Continuous casting spray water performance monitoring and water control chemistry

Abstract

Providing a water analysis and chemical control system for a continuous casting process, etc. 【Solution means】A method for analyzing water in a continuous casting process and controlling the addition of chemicals to the water may include measuring at least one property of the water at a plurality of different locations in a water recycling system for the continuous casting process using a plurality of sensors. The continuous casting process can have a plurality of spray nozzles that spray water onto the metal being cast, and the water recycling system can include a gravity settling tank, a filter, and a cooling tower. A processor can use at least one measured property of the water from the plurality of sensors to determine a composite water quality value of the water in the water recycling system. Chemical additives can be controllably added to the water recycling system based on the determined composite water quality value.

Description

Technical Field

[0001] (Related Matters) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 358,418, filed on July 5, 2022, the entire content of which is incorporated herein by reference.

[0002] (Field of the Invention) The present disclosure relates to metal casting, and more particularly, to a water recycling system for metal casting operations.

Background Art

[0003] Continuous casting is a method of converting molten metal into semi-finished metal products such as billets, blooms, or slabs, and is useful for mass production and continuous production. This process is commonly used to form steel, but may also be used to form other metals such as aluminum and copper. Typically, in continuous casting, the molten metal is collected in a trough called a tundish and then sent to a primary cooling zone. In the primary cooling zone, the molten metal enters a solid mold that is typically water-cooled. The solid mold extracts heat from the molten metal and forms a solid "skin" of metal around the still liquid core. The solid-clad liquid metal is called a strand. The strand then passes through a secondary cooling zone where water is sprayed directly onto the metal strand to further cool the metal.

[0004] The water used as a heat transfer medium to cool the metal being cast is typically recovered and reused to limit the amount of water consumed in the casting process. The water is recovered after direct or indirect contact with the hot metal and can pass through a cooling tower that cools the water by evaporative cooling before being reused in the casting process.

Summary of the Invention

Problems to be Solved by the Invention

[0005] In practice, the water recovered from the casting process may contain contaminants such as corrosive compounds and particulates released from the metal being cast when the spray water comes into direct contact with the hot metal. Over time, these contaminants can accumulate within the water system and potentially cause water-related problems in the casing process. **Means for Solving the Problems**

[0006] Generally, the present disclosure relates to systems and techniques for casting metals, and more particularly, to systems and techniques for analyzing water used in a continuous casting process and / or controlling chemicals added to the water used in a continuous casting process. In some implementations, the system according to the present disclosure includes a continuous casting machine that sprays water directly onto the metal being cast, and a water recycling system that recovers water after it is sprayed onto the hot metal for recycling and reuse. The water recycling system can treat the water recovered through gravity sedimentation, filtration, evaporative cooling, and / or other processing steps, and then return the recycled water to the continuous casting machine to be sprayed again onto another portion of the hot metal being cast.

[0007] In practice, it can be difficult for the operator of a continuous casting water system to evaluate the quality of the water within the water recycling system to detect and address initial problems. The operator may lack insight into the characteristics of the water within the water recycling system and / or may lack an understanding of how discrete water measurements affect the overall quality and effectiveness of the water recycling system. Additionally, since the composition of the water can change as the water moves through different stages of the water recycling system, it can be difficult to evaluate how water measurements taken at one part of the water recycling are compared to different water measurements taken at different parts of the water recycling system in order to evaluate and implement corresponding control actions.

[0008] According to some examples of the present disclosure, a water analysis and chemical control system for a continuous casting process is described that includes a plurality of sensors disposed at different locations within a recycle system to measure one or more characteristics of water at each location within the water recycle system. For example, the system can include one or more sensors upstream of a cooling tower within the water recycle system and one or more sensors downstream of the cooling tower within the water recycle system. Each sensor within the system can measure one or more characteristics of the water indicative of the water quality, with different sensors measuring the same characteristic or different sensors measuring different characteristics. In either case, the system can aggregate water measurement data obtained from different locations and different sources across the system to determine a composite water quality value. The composite water quality value can provide a single value indicative of the overall quality or soundness of the water within the water recycle system. The system can then use this composite water quality value to control the addition of one or more chemical additives to the water within the water recycle system. The chemical additives can maintain or improve the quality of the water recycled and reused within the water recycle system.

[0009] The system may aggregate water measurement data obtained from different locations and / or different sources in several different ways to determine a composite water quality value. In some examples, the system applies a weighting factor to each water measurement value measured by each different sensor within the system. The weighting factors can be different for different water measurement values. Thus, a water measurement taken at one location within the water recycle system can be assigned greater importance in evaluating the overall quality of the water within the system than a water measurement taken at another location. Specific weighting factors can be assigned based on the type of water characteristic measured, the location of the measurement, and / or other factors indicative of the corresponding impact on the water quality and the water recycle system.

[0010] By determining a composite water quality value from a plurality of different sources and locations that provide individualized measurements indicative of water quality, an operator can be provided with an easily monitorable and comparable metric for assessing the overall quality of water within a water recycling system for a continuous casting process. This can remove the complexity and uncertainty associated with attempting to evaluate a large number of different water measurements within the water recycling system that may appear to be uncorrelated and / or may appear to provide conflicting water quality information to the operator. Thereby, for example, by introducing fresh water or makeup water into the system and / or by introducing one or more chemical additives useful for controlling the performance of the water into the system, the operator can take more consistent and predictable actions to control the water within the water recycling system. In some implementations, the system is implemented to automatically control the water within the water recycling system (e.g., by controlling the addition of chemicals to the water) in response to a composite water quality value determined by the system using measurements made by a plurality of sensors arranged throughout the water recycling system.

[0011] In one example, a water analysis and chemical control system for a continuous casting process is described. The system includes a continuous casting machine, a water recycling system, a plurality of sensors, a pump, and a controller. The continuous casting machine has a cooling zone that includes a plurality of spray nozzles configured to spray water onto the metal being cast. The water recycling system includes at least a gravity settling tank, a filter, and a cooling tower. The gravity settling tank is fluidly connected to the cooling zone of the continuous casting machine, configured to receive water from the cooling zone of the continuous casting machine after the water has contacted the metal being cast, and to provide a gravity separated water stream by gravity separating the received water. The filter is downstream of the gravity settling tank, configured to receive the gravity separated water stream and to filter the gravity separated water stream to provide a filtered water stream. The cooling tower is downstream of the filter, configured to receive the filtered water and to reduce the temperature of the filtered water stream by evaporative cooling to provide cooling water supplied to the plurality of spray nozzles of the continuous casting machine. The example specifies that a plurality of sensors are configured to measure at least one characteristic of a water sample to be analyzed, and each of the plurality of sensors is fluidly connected at different positions within the water recycling system to measure at least one characteristic of the water sample at each of the different positions. The pump is arranged to introduce a chemical additive into the water within the water recycling system. The controller is communicatively coupled to the plurality of sensors and the pump. The example specifies that the controller is configured to receive from each of the plurality of sensors data indicative of at least one characteristic of the water sample measured by each of the plurality of sensors, to determine a composite water quality value based on the received data from each of the plurality of sensors, and to control the pump to control the addition of the chemical additive to the water based on the determined composite water quality value.

[0012] In another example, a method for analyzing water and controlling the addition of chemicals to the water in a continuous casting process is described. The method includes using a plurality of sensors to measure at least one characteristic of the water at a plurality of different locations in a water recycling system for a continuous casting process. The examples specify that the continuous casting process has a plurality of spray nozzles for spraying water onto the metal being cast, and that the water recycling system includes at least a gravity settling tank, a filter, and a cooling tower. The method also includes using at least one measured characteristic of the water from the plurality of sensors to determine, using a processor, a composite water quality value of the water in the water recycling system, and controlling the addition of chemical additives to the water in the water recycling system based on the determined composite water quality value.

[0013] In another example, a water analysis system for a continuous casting process is described. The system includes a continuous casting machine, a water recycling system, a plurality of sensors, a display, and a controller. The continuous casting machine has a cooling zone that includes a plurality of spray nozzles configured to spray water onto the metal being cast. The water recycling system includes at least a gravity settling tank, a filter, and a cooling tower. The gravity settling tank is fluidly connected to the cooling zone of the continuous casting machine, configured to receive water from the cooling zone of the continuous casting machine after the water has contacted the metal being cast, and to provide a gravity-separated water stream by gravity-separating the received water. The filter is downstream of the gravity settling tank and is configured to receive the gravity-separated water stream and filter the gravity-separated water stream to provide a filtered water stream. The cooling tower is downstream of the filter and is configured to receive the filtered water and reduce the temperature of the filtered water stream by evaporative cooling to provide cooling water to the plurality of spray nozzles of the continuous casting machine. The example specifies that the plurality of sensors are configured to measure at least one characteristic of a water sample to be analyzed, and each of the plurality of sensors is fluidly connected at different positions within the water recycling system to measure at least one characteristic of the water sample at each of the different positions. The example specifies that the controller is configured to receive data indicating at least one characteristic of the water sample measured by each of the plurality of sensors from each of the plurality of sensors, determine a composite water quality value based on the received data from each of the plurality of sensors, and control the display to display information indicating the composite water quality value.

[0014] Details of one or more examples are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

Brief Description of the Drawings

[0015]

Figure 1

[0016]

Figure 2

[0017]

Figure 3

[0018] The present disclosure generally relates to metal casting, and more specifically, to systems and techniques for monitoring and / or controlling water used in a metal casting process. In some implementations, cooling water is applied directly to hot metal during a metal casting process and is recovered after direct contact with the metal being cast. For example, the cooling water may be sprayed directly onto the metal being cast as part of a secondary cooling system downstream of the runner from which the molten metal exits. The cooling water sprayed onto the molten metal is recovered after direct contact with the metal and can be recycled for reuse in the casting process. Within the water recycling system, the water may undergo one or more steps to remove particulates present in the water. Additionally or alternatively, one or more chemical additives may be injected into the water to control the chemical composition and performance of the water within the casting process and / or the water recycling system.

[0019] To provide information regarding the characteristics of water recovered and processed within a water recycling system for a metal casting process, a plurality of sensors may be implemented at different locations throughout the water recycling system. Each sensor may measure one or more of various different measurable characteristics of the water, such as optical characteristics (e.g., turbidity), electrical characteristics (e.g., redox potential), and / or chemical characteristics (e.g., pH). Different sensors may measure one or more characteristics of the water at different points within the water recycling system, for example, before and / or after the recycled water undergoes various treatment steps within the water recycling system. Each sensor can provide measurement data indicating one or more characteristics of the measured water.

[0020] Measurements made by a plurality of sensors within the water recycling system may be performed in real time and / or intermittently, along with the operation of the water recycling system and / or the casting process. The sensed measurement data may be used alone to evaluate the overall water quality in the water recycling system, or may be combined with one or more other data sources to evaluate the overall water quality. For example, measurements made by a plurality of sensors within the water recycling system may be combined with data generated from one or more offline measurements (e.g., offline chemical analysis of water), and / or data from the water distribution system in the casting process (e.g., the temperature, pressure, and / or flow rate of water supplied to one or more zones and / or nozzles of the water distribution system that sprays water onto the molten metal being cast).

[0021] In any case, the composite water quality value may be determined from a plurality of different measurement values related to the water within the continuous casting process and / or the water recycling system. For example, the composite water quality value may be determined by aggregating different individual water property measurements from different sensors arranged at different positions throughout the water recycling system. The composite water quality value may be a numerical value indicating the quality of the water used in the casting process and recycled in the water recycling system, and is a composite of different water measurement values. The composite water quality value may be displayed on a display viewed by the personnel operating the water recycling system for individual evaluation and / or control actions. Additionally or alternatively, one or more control actions for the water recycling system may be automatically implemented based on the determined composite water quality value. For example, the determined composite water quality value may be compared with one or more threshold values, and one or more chemical pumps may be controlled to introduce one or more chemical additives into the water within the water recycling system based on the comparison.

[0022] Further details regarding an exemplary water recycling system and related art for controlling a water recycling system are described with respect to FIG. 3. 3. However, an exemplary continuous casting process that may include a water recycling system according to the present disclosure and related water analysis and / or chemical control techniques is first described with respect to FIGS. 1 and 2.

[0023] FIG. 1 is a diagram of an exemplary continuous caster 10 that can be used to cast an iron (steel) metal slab. In the illustrated example, liquid metal flows from the bottom of the ladle 12 into a small intermediate vessel known as a tundish 14. The liquid metal exits the bottom of the tundish through a submerged nozzle 16, and a stopper rod or slide gate flow control system can control the amount of liquid metal discharged from the tundish. The liquid metal is directed into a solid mold 18 (often made of copper) that can have a water-cooled wall. Within the mold 18, the liquid metal can form a thin solid shell or skin around the liquid core.

[0024] In the steady state, the solid shell with a liquid core can exit the mold 18 as a stable strand and exhibit sufficient mechanical strength to support the liquid metal core. The caster 10 can include a motor-driven drive roller 20 (and / or idler roller) disposed vertically below the mold to continuously draw the strand downward. Positioning the rollers 20 in close proximity to each other can help support the strand and prevent outward bulging of the shell due to the iron hydrostatic pressure generated from the liquid steel core. Other strategically placed rollers 20 can bend the shell to follow a curved path and then flatten and straighten the shell before a torch that cuts the strand into individual slabs.

[0025] To assist in cooling the metal strand withdrawn from the mold 18 and passing through the rollers 20, the casting machine 10 can include a plurality of spray nozzles 22 arranged to spray water directly and / or indirectly onto the metal strand withdrawn downward from the mold 18. For example, the spray nozzles 22 may be arranged between the rollers 20 and can spray high-pressure water onto the strand to assist in cooling the strand during the solidification process.

[0026] FIG. 2 is a diagram of another exemplary continuous casting machine 10 that can be used to cast non-ferrous (e.g., aluminum, copper) metal ingots. The casting machine 10 of FIG. 2 also includes a tundish 14 and a mold 18. In contrast to the fully continuous casting process of FIG. 2, the casting machine 10 of FIG. 2 may be implemented for semi-continuous casting, and the strand metal having an outer solidified shell and a molten core is pulled vertically downward from the mold 18 by a short length (e.g., 10 meters) until the resulting cast ingot reaches the bottom of the casting pit. The supply of molten metal to the mold 18 may be repeatedly stopped and restarted when the continuously formed ingot is removed from the casting pit and cooled. In either case, the casting machine 10 of FIG. 2 can also include a plurality of spray nozzles 22 for spraying water directly onto the solid shell exiting the mold 18.

[0027] In both casting machines 10 of FIGS. 1 and 2, the thermal energy from the metal being cast can be removed by a primary cooling system and / or a secondary cooling system. First, thermal energy can be removed from the metal being cast by using a water-cooled mold in which cooling water is separated from the metal by the walls of the mold 18 to indirectly cool the metal. The liquid pool inside the mold 18 and the heat transfer at the mold / metal interface can affect both the initial solidification at the meniscus and the growth of the solid shell against the mold. This heat transfer at the metal / mold interface can be referred to as mold cooling or primary cooling.

[0028] After emerging from the mold 18, the casting strand can also be cooled by bringing water into direct contact with the hot meal surface. This can be referred to as secondary cooling. For example, when casting steel as in the configuration of FIG. 1, a bank of nozzles 22 can be placed between the contact rollers 20 under the mold 18 to spray water and cool the moving metal strand. The spray nozzles may be arranged in banks or cooling zones assigned to the upper and lower surfaces of a particular strand segment. The water can be extruded from the spray nozzles 22 as droplets forming a mist under high pressure and continuously impinge on the metal surface. When casting non-ferrous metals as in the configuration of FIG. 2, the spray nozzles 22 in the form of water jets can emerge from holes located under the water-cooled mold 18 and contact the metal surface directly. These jets can form a continuous film of water that wets the vertical ingot surface and rolls downward.

[0029] Regardless of the specific configuration of the casting machine 10, the water used to cool the molten metal in the casting process can be recovered and recycled for reuse in the casting process. FIG. 3 is a diagram of an exemplary water recycling system 50 that can be utilized with the continuous casting machine 10 as described above with respect to FIGS. 1 and 2. In the example of FIG. 3, the water recycling system 50 is shown as a network of one or more fluid-connected processing units that sequentially process the water used to cool the metal being cast on the casting machine 10 and return the water to the casting machine for reuse when cooling subsequent segments of the metal being cast. The water recycling system 50 can include one or more sedimentation tanks, filters, heat transfer units (e.g., heat exchangers, cooling towers), strainers, and / or other processing units effective to recycle the water for reuse in the casting machine 10. As will be described in more detail below, various sensors can be implemented at different locations within the water recycling system 50 to analyze the water characteristics at different points within the water recycling system. The measurement data from the different sensors can be used to evaluate a composite water quality value for the entire water recycling system.

[0030] In the example of FIG. 3, the water recycling system 50 is shown as including a gutter or waterway 52 that recovers water from the cooling zone of the casting machine 10. For example, the waterway 52 may be configured to recover the cooling water that has been sprayed through the spray nozzle 22 directly onto the metal being cast after the cooling water has contacted the metal and fallen downward under gravity into the waterway. The waterway 52 can be fluidly connected to one or more downstream processing units within the water recycling system 50 to treat the cooling water recovered for reuse. The cooling water recovered for treatment in the recycling system 50 can contain scale, particulates, oil (e.g., that can be applied and used to assist in the cooling of steel), and / or other potential contaminants that can be partially or completely removed by the water recycling system 50 before the water is reused in the casting machine 10.

[0031] For example, the water recycling system 50 can include one or more gravity settling tanks 54 that are shown as including a scale pit in the example of FIG. 3. The gravity settling tank 54 can include an oil skimmer and a solid scraper. In the gravity settling tank 54, the received water is gravity-settled over a residence time to remove larger scale and particulates and to skim oil from the water. In some implementations, the water recycling system 50 including the gravity settling tank 54 can receive wastewater from hot rolling and various other processes throughout the rolling mill. This can introduce organic matter, heavy metals, and other contaminants to the scale pit, which are also processed in the water recycling stream. In any case, the gravity settling tank 54 can gravity-separate the received water to provide a gravity-separated water stream 56.

[0032] As described above, the water recycling system 50 can include a plurality of gravity sedimentation tanks 54. For example, in addition to using a scale pit that receives cooling water from the water channel 52, the cooling water system 50 can also include a sedimentation tank 58 downstream of the scale pit 54. In the sedimentation tank 58, the velocity of the cooling water can be reduced to less than the suspension velocity, and the suspended particles settle out of the water by gravity. The sedimentation tank 58 may typically be rectangular or circular with a radial or upward water flow pattern.

[0033] One or more filters 60 may be disposed between the gravity sedimentation tank 54 and the cooling tower 62 within the water recycling system 50. For example, one or more filters 60 may be disposed downstream of the sedimentation tank 56 and upstream of the cooling tower 50 in the water recycling system. One or more filters 60 may be implemented as a deep bed filter having one or more layers of media (e.g., gravel). The deep bed filter can be used to remove fine particles suspended in the water and to aggregate the remaining oil. One or more filters 60 can receive the gravity separation water flow 56 (directly from the gravity sedimentation tank 54 or indirectly via one or more intermediate processes) and filter the gravity separation water flow to provide a filtered water flow 64.

[0034] Downstream of the filter 60 where the cooling tower 62 within the water recycling system 50 is disposed, the filtered water 64 is received, and the temperature of the filtered water flow is reduced by evaporative cooling to provide cooled water, which is then supplied to the plurality of spray nozzles 22 of the continuous casting machine 10. For example, in the cooling tower 62, the thermal energy transferred to the cooling water flow in the casting machine 10 can be removed and discharged to the atmosphere. The cooling tower 62 can bring the cooling water flow into direct contact with air, and as a result, the temperature of the cooling water flow is reduced by evaporative cooling. The cooling water may be sent to a sump or reservoir before being discharged downstream of the casting machine 10.

[0035] The water discharge cooling tower 62 can be supplied downstream of the spray nozzles 22 that supply water to the metal being cast in the casting machine 10. The water may be supplied directly from the cooling tower 62 to the spray nozzles 22 without intermediate treatment, or the water may undergo one or more additional treatment steps downstream of the cooling tower before being supplied to the spray nozzles. For example, a strainer 66 may be fluidly connected between the cooling tower 62 and the plurality of spray nozzles 22 within the casting machine 10. The strainer 66 can strain (e.g., filter) the cooling water before supplying it to the plurality of spray nozzles 22 of the continuous casting machine 10. This can provide a final polishing or purification of the cooling water and help remove residual particulates that could otherwise clog or interfere with the operation of the spray nozzles 22.

[0036] One or more chemical additives can be added to the cooling water to help remove contaminants from the cooling water within the water recycling system 50 and / or to reduce or eliminate potential fouling conditions within the cooling water stream passing through the system. In the configuration of FIG. 1, the water recycling system 50 includes one or more pumps 68 fluidly connected to one or more chemical additive reservoirs 70. The pumps 68 can be operated to add one or more chemical additives to the cooling water. The chemical additives may be selected to function as one or more of a coagulant, a flocculant, a dispersant, a biocide, a corrosion inhibitor additive, and / or a pH control agent. Exemplary chemical additives that can be injected into the cooling water include, but are not limited to, polymers (scale inhibitors), zinc polyphosphate, zinc orthophosphate, and / or organic phosphorus compounds (scale and corrosion inhibitors) such as organic phosphorus compounds, as well as biocides. Additionally or alternatively, one or more chemical additives may be injected into the cooling water to adjust the pH of the cooling water. Examples of pH adjusting compounds include mineral acids, organic acids, and inorganic bases.

[0037] In the configuration shown in FIG. 3, pump 68 is shown as adding a chemical additive to the cooling water in gravity settling tank 54. In practice, one or more chemical additives can be introduced into the cooling water at any suitable location downstream of the cooling tower 62, upstream of the cooling tower, and / or including the cooling tower (such as a sample associated with the cooling tower). Further, although the system 50 of FIG. 3 shows a single pump 68 fluidly coupled to a single chemical additive reservoir 70, pump 68 may selectively fluidly communicate with a plurality of reservoirs containing different chemicals, and / or the system 50 may include a plurality of pumps each configured to introduce a different chemical into the cooling water.

[0038] To assist in monitoring the condition of the cooling water recovered by the waterway 52 and / or processed by the water recycling system 50, a plurality of sensors 80A, 80B,... 80Z (collectively referred to as sensors 80) may be deployed to monitor the cooling water at different locations within the processing circuit of the water recycling system. Each sensor 80 can measure one or more characteristics of the cooling water at a particular location within the water recycling system 50 and provide an indication of the condition of the cooling water at the measured location. Exemplary characteristics of the cooling water that can be measured by the sensors 80 include characteristics indicating the concentration and / or size of particulates in the water (e.g., turbidity, total suspended solids), electrical characteristics of the water (e.g., conductivity, oxidation-reduction potential), the concentration or amount of one or more compounds in the water (e.g., the concentration of oil in the cooling water), the pH of the water, and / or other characteristics indicating the presence and / or degree of one or more contaminants in the cooling water, but are not limited thereto. Each sensor can process the data measured by the sensor, determine a composite water quality value, and optionally communicateably connect to a controller 90 to control one or more chemical additives dispensed into the water flowing through the water recycling system 50.

[0039] Each sensor 80 can be implemented to measure one or more characteristics of the cooling water being processed within the water recycling system 50 at various locations within the water recycling system. In some examples, the water recycling system 50 includes at least one sensor 80 disposed upstream of one or more processing units within the water recycling system and also includes at least one sensor 80 disposed downstream of one or more processing units within the water recycling system. This can provide different measurements and insights regarding changes in the characteristics (s) of the water as it is processed through one or more processing units within the water recycling system.

[0040] For example, in one implementation, the water recycling system 50 includes at least one sensor 80 arranged to measure at least one characteristic of the water that forms the gravity separation water stream 56 (e.g., by measuring the water within and / or discharged from one or more gravity settling tanks 54). The water recycling system 50 additionally or alternatively may include at least one sensor 80 arranged to measure at least one characteristic of the water that forms the filtered water stream 64 (e.g., by measuring the water within and / or discharged from one or more filters 60). As yet another additional or alternative example, the water recycling system 50 includes at least one sensor 80 arranged to measure at least one characteristic of the water downstream of the strainer 66, e.g., between the strainer 66 and the plurality of spray nozzles 22 to which the water is subsequently delivered. Thus, in some implementations, the water recycling system 50 can include at least one sensor 80 arranged to measure at least one characteristic of the water being processed within the water recycling system at a location upstream of the cooling tower 62 and at least one characteristic of the water being processed within the water recycling system at a location downstream of the cooling tower.

[0041] In the example of FIG. 3, the system 50 is shown as including a sensor 80A that measures the properties of water forming the gravity separation water stream 56, a sensor 80B that measures the properties of water forming the filtration water stream 64, and a sensor 80C that measures the properties of water downstream of the strainer 66 and upstream of the spray nozzle 22. The water recycling system 50 can include a processing unit in a different arrangement from the specific example of FIG. 3 and / or sensors 80 in different numbers and / or arrangements. In some examples, for instance, the water recycling system 50 can include one or more sensors 80D...80Z that measure one or more properties of the water in the cooling tower 62. For example, one or more sensors can be arranged to measure one or more properties of the water in the sump of the cooling tower 62 and / or the water discharged from the cooling tower.

[0042] In some examples, one or more of the sensors 80 may be implemented using an optical sensor to provide measurements indicating the concentration and / or size of particles in the cooling water. For example, an optical sensor can be used to measure the turbidity and / or light scattering properties of the water within the water recycling system 50. Additionally, or alternatively, the optical sensor may measure the total suspended solids in the water.

[0043] Other examples of sensors 80 that can be used in addition to or instead of the optical sensor include an ORP sensor that measures the oxidation-reduction potential (ORP) of the cooling water, a pH sensor that measures the pH of the cooling water, a conductivity sensor that measures the conductivity of the cooling water, an oil-in-water sensor that measures the concentration of oil in the cooling water, a fluorometer that directly or indirectly measures the concentration of one or more chemical additives introduced into the system (e.g., by a fluorescence response proportional to the concentration of the chemical additive), a deposit monitor that measures the fouling deposition rate in the water system (e.g., biofilm fouling, inorganic deposit fouling, and / or organic deposit fouling), and / or a sensor that measures the corrosion rate in the water system. Additional or different sensors can be used to measure additional or different properties of the water.

[0044] Each sensor 80 can be implemented in a number of different ways in the water recycling system 50. For example, one or more sensors can be placed along the cooling water flowing directly through a part of the water recycling system 50 (e.g., upstream, downstream, and / or within the processing unit of the water recycling system) or through a slip stream drawn from the main water flow. Alternatively, one or more sensors may be implemented as an off-line monitoring tool that is not in direct fluid communication with the cooling water flowing through the water recycling system 50. In these applications, the cooling water flowing through the water recycling system 50 can be extracted from the system and measured using an off-line analysis system. Such off-line analysis may involve, for example, a direct evaluation of the sample using one or more sensors, or may involve further processing of the sample, such as performing a wet chemical treatment on the sample, to generate data associated with the sample. In either case, the data generated by each of the one or more sensors 80 and / or data associated with the cooling water being evaluated by other means can be received by the controller 90 for storage in, for example, memory and / or for further processing. Further, the description of the sensor 80 for analyzing a water sample from the water recycling system 50 is not intended to limit the way the sensor is exposed to the water or the amount of water provided to the sensor.

[0045] The specific number of sensors 80 implemented within the water recycling system 50 can be varied based on several factors, such as the size and complexity of the water recycling system, as well as the number and configuration of different water treatment units within the water recycling system. In various implementations, the water recycling system 50 can include at least two sensors 80, such as three, four, five, six, or more sensors, that provide measurement data to the controller 90 to determine the composite water quality value. Each sensor 80 may determine the same characteristic (e.g., turbidity, pH, conductivity) of the water being analyzed, or at least one sensor 80 may determine a characteristic of the water being analyzed that is different from the characteristics of the water being analyzed by one or more other sensors 80. Thus, the composite water quality value determined for the water recycling system 50 can be based on the same and / or different measured water characteristics in the water recycling system.

[0046] For example, in the arrangement of FIG. 3, the first sensor 80A may be implemented using an optical sensor that measures the turbidity of the water and / or an in-water oil sensor that measures the concentration of oil in the water. The second sensor 80B may also be implemented using an optical sensor that measures the turbidity of the water and / or an in-water oil sensor that measures the concentration of oil in the water. The third sensor 80C may also be implemented using an optical sensor that measures the turbidity of the water. One or more additional sensors 80D...80Z may measure the conductivity, pH, and / or ORP of the water.

[0047] Although one or more sensors 80 are illustrated and described with respect to FIG. 3 as separate sensors, it should be understood that in other implementations, a single sensor can be implemented to measure the same characteristic from different locations within the water recycling system 50. For example, different conduits can fluidly connect the sensor 80 to different locations within the water recycling system 50 to carry water from different locations to the sensor for analysis. When configured in such a manner, the sensors 80 fluidly communicated with different locations within the water recycling system 50 can be alternately arranged to fluidly communicate with water from different locations to measure the characteristics of the water in different sources.

[0048] The water recycling system 50 can include additional and / or different sensors for measuring different operating parameters of the water recycling system 50. For example, the system can include one or more flow sensors, temperature sensors, and / or pressure sensors for measuring the flow rate, temperature, and / or pressure of the cooling water at one or more desired locations within the water recycling system. The water recycling system 50 including a controller 90 of the water recycling system can monitor the data from one or more sensors online and / or can receive data from a third-party source regarding the water recycling system. An example of such data that can be received from a third-party source can include data regarding the flow rate, temperature, and / or pressure of the cooling water supplied to and / or discharged from the plurality of spray nozzles 22, and these data can be measured by an operator of the casting machine 10 different from the operator of the water recycling system 50. The measurement data received by the controller 90 from a third-party source can be used in determining the composite water quality value of the water recycling system. For example, if the measurement data received from a third-party source indicates a decrease in the pressure and / or flow rate of the cooling water supplied by the spray nozzles 22, such information can indicate that contaminants in the cooling water are clogging or restricting the flow through the spray nozzles.

[0049] The water recycling system 50 in the example of FIG. 3 includes a controller 90. The controller 90 is communicably connected to a plurality of sensors 80 and controllable components of the water recycling system to manage the overall operation of the system. For example, the controller 90 can be communicably connected to each of the sensors 80, the pump 68, and / or other controllable components within the water recycling system.

[0050] Controller 90 includes a processor 92 and a memory 94. Controller 90 can communicate with components communicatively connected via a wired or wireless connection (not shown in the example of FIG. 3 for simplicity). Control signals transmitted from and received by Controller 90 can move through the connection. Memory 94 stores software for operating Controller 90 and may also store data generated or received by processor 92, for example, from sensor 80. Processor 92 executes the software stored in memory 94 to manage the operation of water recycling system 50.

[0051] Controller 90 may be implemented using one or more controllers, and the controller may be located at a facility site that includes a processing unit defining water recycling system 50. Controller 90 can communicate with one or more remote computing devices 96 via network 98. For example, Controller 90 may communicate with a geographically distributed cloud computing network, and this cloud computing network may perform any or all of the functions attributable to Controller 90 in the present disclosure. Data generated and / or received by Controller 90 and / or remote computing device 96 may be displayed on one or more electronic displays 100 visible to an operator of water recycling system 50.

[0052] Network 98 can be configured to couple one computing device to another to enable the devices to communicate together. Network 98 can use any form of computer-readable medium for communicating information from one electronic device to another. Further, network 98 can include a wireless interface and / or a wired interface such as the Internet, in addition to a local area network (LAN), a wide area network (WAN), a direct connection via a universal serial bus (USB) port, other forms of computer-readable media, or any combination thereof. On an interconnected set of LANs, including those based on different architectures and protocols, a router can act as a link between the LANs and can be capable of transmitting messages from one to the other. Communication links within a LAN can include twisted pair wires or coaxial cables, while communication links between networks can utilize analog telephone lines, full or fractional dedicated digital lines, integrated services digital network (ISDN), digital subscriber line (DSL), wireless links including cellular and satellite links, or other communication links. Additionally, remote computers and other associated electronic devices can be remotely connected to either a LAN or a WAN via a modem and a temporary telephone link.

[0053] The display 100 can display information indicating the water characteristics measured by each of the individual sensors 80, the composite water quality value determined for the water recycling system 50, and / or the control of one or more chemical additives added to the water being processed in the water recycling system. The information can be displayed to the operator of the water recycling system 50 in any suitable format including text and graphics. In some examples, the display 100 is controlled to display information indicating the composite water quality value determined for the water recycling system 50. Such information can be displayed in the form of a numerical output that can be an absolute value or a scaled value of the composite water quality value (e.g., as a ratio of 1.0 or a percentage of 100%). Additionally or alternatively, information associated with the determined composite water quality value can be displayed along with a corresponding indication of the desirability of taking a risk or control action. For example, a color coding (e.g., red, yellow, green) associated with the composite water quality value can be determined by the controller 90 and displayed on the display 100 to indicate the relative risk associated with the determined composite water quality value.

[0054] During operation, the plurality of sensors 80 can generate data indicating one or more characteristics of the water in the water recycling system 50. Further, when implemented with additional sensors such as temperature sensors, flow rate sensors, and / or pressure sensors, such sensors can generate data indicating the corresponding measured characteristics. The controller 90 can receive data from sensors disposed throughout the water recycling system 50 (in addition to, or instead of, receiving data from external sources such as data indicating the operation of the casting machine 10 and / or the cooling tower 62) and use the received data to determine a composite water quality value for the water recycling system 50. The composite water quality value can provide a single parameter that aggregates different measured values and / or data streams across the water recycling system 50. This can reconcile and aggregate different discrete measurements for analysis and system control, leading to more consistent, predictable, and effective control of the water recycling system 50 in the water flowing through the system.

[0055] The controller 90 can receive data from sensors within the water recycling system 50 and continuously or periodically determine the composite water quality value. For example, the controller 90 can determine the composite water quality value at least once a day, such as at least once an hour, at least once a minute, or at least once a second. The frequency at which the controller 90 calculates the composite water quality value can vary according to the sampling rate of the sensors within the water recycling system 50, the processing capacity of the controller 90, and / or operator input selecting the frequency at which the composite water quality value should be calculated.

[0056] In some examples, the controller 90 processes the received data from the sensors 80 before calculating the composite water quality value. For example, the controller 90 can use a statistical smoothing algorithm to smooth the data and remove noise and outliers from the data. The controller 90 can then use the smoothed data to determine the composite water quality value. Alternatively, the controller 90 can calculate the composite water quality value of the raw data and apply a smoothing algorithm to the calculated value.

[0057] Generally, the controller 90 can determine the composite water quality value of the water recycling system 50 based on the received data from the plurality of sensors 80 and / or based on the received data from sources other than the sensors 80. The controller 90 may aggregate data from different sensors using various different calculations and / or sensor fusion techniques. In some examples, the controller 90 applies weighting factors to the measured characteristics from each sensor 80. Each weighting factor can correspond to the predicted strength and evidentiary value that a particular measurement has with respect to the quality of the water within the water recycling system 50. A particular weighting factor can be determined based on a causal analysis of empirical data that associates a particular measured water characteristic at a particular location within the water recycling system 50 with the quality of the water within the water recycling system. The weighting factors can be further adjusted upward or downward based on application-specific factors related to the particular water recycling system 50 being monitored and controlled. The weighting factors are programmed into a memory associated with the controller 90 and can be used by the controller to determine the predicted causes of fouling associated with detected changes in heat transfer efficiency trends.

[0058] In some implementations, the weighting factors applied to different measured water characteristics from different locations within the water recycling system 50 can be scaled as a ratio of 1.0 or a percentage of 100%. For example, a number of weighting factors corresponding to the number of parameters included in the calculation of the composite water quality value may be assigned. The individual weighting factors can sum to equal 1.0 or 100%. Parameters that are relatively highly correlated with the quality of the water within the water recycling system 50 can receive a relatively high weighting (e.g., a weighting factor of 15% or more, such as 20% or more, or 25% or more). Parameters that are moderately correlated with the quality of the water within the water recycling system 50 can receive a relatively moderate weighting (e.g., a weighting factor of 7% - 15%). Parameters that are not very correlated with the quality of the water within the water recycling system 50 can receive a relatively low weighting (e.g., a weighting factor of less than 7%, such as 5% or less, or 3% or less, or 2% or less). The weighting factors applied to different measured water characteristics may include a combination of high, moderate, and / or low weightings.

[0059] The controller 90 can apply the weighting factor by multiplying each data parameter by its corresponding weighting factor. Depending on the number of data points available for a particular parameter, the controller 90 can average multiple measurements of the parameter and apply the weighting factor to the average value of the parameter. For example, the controller 90 may determine the average value, median value, or mode value of the multiple data points to provide an average of the parameter and then apply the weighting factor to the averaged parameter.

[0060] The controller 90 may apply the weighting factor to the parameters by multiplying the weighting factor by individual measurement parameters (e.g., turbidity value, pH value, conductivity value, oil concentration value, ORP value, pressure value). Additionally, or alternatively, the controller 90 may normalize different individual measured parameters to a uniform numerical scale and apply the weighting factor to each normalized parameter. Normalizing different individual measured parameters can be useful when determining a composite water quality value based on different measured characteristics of water, each of which can be scaled differently and / or within different numerical ranges.

[0061] For example, the controller 90 may compare each parameter (e.g., each measured water characteristic from a plurality of sensors 80) included in the calculation of the composite water quality value to a pre - established risk category stored in the memory 94 of the controller 90. Each risk category may have a plurality of corresponding thresholds (e.g., high, medium, and / or low thresholds) for the parameter, and different categories cover different ranges for the associated parameter. For example, the memory 94 of the controller 90 may store a low - risk category associated with a first numerical range or value of a particular parameter, a medium - risk category associated with a second numerical range or value of the particular parameter different from the first numerical range, and / or a high - risk category associated with a third numerical range or value of the particular parameter different from the first and second numerical ranges. The third numerical range or value may be greater than or less than the second numerical range or value, and the second numerical range or value may then be greater than or less than the first numerical range or value. Any number of different categories can be stored within the memory 94 of the controller 90, each of which can be defined by numerical ranges for the associated parameter, such as two, three, four, or more categories for each parameter.

[0062] The controller 90 can compare the measured and / or received values of specific parameters (the measured values of the water properties of each of the plurality of sensors 80) and compare the actual values with the corresponding value ranges associated with different categories stored in the memory 94. The controller 90 can determine within which range the measured and / or received value lies and assign the measured and / or received value to the category associated with that range.

[0063] The memory 94 of the controller 90 can store normalized numerical values associated with each risk category, and different parameters have the same normalized numerical values for each risk category associated with that parameter. The normalized numerical values can be higher (or lower depending on the scaling) for each category designated as having a relatively higher comparison risk than for each category designated as having a relatively lower risk. The controller 90 can then apply the weighting factor to the normalized numerical value associated with each individual measured parameter by multiplying the normalized numerical parameter by the weighting factor.

[0064] The specific weighting factors and normalized numerical values applied by the controller 90 can vary based on the application, but Table 1 provides an example range of weighting factors and normalized numerical values that can be applied to different parameters.

[0065]

Table 1

[0066] To determine the composite water quality value, the controller 90 can sum the individual measurement and / or received parameters on which the composite water quality value is based, such as by summing the weighted individual measurement parameters and / or weighted normalization parameters. For example, the controller 90 may calculate a numerical composite water quality value by adding the individual numerical values associated with each measurement and / or received parameter (e.g., processed as described herein). The calculated composite water quality value may be further scaled or normalized by the controller 90.

[0067] In some examples, the controller 90 compares the determined composite water quality value to one or more threshold water quality values. Each threshold water quality value can indicate a different quality level of the water within the water recycling system 50. The specific threshold against which the controller 90 compares the composite water quality value may vary, for example, based on the magnitude of the applied weighting factor.

[0068] In response to the composite water quality value determined by the controller 90 and / or based on the comparison of the composite water quality value to one or more thresholds, various control actions can be taken. As an example, the controller 90 can control one or more pumps 68 to control the addition of one or more chemicals to the cooling water. In some examples, the controller 90 starts the pump 68 or increases the operating speed of the pump 68. Additional control actions that can be performed by the controller 90 and / or the operator of the system 50 include, for example, introducing fresh water into the water recycling system, flushing or controlling a processing unit (e.g., a filter of the system), or performing control actions to modify the operation of the water recycling system 50. In addition to or instead of taking control actions, information indicating the determined composite water quality value can be displayed on the display 100 for visualization by the operator of the water recycling system 50.

[0069] The above-described corrective actions can be performed by the controller 90, but it should be understood that in some cases, operator intervention may be required to perform some or all of these actions, while in other cases it may not be required. For example, in practice, the controller 90 may issue user warnings (e.g., visual text and / or graphics) on a computer user interface that provides control instructions and / or recommended operating guidelines. The operator may interact with the plant equipment manually or through a controller interface (e.g., a computer) that controls the plant equipment to implement the desired operation.

[0070] In applications where there are multiple different chemical additives available for introduction into the cooling water, the controller 90 can select one or more of the different chemical additives introduced into the cooling water by controlling valves and / or pumps that fluidly couple one or more different chemical additives to the cooling water stream. For example, the controller 90 can vary the type of chemical additive introduced into the cooling water and / or the rate at which the chemical additive is introduced into the cooling water.

[0071] The techniques described in this disclosure may be implemented, at least in part, in hardware, software, firmware, or any combination thereof. For example, various aspects of the described techniques can be implemented within one or more processors that include one or more microprocessors, digital signal processors (DSPs), application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), or other equivalent integrated or discrete logic circuits, and any combination of such components. The term "processor" or "processing circuit" can generally refer to any of the foregoing logic circuits, either alone or in combination with other logic circuits or other equivalent circuits. A control unit comprising hardware can also execute one or more of the techniques of this disclosure.

[0072] Such hardware, software, and firmware may be implemented within the same device or in separate devices to support the various operations and functions described in this disclosure. Further, any of the units, modules, or components described may be implemented together or separately as discrete but interoperable logical devices. The description of various features as modules or units is for the purpose of highlighting various functional aspects and does not necessarily mean that such modules or units must be realized by separate hardware or software components. Rather, the functions associated with one or more modules or units may be performed by individual hardware or software components or integrated within common or individual hardware or software components.

[0073] The techniques described in this disclosure may also be embodied or encoded on a computer-readable medium such as a non-transitory computer-readable storage medium containing instructions. The instructions embedded or encoded on the computer-readable storage medium may cause a programmable processor or other processor to perform a method when the instructions are executed. The non-transitory computer-readable storage medium may include volatile and / or non-volatile memory forms such as, for example, random access memory (RAM), read only memory (ROM), programmable read only memory (PROM), erasable programmable read only memory (EPROM), electronically erasable programmable read only memory (EEPROM), flash memory, hard disk, CD-ROM, floppy disk, cassette, magnetic media, optical media, or other computer-readable media.

[0074] Various examples have been described. These and other examples are within the scope of the following claims.

Claims

1. A water analysis and chemical control system for a continuous casting process, wherein the system is A continuous casting machine having a cooling zone equipped with multiple spray nozzles configured to spray water onto the metal being cast, The water recycling system comprises at least a gravity sedimentation tank, a filter, and a cooling tower. The gravity sedimentation tank is fluidly connected to the cooling zone of the continuous casting machine, and is configured to receive water from the cooling zone of the continuous casting machine after the water has come into contact with the metal being cast, and to gravity-separate the received water to provide a gravity-separated water flow. The filter is located downstream of the gravity sedimentation tank and is configured to receive the gravity-separated water flow and filter the gravity-separated water flow to provide a filtered water flow. The cooling tower is located downstream of the filter and is configured to receive the filtered water, reduce the temperature of the filtered water stream by evaporative cooling, and supply cooling water to the plurality of spray nozzles of the continuous casting machine. A plurality of sensors configured to measure at least one characteristic of a water sample to be analyzed, each of the plurality of sensors being fluidly connected to a different location in the water recycling system to measure the at least one characteristic of the water sample at each different location, A pump arranged to introduce chemical additives into the water in the water recycling system, A controller that is communicatively coupled to the plurality of sensors and the pump, Data indicating at least one characteristic of the water sample, measured by each of the plurality of sensors, is received from each of the plurality of sensors. Based on the received data from each of the plurality of sensors, a composite water quality value is determined. A water analysis and chemical control system comprising: a controller configured to control the pump to control the addition of the chemical additive to the water based on the determined composite water quality value.

2. At least one of the plurality of sensors is positioned upstream of the cooling tower to measure at least one of the properties of the water sample. The system according to claim 1, wherein at least one of the plurality of sensors is arranged to measure the at least one characteristic of the water sample at a location downstream of the cooling tower.

3. At least one of the plurality of sensors is arranged to measure at least one characteristic of the water sample from the gravity-separated water flow, The system according to claim 1 or 2, wherein at least one of the plurality of sensors is arranged to measure the at least one characteristic of the water sample from the filtered water flow.

4. The system according to claim 1 or 2, further comprising a strainer fluidly connected between the cooling water tower and the plurality of spray nozzles, wherein the strainer is configured to filter the cooling water before supplying it to the plurality of spray nozzles of the continuous casting machine, and at least one of the plurality of sensors is arranged to measure the at least one characteristic of the water sample downstream of the strainer and upstream of the spray nozzles.

5. The system according to claim 1 or 2, wherein the controller is configured to determine the composite water quality value based on the received data from each of the plurality of sensors by generating weighted sensor values ​​by applying at least a weighting coefficient to the received data from each of the plurality of sensors.

6. The system according to claim 5, wherein applying the weighting coefficient to the received data from each of the plurality of sensors includes applying different weighting coefficient values ​​to the received data from different sensors among the plurality of sensors.

7. The system according to claim 5, wherein the controller is configured to determine the composite water quality value based on the sum of the weighted sensor values.

8. The system according to claim 1 or 2, wherein the controller is configured to compare the combined water quality value with a threshold water quality value, and to control the pump to control the addition of the chemical additive to the water when the combined water quality value exceeds the threshold water quality value.

9. The system according to claim 1 or 2, wherein the plurality of sensors include a plurality of optical sensors configured to perform optical measurements of the water sample.

10. The system according to claim 1 or 2, wherein the at least one water characteristic includes turbidity.

11. The system according to claim 1 or 2, further comprising at least one sensor configured to measure the properties of the water in the cooling tower, wherein the controller is configured to receive data indicating the water properties in the cooling tower from the at least one sensor and to determine the composite water quality value based on both the received data from each of the plurality of sensors and the received data from the at least one sensor indicating the water properties in the cooling tower.

12. The system according to claim 11, wherein the properties of the water in the cooling tower include at least one of conductivity, pH, and oxidation-reduction potential (ORP).

13. The system according to claim 1 or 2, wherein the controller is further configured to receive data indicating the water flow through the plurality of spray nozzles and to determine the composite water quality value based on both the received data from each of the plurality of sensors and the received data indicating the water flow through the plurality of spray nozzles.

14. The system according to claim 13, wherein the data indicating the water flow through the plurality of spray nozzles includes at least one of the flow rate of water supplied to the plurality of spray nozzles and the pressure of water supplied to the plurality of spray nozzles.

15. The system according to claim 1 or 2, wherein the chemical additive is at least one of a coagulant, a dispersant, a biocide, a corrosion inhibitor, and a pH control agent.

16. The system according to claim 1 or 2, wherein the pump is arranged to control the addition of the chemical additive to the gravity sedimentation tank.

17. The system according to claim 1 or 2, wherein the pump is arranged to control the addition of the chemical additive downstream of the cooling tower.

18. The system according to claim 1 or 2, wherein the gravity settling tank includes a scale pit, the filter includes a bed filter, and the system further includes a settling tank between the gravity settling tank and the bed filter.

19. A method for analyzing water in a continuous casting process and controlling the addition of chemical substances to the water, wherein the method is: Measuring at least one characteristic of water at multiple different locations in a water recycling system for a continuous casting process using multiple sensors, wherein the continuous casting process has multiple spray nozzles for spraying water onto the metal being cast, and the water recycling system comprises at least a gravity sedimentation tank, a filter, and a cooling tower. Using the measured characteristics of the water from the plurality of sensors, the processor determines a composite water quality value for the water in the water recycling system. A method comprising controlling the addition of chemical additives to the water in the water recycling system based on the determined composite water quality values.

20. The method according to claim 19, wherein the plurality of positions include at least one position upstream of the cooling tower and at least one position downstream of the cooling tower.

21. The method according to claim 19 or 20, wherein the plurality of positions include a first position that provides an outflow from the gravity sedimentation tank and a second position that provides an outflow from the filter.

22. Determining the composite water quality value of the water in the water recycling system is, Applying weighting coefficients to the measured characteristics of the water from the plurality of sensors to generate weighted sensor values, The method according to claim 19 or 20, comprising summing the weighted sensor values.

23. The method according to claim 22, wherein applying the weighting coefficient to the received data from each of the plurality of sensors includes applying different weighting coefficient values ​​to the received data from different sensors among the plurality of sensors.

24. The method according to claim 19 or 20, wherein measuring at least one property of the water at the plurality of different locations includes measuring an optical property.

25. The method according to claim 19 or 20, further comprising measuring the properties of the water in the cooling tower, and determining the composite water quality value of the water in the water recycling system, wherein the composite water quality value is determined using both the measured at least one property of the water from the plurality of sensors and the property of the water in the cooling tower.

26. The method according to claim 19 or 20, further comprising receiving data indicating the water flow through the plurality of spray nozzles, and determining the composite water quality value for the water in the water recycling system, comprising determining the composite water quality value using both the measured at least one characteristic of the water from the plurality of sensors and the received data indicating the water flow through the plurality of spray nozzles.

27. The method according to claim 19 or 20, wherein controlling the addition of the chemical additive to the water in the water recycling system based on the determined composite water quality value includes comparing the composite water quality value with a threshold water quality value and controlling the addition of the chemical additive to the water if the composite water quality value exceeds the threshold water quality value.

28. The method according to claim 19 or 20, wherein the chemical additive is at least one of a coagulant, a dispersant, a biocide, a corrosion inhibitor, and a pH control agent.

29. A water analysis system for a continuous casting process, wherein the system is A continuous casting machine having a cooling zone equipped with multiple spray nozzles configured to spray water onto the metal being cast, The water recycling system comprises at least a gravity sedimentation tank, a filter, and a cooling tower. The gravity sedimentation tank is fluidly connected to the cooling zone of the continuous casting machine, and is configured to receive water from the cooling zone of the continuous casting machine after the water has come into contact with the metal being cast, and to gravity-separate the received water to provide a gravity-separated water flow. The filter is located downstream of the gravity sedimentation tank and is configured to receive the gravity-separated water flow and filter the gravity-separated water flow to provide a filtered water flow. The cooling tower is located downstream of the filter and is configured to receive the filtered water, reduce the temperature of the filtered water stream by evaporative cooling, and supply cooling water to the plurality of spray nozzles of the continuous casting machine. A plurality of sensors configured to measure at least one characteristic of a water sample to be analyzed, each of the plurality of sensors being fluidly connected to a different location in the water recycling system to measure the at least one characteristic of the water sample at each different location, The display and One or more controllers, Receiving data measured from each of the plurality of sensors, which shows at least one characteristic of the water sample measured by each of the plurality of sensors, Based on the received data from each of the plurality of sensors, a composite water quality value is determined. A water analysis system comprising one or more controllers configured to control the display to display information indicating the composite water quality values.

30. The system according to claim 29, wherein one or more controllers are configured to compare the determined composite water quality value with a plurality of threshold water quality values ​​and to control the display to display a different composite water quality classification based on whether the determined composite water quality value exceeds one or more of the plurality of threshold water quality values.

31. The system according to claim 30, wherein the different composite water quality classifications include different color coding.

32. The system according to any one of claims 29 to 31, wherein one or more controllers are configured to compare the determined composite water quality value with a threshold water quality value and to control the display to issue a warning if the determined composite water quality value exceeds the threshold water quality value.

33. The system according to any one of claims 29 to 31, wherein the controller is configured to determine the composite water quality value based on the received data from each of the plurality of sensors by generating weighted sensor values ​​by applying at least a weighting coefficient to the received data from each of the plurality of sensors.

34. The system according to claim 33, wherein applying the weighting coefficient to the received data from each of the plurality of sensors includes applying different weighting coefficient values ​​to the received data from different sensors among the plurality of sensors.

35. The system according to claim 33, wherein the controller is configured to determine the composite water quality value based on the sum of the weighted sensor values.

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