Double side sampler device for taking samples for direct analysis from a molten metal bath

Abstract

The present invention provides a sampler device (100) having two sides, each side for extracting samples of molten metal for direct analysis from a bath of molten metal. The sampler device includes a carrier tube (102) at least partially enclosable inside a mechanical enclosure (104). The carrier tube (102) having a first immersion end (106) with a first sample collection chamber (110) connected thereto for extracting a first sample from the samples, and a second emersion end (108) having a second sample collection chamber (112) connected thereto for extracting a second sample from the samples. The mechanical enclosure (104) is adapted to receive the second emersion end (108) while extracting the first sample using the first immersion end (106), and the mechanical enclosure (104) is adapted to receive the first immersion end (106) while extracting the second sample using the second emersion end (108), to thereby enable the sampler device to extract two molten metal samples.

Description

DOUBLE SIDE SAMPLER DEVICE FOR TAKING SAMPLES FOR DIRECT ANALYSIS FROM A MOLTEN METAL BATHFIELD OF INVENTION

[0001] The present invention relates to a field of immersion samplers (also interchangeably referred to as “probes”). In particular, the present invention pertains to a double side sampler device for taking samples for direct analysis from a molten metal bath.BACKGROUND

[0002] Samplers for molten metal baths are specialized tools designed to extract small quantities of molten metal fortesting and analysis. These samplers are used in foundries, steel plants, and metal processing industries to ensure the quality and consistency of the metal before it is cast or processed further.

[0003] There are many types of samplers available in the market today. Few of them are mentioned below:

[0004] Immersion Samplers: They are typically a small container or cavity attached to a long handle that can be immersed into the molten metal. These samplers are inserted into the molten bath, allowing the cavity to fill with metal. Once filled, the sampler is removed and cooled. These are normally used in steel production, iron foundries, and aluminum plants to collect samples at high temperatures (up to 1700°C or more).

[0005] Lance-type Samplers: In these types of samplers, a lance is used with a small container at the end to collect the molten sample. Similar to immersion samplers, these lances are thrust into the bath. The sample is drawn into the container through vacuum or pressure differentials. These types of samplers are suitable for deep or large molten baths, such as those in steelmaking furnaces.

[0006] Dip-type Samplers: These samplers are often a simple ceramic or quartz tube connected to a sample collection vessel. The dip-type sampler is immersed into the bath to collect molten metal. The metal solidifies inside the tube, which is then removed and analyzed. These are commonly used for lower volume baths or where the molten metal is not as aggressive.

[0007] Vacuum-based Samplers: In these types of samplers, a vacuum is applied to draw molten metal into a sealed container. When inserted into the molten metal, the vacuum helps draw the sample into the container for testing. These are used when a clean, oxygen-free sample is necessary.

[0008] Once the sample is extracted, it is typically allowed to cool and solidify before being analysed for one of the following analyses:

[0009] Chemical composition: To ensure the right alloy mix (e.g., carbon content in steel, impurities).

[0010] Microstructure examination: Microscopic analysis of the solidified sample to inspect grain structure or any defects.

[0011] However, as shown in FIG. 1, the traditional samplers can only be used ones (disposable samplers) and that to for collection of a single sample at a time. This is because the mechanism to extract is provided only at one end. Further, the traditional samplers being a paper based / made sampler, the sustainability of these sampler is another concern since molten metal can reach temperatures well over 1100°C - 1800°C.

[0012] There is, therefore, a need for improvement in the existing molten metal samplers / probes from the perspective of its usability and operating time.SUMMARY

[0013] The present invention provides a double side sampler device for taking samples for direct analysis from a molten metal bath that enables the user to take two measurement / sample from a single probe.

[0014] The double side sampler device includes two collection chambers on both the ends of a paper tube of the device. Further, to protect the other end from burning when probe is submerged in molten steel, the device comprises a special lance holder which protect the probe from burning on such a high temperature.

[0015] The double side sampler device holding lance together will provide following advantages:

[0016] Analysis accuracy of the samplers will be increases;

[0017] Cost of the sampler will be reduced by 25%;

[0018] Shelflife of the sampler probes will be increased;

[0019] Carbon emission will be reduced by 50%;

[0020] Transportation cost will be reduced by 30%;

[0021] Packing cost will be reduced by 40%;

[0022] As paper in main component of molten metal sampler, therefore paper consumption will be reduced by 50%;

[0023] For one tone of paper approx. 17 to 24 trees are cut, the double side sampler device will directly reduce the cutting of trees for paper manufacturing;

[0024] Probe can be used in all the sizes required in the industry starting from 100 mm to 4000 mm;

[0025] Probe will accommodate all the deoxidant which are used in steel making process like AL, ZR, titanium etc;

[0026] Probe can accommodate all the sample shape required for analysis like round, ovel, elliptical, double thickness, cylindrical etc;

[0027] Probe will also support plan paper tube, paper tube with anti-splash sleeve, paper tube with any kind of fire resistance chemical / any kind of quoting

[0028] This probe design can be used in any industry where metal is melted / casted like steel, AL, copper, Ferro alloys etc.; and

[0029] This probe design accommodates any kind of paper tube like parallel, spiral and other kinds.BRIEF DESCRIPTION OF DRAWINGS

[0030] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0031] FIG. 1 illustrates a conventional sampler device for extracting sample for direct analysis from a bath of molten metal.

[0032] FIG. 2 illustrates a sampler device for extracting sample for direct analysis from a bath of molten metal, in accordance with an embodiment of the present disclosure.

[0033] FIGs. 3A-3E illustrates a sampler device for extracting multiple samples for direct analysis from a bath of molten metal, in accordance with an embodiment of the present disclosure.DETAILED DESCRIPTION

[0034] Immersion samplers are used for taking samples of molten metal (for example steel or iron). The sampling probes are designed with advance techniques for a safe, rapid and direct sampling and for reduction of total sampling and analysis time for producing clean steel. Sampler is mainly used to quickly take out a steel sample for spectrum analysis; it has structure, convenient application, widely used in electric furnace steel making, converter steel making, continuous casting and other process. Molten steel sampler, which are widely used in continuous casting and secondary steel making furnace converter refining process etc.Normally, it is used for process analysis of molten metal for instantaneous sampling techniques and reinforces quality control. This product is used for sampling directly from a stream or a ladle spoon.

[0035] However, from years steel melting shops are using traditional design samplers to collect molten steel / Iron sample for analysis, traditional design samplers / probe can only be used ones (disposable samplers).

[0036] The present invention provides a double side sampler device for taking samples for direct analysis from a molten metal bath that enables the user to take two measurement / sample from a single probe.

[0037] The double side sampler device includes two collection chambers on both the ends of a paper tube of the device. Further, to protect the other end from burning when probe is submerged in molten steel, the device comprises a special lance holder which protect the probe from burning on such a high temperature.

[0038] FIG. 1 illustrates a conventional sampler device for extracting sample for direct analysis from a bath of molten metal. As shown, the immersion sampler is used to collect samples of molten metal. The sampler is mainly used to quickly take out molten metal samples for spectral analysis.

[0039] When a sampler was inserted into the hot metal liquid, under the static pressure, the hot metal liquid breaks the slag protective layer / cap, through the sampler inlet (a tube referred to as “silica tube), into the sampling chamber (which is referred to as “sample collection chamber” throughout the specification) automatically. Then the alloying element content in the steel can be analyzed by spectral analysis.

[0040] FIG. 2 illustrates a sampler device for extracting sample for direct analysis from a bath of molten metal, in accordance with an embodiment of the present disclosure.

[0041] The present invention provides a device designed to extract and collect samples from molten metal, typically steel or iron, for direct analysis. The device is structured to allow for the collection of two separate samples from the same bath of molten metal.

[0042] Following are the key components of the device which are further elaborated in FIGs. 3A-3E below:

[0043] Sampler Device (100): The main apparatus that houses all components required for sample collection.

[0044] Carrier Tube (for example, paper tube) (102): This tube is designed to be partially enclosed within a mechanical enclosure, and it has two ends:

[0045] First Immersion End (106): Designed for extracting the first sample.

[0046] Second Emersion End (108): Designed for extracting the second sample.

[0047] Sample Collection Chambers: First Sample Collection Chamber (110): Attached to the first immersion end. Second Sample Collection Chamber (112): Attached to the second emersion end.

[0048] Mechanical Enclosure (104): This enclosure is adaptable to house either end of the carrier tube and is responsible for providing mechanical stability during sampling.

[0049] Working and Operation: The device is designed to collect two samples from a bath of molten metal. When the first immersion end (106) is used to collect the first sample, the second emersion end (108) is housed within the mechanical enclosure (104). After the first sample is collected, the roles of the two ends can be reversed. The second emersion end (108) is then used to collect a second sample, while the first immersion end (106) is housed within the mechanical enclosure.

[0050] Mechanical Enclosure (104):

[0051] The enclosure is adaptable, allowing either end of the carrier tube to be received during the sampling process. This provides mechanical stability and protects the tube from breaking.

[0052] It includes receptor ends (105-1, 105-2) that can receive either the immersion or emersion end of the carrier tube during the sampling process.

[0053] Sample Collection Chambers: Each collection chamber (110, 112) is structured like a spoon with a shallow bowl, which is used to scoop the molten metal. These chambers are either rigidly or non-rigidly connected to the respective ends of the carrier tube. They also serve as inflow conduits (a tube referred to as “silica tube) for the molten metal, directing it into the shallow bowl for sample collection.

[0054] Materials and Protection: The carrier tube (102) can be made of paper, which is commonly used in high-temperature environments like those involved in molten metal handling. The mechanical enclosure (104) is designed not only to hold the tube but also to protect it from the harsh conditions of the molten metal bath, such as extreme temperatures and physical stress, thereby preventing it from breaking during sample extraction.

[0055] The sampler device is designed with a predetermined distance separating the first immersion end from the second emersion end, ensuring that each sample is taken from different parts of the molten bath. In an example, the predetermined distance is decided based on requirements or application for extracting the molten metal. In another example, if the length of paper tube is 300 mm and size of sand mold is 3 inches, so the first immersion endfrom the second emersion ends is specked from each other approximately by a distance of 150-155 mm.

[0056] The molten metal for which the device is intended includes high-temperature metals like steel or iron.

[0057] This device offers a practical solution for obtaining multiple samples from a bath of molten metal. Its design ensures that samples can be collected safely and effectively while protecting the device's components from the harsh conditions associated with molten metal. The dual-sample capability allows for more comprehensive analysis by enabling the collection of samples from different locations within the molten bath.

[0058] FIGs. 3A-3E illustrates a sampler device for extracting multiple samples for direct analysis from a bath of molten metal, in accordance with an embodiment of the present disclosure.

[0059] As shown in FIGs. 3A-3E, a sampler device (100) having two sides, each side for extracting samples of molten metal for direct analysis from a bath of molten metal.

[0060] The sampler device (100) includes a carrier tube (102) at least partially enclosable inside a mechanical enclosure (104). The carrier tube (102) having a first immersion end (106) with a first sample collection chamber (110) connected thereto for extracting a first sample from the samples, and a second emersion end (108) having a second sample collection chamber (112) connected thereto for extracting a second sample from the samples.

[0061] The mechanical enclosure (104) is adapted to receive the second emersion end (108) while extracting the first sample using the first immersion end (106). The mechanical enclosure (104) is adapted to receive the first immersion end (106) while extracting the second sample using the second emersion end (108).

[0062] In an exemplary embodiment, the mechanical enclosure (104) having a first receptor end (105-1) and a second receptor end (105-2). Each of the first receptor end (105-1) and the second receptor end (105-2) is adapted to receive the first immersion end (106) or the second emersion end (108).

[0063] In an exemplary embodiment, each of the first sample collection chamber (110) and the second sample collection chamber (112) comprises a spoon like structure having a shallow bowl oval or round at the end of a handle (116, 118).

[0064] The first sample collection chamber (110) and the second sample collection chamber (112) are rigidly or non-rigidly connected to the first immersion end (106) and the second immersion end (108).

[0065] The handle (116, 118) of each of the first sample collection chamber (110) and the second sample collection chamber (112) is an inflow conduit or operates as an inflow conduit (a tube referred to as “silica tube) being received at the shallow bowl oval or round.

[0066] In an exemplary embodiment, the carrier tube (102) is paper carrier tube.

[0067] In an exemplary embodiment, the mechanical enclosure (104) is a lance.

[0068] In an exemplary embodiment, the mechanical enclosure (104) is a carrier tube holder to provide a mechanical stability to the carrier tube upon submersion of the first immersion end and / or the second emersion end in the bath of the molten metal.

[0069] In an exemplary embodiment, the first immersion end is separated from the second emersion end by a pre-determined distance.

[0070] In an exemplary embodiment, the mechanical enclosure (104) is adapted to protect the carrier tube (102) from breaking while extraction of the multiple samples.

[0071] In an exemplary embodiment, the molten metal is a molten steel or a molten iron.

[0072] In an exemplary embodiment, the second receptor end (105-2) is connected to an extended holder (120) when the first receptor end (105-1) receives the second emersion end (108).

[0073] In an exemplary embodiment, the first receptor end (105-1) is connected to the extended holder (120) when the second receptor end (105-2) receives the first immersion end (106).

[0074] In an exemplary embodiment, the first sample collection chamber is adapted to extract a first sample selected from the multiple samples, and the second sample collection chamber is adapted to extract a second sample selected from the multiple samples, thereby enabling the sampler device extraction of the two samples at a single instance.

[0075] In an exemplary embodiment, the molten metal is a molten steel or a molten iron.

[0076] Again, referring to FIGs. 3A-3E, a sampler device (100) for taking samples from a molten metal bath is shown. The sampler device (100) is suitable for immersion in and sampling of molten steel. The shown sampler device (100) may include a measuring head which can be made of resin bonded silica sand. The measuring head is supported on a mechanical enclosure (104). In use, a carrier tube (102), which can be a paper carrier tube, is preferably inserted at least partially into the interior volume of the mechanical enclosure (104) or lance such that mechanical enclosure (104) provides the mechanical action necessary to submerse the measuring head below the surface of a bath of molten metal (not shown) in the immersion direction.

[0077] It will be understood by those skilled in the art that the phrase “immersion end” means the end of the body which is first immersed into molten metal.

[0078] The mechanical enclosure (104) having a first measuring end (105-1) and a second measuring end (105-2). Upon insertion, the first immersion end (106) is adapted to reach and couple to the first measuring end (105-1). Similarly, the second immersion end (108) is adapted to reach and couple to the second measuring end (105-2).

[0079] The spoon like structure is formed of one or more materials which are good thermal and electrical conductors, such as, but not limited to, aluminum, copper and other metals having similar thermal and electrical conductivity properties for being electrically coupled to the retrieved metal sample.

[0080] As shown in FIGs. 3A-3E, when a sampler was inserted into the hot metal liquid, under the static pressure, the hot metal liquid breaks the slag protective layer / cap (also conventionally referred to as “outer slag cap”), through the sampler inlet (a tube referred to as “silica tube), into the sampling chamber (which is referred to as “sample collection chamber” throughout the specification) automatically. Then the alloying element content in the steel can be analyzed by spectral analysis.

[0081] In an example, due to the concavely shaped indentation (i.e., shallow bowl oval or round) of the the sampling chamber, the temperature of the sample can be minimized, while the thickness of the sample can be increased. In particular, the mass of the sample is reduced by creating circle segment-shaped sample. This allows to reduce the sampled mass with up to 50% without increasing the effect of heating during sparking. The lowered temperature of the sample reduces the temperature requirements of the sealing accordingly. The maximum temperature of the sample is creating the highest risk regarding components released from the sealing that might influence the analysis result.

[0082] The handle (116, 118) of each of the first sample collection chamber (110) and the second sample collection chamber (112) is an inflow conduit or operates as an an inflow conduit (a tube referred to as “silica tube) where the inflow conduit is received at the shallow bowl oval or round. The inflow conduit can be made of a quartz material, more preferably a fused quartz material. The respective inflow conduit (a tube referred to as “silica tube) enables the flow of molten metal from the molten metal bath into the associated first immersion end (106) and the associated second immersion end (108). Thus, molten metal is introduced into the associated first immersion end (106) and the associated second immersion end (108) in a direction opposite the immersion direction.

[0083] As shown in FIGs. 3A-3E, the handle (116, 118) which may be the inflow conduit (a tube referred to as “silica tube) are connected to the first measuring end (105-1) and the second measuring end (105-1). The first measuring end (105-1) and the second measuring end (105-1) may have a small aperture to allow the molten metal to be introduced into the associated handle (116, 118) and thereby into the associated shallow bowl oval or round.

[0084] However, the person skilled in the art would know that other shapes, such as polygonal shapes, can be used instead of the shapes as discussed above (for any or all components) to achieve similar results.

[0085] The features disclosed in the claims, the specification, and the drawings maybe essential for different embodiments of the claimed invention, both separately or in any combination with each other.

[0086] Exemplary using method: Sample taken from the metal bath must be Representative, Free of inclusions, cracks and holes Suitable, in shape and size. While taking the sample of molten metal the sampler should be sunk to the depth depending on the temperature and the viscosity of the melt at an angle say for example 55° for approximately 3 to 5 second (the depth and time should be strictly carried out for its best performance). After taking the sample instrument from the furnace, knock the non-immersed part on the ground, so the sample of steel will fall down on the ground. It is best to take a sample when the molten steel temperature is above 1500°C.

[0087] It is used for process analysis of molten metal for instantaneous sampling techniques and reinforces quality control. This product is used for sampling directly from a stream or a ladle spoon.

[0088] It may be appreciated that, in use, when the first immersion end (106) with the first sample collection chamber (110) connected thereto is inserted into the bath for extracting the first sample from the samples, after extraction, the first immersion end (106) with the first sample collection chamber (110) tends to break making them unusable / reusable. This broken first sample collection chamber (110) is to be taken to lab for further testing. The same is shown in FIGs. 3B and 3D.

[0089] Once this process is completed, the mechanical enclosure (104) is then inserted into this broken end of the tube as shown in shown in FIGs. 3B and 3D, so that the second emersion end (108) having the second sample collection chamber (112) can be used for extracting a second sample from the samples.

[0090] Thus, the sampler device (100) can be used for extraction of samples from each side for direct analysis from a bath of molten metal.

[0091] It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

[0092] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

[0093] While the foregoing description discloses various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope of the disclosure. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

Claims

We Claim:

1. A sampler device (100) having two sides, each side for extracting samples of molten metal for direct analysis from a bath of molten metal, the sampler device comprising: a carrier tube (102) at least partially enclosable inside a mechanical enclosure (104), the carrier tube (102) having: a first immersion end (106) with a first sample collection chamber (110) connected thereto for extracting a first sample from the samples, and a second emersion end (108) having a second sample collection chamber (112) connected thereto for extracting a second sample from the samples; and wherein the mechanical enclosure (104) is adapted to receive the second emersion end (108) while extracting the first sample using the first immersion end (106), and the mechanical enclosure (104) is adapted to receive the first immersion end (106) while extracting probes the second sample using the second emersion end (108).

2. The sampler device as claimed in claim 1, wherein the mechanical enclosure (104) having a first receptor end (105-1) and a second receptor end (105-2), wherein: each of the first receptor end (105-1) and the second receptor end (105-2) is adapted to receive the first immersion end (106) or the second emersion end (108).

3. The sampler device as claimed in claim 1, wherein each of the first sample collection chamber (110) and the second sample collection chamber (112) comprises a spoon like structure having a shallow bowl oval or round at the end of a handle (116, 118), wherein: the first sample collection chamber (110) and the second sample collection chamber (112) are rigidly or non-rigidly connected to the first immersion end (106) and the second immersion end (108); and the handle (116, 118) of each of the first sample collection chamber (110) and the second sample collection chamber (112) is an inflow conduit or operates as an an inflow conduit being received at the shallow bowl oval or round.

4. The sampler device as claimed in claim 1, wherein the carrier tube (102) is paper carrier tube.

5. The sampler device as claimed in claim 1, wherein the mechanical enclosure (104) is a lance.

6. The sampler device as claimed in claim 1, wherein the mechanical enclosure (104) is a carrier tube holder to provide a mechanical stability to the carrier tube upon submersion of the first immersion end and / or the second emersion end in the bath of the molten metal.

7. The sampler device as claimed in claim 1, the first immersion end is separated from the second emersion end by a pre-determined distance.

8. The sampler device as claimed in claim 1, wherein the mechanical enclosure (104) is adapted to protect the carrier tube (102) from breaking while extraction of the multiple samples.

9. The sampler device as claimed in claim 1, wherein the molten metal is a molten steel or a molten iron.

10. The sampler device as claimed in claim 2, wherein: the second receptor end (105-2) is connected to an extended holder (120) when the first receptor end (105-1) receives the second emersion end (108); and the first receptor end (105-1) is connected to the extended holder (120) when the second receptor end (105-2) receives the first immersion end (106).

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