and is a DC casting system according to any one of the preceding or subsequent examples or combinations of examples.

[0048] Example 10. The cooling device described above is a DC casting system according to any of the preceding or subsequent examples or combinations of examples, including at least one of the process gas line for the DC casting process described above or a plurality of heat exchanger fins.

[0049] Example 11. A DC casting system for casting a metal ingot, comprising a cooling system configured to at least partially cool the metal ingot during the DC casting process by directing water from a coolant supply unit towards the metal ingot described above, and the cooling system described above further includes a steam condensation system for condensing steam generated during the DC casting process.

[0050] Example 12. The steam condensation system described above is configured to condense the steam generated by cooling the metal ingot described above as recycled water and provide the recycled water described above to the coolant supply unit, and is a DC casting system according to any of the preceding or subsequent examples or combinations of examples.

[0051] Example 13. The steam condensation system described above includes an atomizer configured to spray water to condense the steam described above, and is a DC casting system according to any of the preceding or subsequent examples or combinations of examples.

[0052] Example 14. The steam condensation system described above further includes a conduit and a suction device for drawing steam into the conduit described above, and the atomizer is in the conduit described above, and is a DC casting system according to any of the preceding or subsequent examples or combinations of examples.

[0053] Example 15. The steam condensation system described above includes a conduit for receiving the steam described above and a cooling device for condensing the steam described above into recycled water, and is a DC casting system according to any of the preceding or subsequent examples or combinations of examples.

[0054] Example 16. The cooling device described above is at least one atomizer within the conduit described above, and the at least one atomizer is configured to spray water to condense the steam described above into recycled water, and is a DC casting system described in any of the preceding or subsequent examples or combinations of examples.

[0055] Example 17. The cooling device described above is on the outer surface of the conduit described above and is configured to cool the conduit described above, and is a DC casting system described in any of the preceding or subsequent examples or combinations of examples.

[0056] Example 18. The cooling device described above includes at least one of the process gas line for the DC casting process described above or a plurality of heat exchanger fins, and is a DC casting system described in any of the preceding or subsequent examples or combinations of examples.

[0057] Example 19. A method for DC casting a metal ingot, comprising cooling the metal ingot exiting the mold by directing water from a coolant source towards the metal ingot described above, condensing the steam generated by cooling the metal ingot described above into recycled water, and providing the recycled water described above to the coolant supply section described above.

[0058] Example 20. Condensing the steam described above includes spraying water onto the steam described above, and is a method described in any of the preceding or subsequent examples or combinations of examples.

[0059] Example 21. Condensing the steam described above includes feeding the steam described above into a conduit and condensing the steam described above within the conduit using a cooling device, and is a method described in any of the preceding or subsequent examples or combinations of examples.

[0060] Example 22. The cooling device described above includes an atomizer within the conduit described above, and condensing the steam described above includes spraying water onto the steam within the conduit described above, and is a method described in any of the preceding or subsequent examples or combinations of examples.

[0061] Example 23. The cooling device described above is on the outer surface of the conduit described above, and condensing the steam described above includes cooling the conduit described above using the cooling device described above, and is a method described in any of the preceding or subsequent examples or combinations of examples.

[0062] Example 24. The cooling device described above includes at least one of the process gas line for the DC casting process described above or a plurality of heat exchanger fins, and is a method described in any of the preceding or subsequent examples or combinations of examples.

[0063] Example 25. A metal processing system for processing a metal substrate, the metal processing system including a steam condensation system for condensing steam generated during the metal processing of the metal substrate described above.

[0064] Example 26. The metal processing system described above is a metal processing system described in any of the preceding or subsequent examples or combinations of examples, including a casting system for manufacturing metal ingots from molten metal.

[0065] Example 27. The casting system described above is a direct chill (DC) casting system, and is a metal processing system described in any of the preceding or subsequent examples or combinations of examples.

[0066] Example 28. Further includes a cooling system for distributing water onto the metal substrate during metal processing, and the steam condensation system described above is configured to condense the steam described above as recycled water and return the recycled water to the cooling system described above, and is a metal processing system described in any of the preceding or subsequent examples or combinations of examples.

[0067] Example 29. The steam condensation system described above includes a plurality of sprayers configured to spray water within the steam generation region of the metal processing system described above, and is a metal processing system described in any of the preceding or subsequent examples or combinations of examples.

[0068] Example 30. The steam condensation system described above includes at least one inlet and at least one outlet, a conduit configured to receive the steam described above, and a suction device configured to generate a suction force for drawing the steam described above into the conduit through the at least one inlet described above, and at least one atomizer in the conduit described above for spraying water into the conduit described above, and is a metal treatment system described in any one of the preceding or subsequent examples or combinations of examples.

[0069] Example 31. The steam condensation system described above includes a conduit for receiving the steam described above and a cooling device on the outer surface of the conduit described above for cooling the conduit described above, and is a metal treatment system described in any one of the preceding or subsequent examples or combinations of examples.

[0070] Example 32. The cooling device described above includes at least one of a process gas line for the DC casting process described above or a plurality of heat exchanger fins, and is a metal treatment system described in any one of the preceding or subsequent examples or combinations of examples.

[0071] Example 33. A metal treatment system for treating a metal substrate, including a steam condensation system for directing the flow of steam generated during the metal treatment of the metal substrate described above by spraying water in the direction of the flow of the steam described above.

[0072] Example 34. The metal treatment system described above is a direct chill (DC) casting system, and is a metal treatment system described in any one of the preceding or subsequent examples or combinations of examples.

[0073] Example 35. The steam condensation system described above is configured to spray water parallel to the direction of the flow of the steam described above or in a direction intersecting the direction of the flow of the steam described above, and is a metal treatment system described in any one of the preceding or subsequent examples or combinations of examples.

[0074] Example 36. The steam condensation system described above is a metal treatment system according to any of the preceding or subsequent examples or combinations of examples, which is adjustable such that the direction of the water sprayed by the steam condensation system described above can be adjusted with respect to the direction of the flow of the steam described above.

[0075] The subject matter of the embodiments has been described herein with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The subject matter for which a patent is claimed may be embodied in other ways, may include different elements or steps, and may be used in combination with other existing or future technologies. This description should not be construed as implying a particular order or arrangement between various steps or elements, except when the order of individual steps or the arrangement of elements is explicitly described. In particular, references to directions such as "above", "below", "upper", "bottom", "left", "right", "front", and "rear" are intended to refer to the orientation shown and described in the drawing (or drawings) to which the component and direction refer. In the drawings and description, like numbers are intended to represent like elements. As used herein, the meanings of "a", "an", and "the" include references to both the singular and plural forms unless the context clearly dictates otherwise.

[0076] The above aspects are merely possible examples of embodiments and are described merely to clearly understand the principles of the present disclosure. Many variations and modifications may be made to the above embodiments (s) without substantially departing from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Further, certain terms are used in this specification and the following claims, but they are used only in a general and descriptive sense and not for the purpose of limiting the embodiments described or the scope of the following claims.

Claims

1. A direct chill (DC) casting system for casting a metal ingot, the DC casting system including a vapor condensation system for condensing vapor generated during the DC casting process as recycled water.

2. The DC casting system according to claim 1, wherein the vapor condensation system includes a plurality of sprayers configured to spray water into a casting pit of the DC casting system.

3. The DC casting system according to claim 2, wherein the plurality of sprayers includes a plurality of nozzles.

4. The DC casting system according to claim 2, wherein the plurality of sprayers is configured to control a direction of a vapor flow and / or an air flow by spraying the water inside the casting pit.

5. The DC casting system according to claim 4, wherein the plurality of sprayers is adjustable so as to be able to adjust the direction of the vapor flow and / or the air flow by spraying the water inside the casting pit.

6. The vapor condensation system includes a conduit configured to receive the vapor, the conduit including at least one inlet and at least one outlet, a suction device configured to generate a suction force for drawing the vapor into the conduit through the at least one inlet, and at least one sprayer inside the conduit for spraying water into the conduit, and is the DC casting system according to claim 1.

7. The DC casting system according to claim 6, wherein the conduit includes a first end portion, a second end portion, and a side wall extending from the first end portion to the second end portion, the suction device is provided at the first end portion, and the at least one inlet and the at least one outlet are provided on the side wall of the conduit.

8. The DC casting system according to claim 1, wherein the vapor condensation system includes a conduit for receiving the vapor and a cooling device on an outer surface of the conduit for cooling the conduit.

9. The DC casting system according to claim 8, wherein the cooling device includes at least one of a process gas line for the DC casting process or a plurality of heat exchanger fins.

10. The DC casting system according to claim 1, further including means for returning the recycled water to the DC casting process and / or other processing steps of the metal ingot.

11. A method for direct chill (DC) casting a metal ingot, comprising By directing water from the coolant supply towards the metal ingot, cooling the metal ingot emerging from the mold, condensing the vapor generated by the cooling of the metal ingot as recycled water, and providing the recycled water to the coolant supply, the method comprising.

12. The method according to claim 11, wherein condensing the vapor includes spraying water into the vapor.

13. The method according to claim 11, wherein condensing the vapor includes feeding the vapor into a conduit and condensing the vapor in the conduit using a cooling device.

14. The method according to claim 13, wherein the cooling device includes at least one of the following: An atomizer within the conduit, wherein condensing the vapor includes spraying water into the vapor in the conduit, or A cooling device on the outer surface of the conduit, wherein condensing the vapor includes cooling the conduit using the cooling device.

15. A metal processing system for processing a metal substrate, the metal processing system including a vapor condensation system that directs a flow of vapor generated during metal processing of the metal substrate by spraying water in the direction of the flow of the vapor.

16. The metal processing system according to claim 15, wherein the metal processing system is a direct chill (DC) casting system for manufacturing metal ingots from molten metal.

17. The metal processing system according to claim 15, wherein the vapor condensation system is configured to spray water parallel to the direction of the flow of the vapor or in a direction intersecting the direction of the flow of the vapor.

18. The metal processing system according to claim 15, wherein the vapor condensation system is adjustable such that the direction of the water sprayed by the vapor condensation system can be adjusted relative to the direction of the flow of the vapor.

19. The metal processing system according to claim 15, wherein the vapor condensation system is further configured to condense the vapor generated during metal processing of the metal substrate.

20. The metal processing system according to claim 15, wherein the vapor condensation system includes a plurality of atomizers configured to spray water within the vapor generation region of the metal processing system.

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