Method for heating a steel semi-product and installation thereof

Abstract

The invention relates to a method for heating a steel semi-product that comprises the following steps: - putting a steel semi-product to be heated inside a furnace, - introducing an entry gas flow into a device for heating gas, being connected to said furnace and comprising: o a pipe allowing gas to flow inside of it, o an insert located inside said pipe, being electrically conductive, o an inductor located in the vicinity of said pipe, - feeding energy into said insert using said inductor of said device for heating gas so that said energy fed into the insert is transferred to the gas introduced into said device for heating gas, to heat said gas to a temperature from 450°C to 1500°C, - releasing said heated gas into the furnace so that said steel semi-product is heated, - removing the heated steel semi-product from the furnace.

Description

[0001] Method for heating a steel semi-product and installation thereof

[0002]

[0001] The present invention relates to a method for heating a steel semiproduct and the associated installation. More precisely, the present invention relates to a method for heating a steel semi-product with a gas heated using induction heating.

[0003]

[0002] In the process of making steel products, thermal treatments are done to give the steel its desired properties. It is done by heating homogeneously the steel product to be treated at one or several target temperatures that corresponds to the desired properties. There are various furnaces that are designed for the heat treatment of steel products.

[0004]

[0003] For steel semi-products, batch furnaces can be used for austenitization or tempering. It consists in a simple furnace with burners that produce combustion gas and that heats the steel semi-product to the desired temperature during a defined period of time.

[0005]

[0004] However, this process causes CO2 emissions because of the combustion gas and CO2 emissions need to be reduced in the steel industry. There is also a problem in that current batch furnaces are configured to perform only a definite thermal treatment at a definite temperature. There is thus a need for an alternative method that solve these problems.

[0006]

[0005] The aim of the present invention is therefore to remedy to the aforementioned drawbacks by providing a method that provides a homogeneous heating of a steel semi-product that is more flexible, has a better energy efficiency while reducing CO2 emissions.

[0007]

[0006] For this purpose, a first object of the present invention consists in a method for heating a steel semi-product wherein said method comprises the following steps:

[0008] - putting at least one steel semi-product 6 to be heated inside a furnace 5, - introducing an entry gas flow into at least one device for heating gas 1 , said device for heating gas 1 being connected to said furnace 5 and comprising: o a pipe 2 allowing gas to flow inside of it,

[0009] o an insert 3 located inside said pipe 2, said insert being electrically conductive,

[0010] o an inductor 4 located in the vicinity of said pipe 2,

[0011] - feeding energy into said insert 3 using said inductor 4 of said device for heating gas 1 so that said energy fed into the insert 3 is transferred to the gas introduced into said device for heating gas 1 , to heat said gas to a temperature from 450°C to 1500°C,

[0012] - releasing said heated gas into the furnace 5 so that said steel semiproduct 6 is heated,

[0013] - removing the heated steel semi-product 6 from the furnace 5.

[0014]

[0007] The method for heating a steel semi-product according to the invention may also have the optional features listed below, considered individually or in combination:

[0015] - the steel semi-product 6 is heated to a temperature from 250°C to 1300°C,

[0016] - the method comprises an additional step of retrieving the heated gas from the furnace 5 to be used again to heat said steel semi-product 6, - the retrieved gas is mixed with the entry gas flow before being heated again with the device for heating gas 1 ,

[0017] - several steel semi-products 6 are heated at the same time in the furnace 5,

[0018] - gas is released through several feeding pipes 7 arranged to feed the inner volume of the furnace 5,

[0019] - at least one device for heating gas 1 is connected to each of said feeding pipes 7,

[0020] - the entry gas flow is composed of one or more of the following gases:

[0021] syngas, CO2, CO, H2, H2O, hydrocarbons, N2.

[0022]

[0008] A second object of the invention consists in an installation for heating a steel semi-product, wherein said installation comprises: - a furnace 5 allowing at least one steel semi-product 6 to be put inside of it,

[0023] - at least one device for heating gas 1 , said device for heating gas 1 comprising:

[0024] o a pipe 2 allowing gas to flow inside of it,

[0025] o an insert 3 located inside said pipe 1 , said insert 3 being electrically conductive,

[0026] o an inductor 4 located in the vicinity of said pipe 2 and able to feed energy into said insert 3, so that said energy fed into said insert 3 is transferred to the gas flowing into said pipe 2, to heat said gas is to a temperature from 450°C to 1500°C.

[0027] - a means for introducing an entry gas flow into the device for heating gas 1 ,

[0028] - at least one feeding pipe 7, connected to the device for heating gas 1 and the furnace 5, for releasing the heated gas into the furnace 5.

[0029]

[0009] The installation according to the invention may also have the optional features listed below, considered individually or in combination:

[0030] - the installation further comprises a means for retrieving gas from the furnace 5 to be used again to heat the steel semi-product 6,

[0031] - the installation further comprises a mixing station able to mix said retrieved gas with the entry gas flow before being introduced into said at least one device for heating gas 1 ,

[0032] - the installation comprises several feeding pipes 7 arranged to feed the inner volume of the furnace 5,

[0033] - at least one device for heating gas 1 is connected to each of said feeding pipes 7,

[0034] - the insert 3 is designed to have an exchange surface with the gas to be heated that ranges from 0.5m2to 100m2by meter of pipe 2,

[0035] - the insert 3 shape is designed to provide a turbulent flow to the gas flowing into the pipe 2.

[0010] Other characteristics and advantages of the invention will be described in greater detail in the following description.

[0036]

[0011] The invention will be better understood by reading the following description, which is provided purely for purposes of explanation and is in no way intended to be restrictive, with reference to:

[0037]

[0012] Figure 1 , which is a general view of the device for heating gas according to the invention,

[0038]

[0013] Figure 2, which is a cross-sectional view of the interior of the pipe of the device for heating gas according to one embodiment,

[0039]

[0014] Figures 3a and 3b, which are representations of embodiments of the insert of the device for heating gas according to the invention,

[0040]

[0015] Figure 4, which is a representation of an embodiment of the installation for heating a steel semi-product according to the invention.

[0041]

[0016] With reference to Figure 1 , 2 and 4, the method for heating a steel semi-product and the installation for heating a steel semi-product according to the invention will be described in detail.

[0042]

[0017] The method for heating a steel semi-product 6 according to the invention comprises several steps. The first step consists in putting the steel semi-product 6 to be heated inside a furnace 5. For the second step, an entry gas flow is introduced into at least one device for heating gas 1 that is connected to the furnace 5. The device for heating gas 1 comprises a pipe 2 that allows the gas to flow inside of it, an insert 3 located inside the pipe 2 and that is electrically conductive as well as an inductor 4 located in the vicinity of the pipe 2. The third step consists in feeding energy to the insert 3. To achieve this, the inductor 4 creates a magnetic field that induces a current in the insert 3. This energy fed to the insert 3 results in the heating of the insert 3. This energy is then transferred from the hot insert 3 to the gas flowing into the pipe 2 that is thus heated to a temperature from 450°C to 1500°C. Preferably to a temperature from 450°C to 1300°C. More preferably to a temperature from 600°C to 1300°C. The gas is then released into the furnace 5 through at least one feeding pipe 7 so that the gas that is heated by the device for heating gas 1 transfers its energy to the steel semi-product 6 that is thus also heated. The steel semi-product 6 is then removed from the furnace 5 after being heated.

[0043]

[0018] Heating the steel semi-product 6 with a gas that is heated with induction instead of a combustion gas allows to have more control over the atmosphere and the temperature inside of the furnace 5. The temperature can be adapted to the thermal treatment that is desired for the steel semiproduct 6 to be heated. The method is thus more flexible as only one furnace 5 is needed to perform various thermal treatments. It also reduces the emissions of CO2 of the installation as the gas heated can contain less CO2 than the combustion gas or no CO2 at all.

[0044]

[0019] Preferably, the steel semi-product 6 is heated to a temperature from 250°C to 1300°C. Preferably to a temperature from 400°C to 1100°C. To heat the steel semi-product 6 to a desired temperature, it is preferable to heat the gas to a temperature higher than that of the desired temperature to take into account the heat losses as not all energy from the gas is transferred to the steel semi-product 6.

[0045]

[0020] Preferably, the method for heating a steel semi-product according to the invention comprises an additional step of retrieving the heated gas that circulates inside the furnace 5. This allows the gas to be used again to heat the steel semi-product 6.

[0046]

[0021] Preferably, the retrieved gas is introduced into a mixing station 8 that mixes it with the entry gas flow. The mix of entry gas flow and retrieved gas can then be introduced into the at least one device for heating gas 1 so that the retrieved gas is heated again together with the entry gas flow.

[0047]

[0022] This step is a recycling step that allows to reuse the gas after it has heated the steel semi-product 6. It allows to save gas and energy as the retrieved gas is hotter than the entry gas flow and thus the mix of retrieved gas and entry gas flow requires less energy to heat than a gas composed only of entry gas flow at ambient temperature. This step thus allows to reduce even more the CO2 emissions and to have an even better energy efficiency.

[0023] Alternatively, the mixing station 8 can be positioned after the device for heating gas 1 to mix the retrieved gas with the heated gas just before being injected into the furnace.

[0048]

[0024] Preferably, several steel semi-products 6 are heated at the same time in the furnace 5. It allows to further increase the energy efficiency of the method.

[0049]

[0025] Preferably, the heated gas is released through several feeding pipes 7 arranged to feed the inner volume of the furnace 5. This allows the steel semi-product 6 to be heated homogeneously.

[0050]

[0026] Preferably, at least one device for heating gas 1 is connected to each of the feeding pipes 7.

[0051]

[0027] The means for retrieving gas from the furnace 5 is preferably a fan.

[0052]

[0028] Preferably, the steel semi-product 6 undergoes a process of austenitization or tempering inside the furnace 5. Preferably, the steel semiproduct 6 undergoes a step of forging or a step of hot rolling after being heated. Other types of thermal treatments can be performed using the invention.

[0053]

[0029] Preferably, the steel semi-products 6 that are heated using the invention are ingots, slabs or steel semi-products for specific applications.

[0054]

[0030] An embodiment of the invention is represented in Fig 4. In this embodiment, the steel semi-product 6 is put inside a furnace 5. The entry gas flow goes to the mixing station 8 where it is mixed with the gas retrieved from the furnace 5. The mix of gas is then sent to a device for heating gas 1 and after being heated and exiting the device for heating gas 1 , the hot gas is released into the furnace 5 through feeding pipes 7 that connect the device for heating gas 1 to the inside of the furnace 5, to increase the temperature inside the furnace 5 to heat the steel semi-product 6. The gas is retrieved from the furnace 5 and is sent to the mixing station 8 to be mixed with the entry gas flow and heated again. The flow of gas is arranged to feed the inner volume of the furnace 5.

[0031] The invention is not limited to the embodiment represented in Fig 4 and other configurations can be considered.

[0055]

[0032] The insert 3 is a piece that is located inside the pipe 2. Its purpose is to transfer energy to the gas flowing into the pipe 2. This transfer occurs as the gas flows into the pipe 2 and enters in contact with the exchange surface of the insert 3. The gas is thus heated by forced convection and / or radiation.

[0056]

[0033] For the structure of the insert 3, increasing the exchange surface will improve the efficiency of the heating as the insert 3 can transfer more energy to the gas over the length of the pipe 2. The exchange surface corresponds to the surface of the insert 3 that the gas can enter in contact with. The higher the surface exchange of the insert 3 is, the shorter the pipe 2 length required to reach a given target temperature is as well.

[0057]

[0034] For each meter of length of pipe 2, the insert 3 preferably has an exchange surface from 0.5 m2to 100 m2. For an exchange surface below 0.5 m2for each meter of length of pipe 2, the efficiency of the heating can be insufficient to reach the target temperature. For an exchange surface above 100 m2for each meter of pipe 2, the gas could reach the target temperature way before the end of the pipe 2 thus reducing the efficiency of the heating compared to the material used. Preferably, for each meter of length of pipe 2, the insert 3 has an exchange surface from 0.5 m2to 80 m2or from 0.5 m2to 60 m2or from 0.5 m2to 50 m2or from 0.5 m2to 40 m2or from 0.5 m2to 30 m2or from 0.5 to 25 m2or from 0.5 m2to 20 m2or from 0.5 m2to 15 m2or from 0.5 m2to 10 m2or from 0.5 m2to 7.5 m2or from 0.5 m2to 5 m2or from 0.5 to 2.5 m2or from 1 m2to 100 m2or from 1 m2to 80 m2or from 1 m2to 60 m2or from 1 m2to 50 m2or from 1 m2to 40 m2or from 1 m2to 30 m2or from 1 to 25 m2or from 1 m2to 20 m2or from 1 m2to 15 m2or from 1 m2to 10 m2or from 1 m2to 7.5 m2or from 1 m2to 5 m2or from 1 m2to 2.5 m2.

[0058]

[0035] The efficiency of the heating can also be improved by imposing an agitation to the gas flow inside the pipe 2. This is provided by creating a turbulent flow inside the pipe 2.

[0036] The flow patterns are usually characterized by the Reynolds number (Re). Usually, the Reynolds number is defined as:

[0059] puL

[0060] Re = - —

[0061] A

[0062] p: density of the fluid (kg / m3)

[0063] u: flow speed (m / s)

[0064] L: characteristic length (m)

[0065] p: dynamic viscosity (kg / (m.s))

[0066] A turbulent flow is characterized by a Reynolds number Re > 2800.

[0067]

[0037] The shape of the insert 3 has an influence on the Reynolds number as it modifies the characteristic length L of the system. A shape designed to provide turbulent flow to the gas flowing into the pipe 2 can thus improve the efficiency of the heating of the gas.

[0068]

[0038] To further improve the efficiency, the insert 3 preferably extends from the entrance of the pipe 2 to the exit of the pipe 2. The insert 3 also preferably has a section that represents from 50% to 100% of the free section inside the pipe 2, that is to say, the section where the gas is flowing. Having an insert 3 with a section that is almost the same as the free section of the pipe 2 allows to avoid that a large fraction of the gas flows around the insert 3 without being heated by the insert 3. However, having a smaller section allows the insert 3 to expand more freely with thermal dilatation without damaging the device for heating gas 1 . An insert 3 with a section of 100% of the free section of the pipe 2 can be considered with a material such as Invar™ that has a thermal expansion rate sufficiently low so as not to damage the pipe 2. With a section lower than 50% of the free section of the pipe 2, the efficiency of the heating could be too low. Preferably, the section of the insert 3 comparatively to the free section of the pipe 2 is from 50% to 97.5% or from 50% to 95% or from 50% to 92.5% or from 50 to 90% or from 50% to 85% or from 50% to 80% or from 50% to 75% or from 60% to 97.5% or from 60% to 95% or from 60% to 92.5% or from 60 to 90% or from 60% to 85% or from 60% to 80% or from 60% to 75% or from 65% to 97.5% or from 65% to 95% or from 65% to 92.5% or from 65 to 90% or from 65% to 85% or from 65% to 80% or from 65% to 75% or from 70% to 97.5% or from 70% to 95% or from 70% to 92.5% or from 70 to 90% or from 70% to 85% or from 70% to 80% or from 70% to 75%.

[0069]

[0039] Examples for insert designs are represented in Fig 3a and Fig 3b. The insert represented in Fig 3a has a screw shape and the insert represented in Fig 3b has a perforated twisted tape shape. These designs provide a high exchange surface comparatively to the length of the pipe 2 and can also provide a turbulent flow for a large range of gas speeds.

[0070]

[0040] The designs of the insert 3 are not limited to the ones represented in Fig 3a and Fig 3b and other designs can be considered.

[0071]

[0041] In order to be heated, the insert 3 has to be made of a material that is electrically conductive. The insert 3 is preferably made of magnetic steel or graphite but can also be made of any electrically conductive material. An electrically conductive material is any material that has an electrical conductivity value o > 10 000 (Q.m)-1.

[0072]

[0042] Magnetic steel can be used as a material for the insert 3 for heating non oxidizing gas to temperatures up to 1000°C, preferably up to 1 100°C without material degradation. For higher temperatures, it is preferable to use graphite as a material for the insert 2 as graphite can reach temperatures higher than 3000°C. Tungsten and molybdenum can also be considered as material for the insert 3 for high temperatures as they can resist to temperatures higher than 3000°C. For heating oxidizing gases, stainless steel can be used as the induced material.

[0073]

[0043] The insert 3 can also be covered by a coating to make it more resistant to oxidation or creep and thus increasing its life.

[0074]

[0044] The inductor 4 is preferably a coil and is located in the vicinity of the pipe 2. Preferably, the inductor 4 is located inside the pipe 2 close to its wall as represented in Fig 2. This configuration allows to avoid heating the pipe 2 alongside the insert 3 if the pipe 2 is made of a material that is also electrically conductive. In this configuration, a refractory material is placed between the insert 3 and the inductor 4 to serve as a thermal insulator. A magnetic yoke is also preferably installed inside the pipe 2, between the inductor 4 and the wall of the pipe 2. It can be a plate of electric steel. Its purpose is to confine the magnetic field inside the pipe 2 so as not to heat the pipe 2, to increase the energy efficiency. Alternatively, the inductor 4 can be placed outside the pipe 2, as in Fig 1 , if the pipe 2 is made of a material that is not electrically conductive.

[0075]

[0045] A various number of gases can be heated by the device for heating gas used in the method according to the invention. The following Table 1 gives a list of gases that can be heated using two specific materials for the insert 3.

[0076]

[0077] Table 1

[0078]

[0046] Preferably, the gas that is heated using the device for heating gas 1 depends on the atmosphere that is required inside the furnace 5. Depending on the application, the atmosphere can be oxidizing, neutral or reducing.

[0079]

[0047] The gases that are listed in Table 1 are only listed as examples and the gases that can be heated using the invention are not limited to these gases. In the same way, the materials that are listed in Table 1 are only listed as examples and the materials that are used for the insert in the invention are not limited to these materials.

[0080]

[0048] The pipe 2 preferably has a cylindrical shape. To reach a certain power, a minimal surface and / or mass of induced material is needed in the form of the insert 3. The shape of the insert 3 and the dimensions of the pipe 2 are arranged to provide optimal efficiency and compacity of the device for heating gas 1 depending on the power needed for the application it is used for. As the pipe 2 is not heated in the device for heating gas 1 according to the invention, the thickness of the pipe 2 does not have an influence on the efficiency of the heating.

[0081]

[0049] The global flow rates for the gas that are considered for the invention depend on the temperature that need to be attained for the steel semi-product 6 and the gas used. The higher the temperature needed, the higher the flow rate needed. Moreover, the more thermal radiation a gas provides, the less flow rate needed to heat the steel semi-product 6.

[0082]

[0050] In the applications of the method according to the invention, a given global gas flow rate of a given composition is heated to a target temperature. Depending on the value of this entry gas flow rate and the target temperature, the required global heating power can range from 1 kW to 50MW. For low power values, for example in the order of 1 kW to 10kW, a single device for heating gas 1 would be sufficient to provide this level of power. For higher power range, for example in the order of 10MW to 50MW, depending on the technology available to the person skilled in the art, a single device for heating gas 1 can be insufficient to obtain this level of power. In this case, the global gas flow rate to be heated can be divided in several streams of lower flow rate that will each be heated by a single device for heating gas and require much lower power to reach the same target temperature.

[0083]

[0051] The method according to the invention allows to successfully provide a homogeneous heating of a steel semi-product that has better energy efficiency while reducing CO2 emissions.

Claims

CLAIMS1 ) A method for heating a steel semi-product wherein said method comprises the following steps:- putting at least one steel semi-product (6) to be heated inside a furnace, - introducing an entry gas flow into at least one device for heating gas (1 ), said device for heating gas (1 ) being connected to said furnace (5) and comprising:o a pipe (2) allowing gas to flow inside of it,o an insert (3) located inside said pipe (2), said insert being electrically conductive,o an inductor (4) located in the vicinity of said pipe (2),- feeding energy into said insert (3) using said inductor (4) of said device for heating gas (1 ) so that said energy fed into the insert (3) is transferred to the gas introduced into said device for heating gas (1 ), to heat said gas to a temperature from 450°C to 1500°C,- releasing said heated gas into the furnace (5) so that said at least one steel semi-product (6) is heated,- removing the heated steel semi-product (6) from the furnace (5).2) A method for heating a steel semi-product according to claim 1 , wherein said steel semi-product (6) is heated to a temperature from 250°C to 1300°C.3) A method for heating a steel semi-product according to claim 1 or 2, wherein said method comprises an additional step of retrieving said heated gas from the furnace (5) to be used again to heat said steel semi-product (6).4) A method for heating a steel semi-product according to claim 3, wherein said retrieved gas is mixed with the entry gas flow before being heated again with the device for heating gas (1 ).5) A method for heating a steel semi-product according to any of the preceding claims, wherein several steel semi-products (6) are heated at the same time in the furnace (5).6) A method for heating a steel semi-product according to any of the preceding claims, wherein the heated gas is released through several feeding pipes (7) arranged to feed the inner volume of the furnace (5).7) A method for heating a steel semi-product according to claim 6, wherein at least one device for heating gas (1 ) is connected to each of said feeding pipes (7).8) A method for heating a steel semi-product according to any of the preceding claims, wherein said entry gas flow is composed of one or more of the following gases: syngas, CO2, CO, H2, H2O, hydrocarbons, N2.9) An installation for heating a steel semi-product, wherein said installation comprises:- a furnace (5) allowing at least one steel semi-product (6) to be put inside of it,- at least one device for heating gas (1 ), said device for heating gas (1 ) comprising:o a pipe (2) allowing gas to flow inside of it,o an insert (3) located inside said pipe (1 ), said insert (3) being electrically conductive,o an inductor (4) located in the vicinity of said pipe (2) and able to feed energy into said insert (3), so that said energy fed into said insert (3) is transferred to the gas flowing into said pipe (2), to heat said gas is to a temperature from 450°C to 1500°C.- a means for introducing an entry gas flow into the device for heating gasat least one feeding pipe (7), connected to said at least one device for heating gas (1 ) and the furnace (5), for releasing the heated gas into said furnace (5) to heat said at least one steel semi-product (6).10) An installation for heating a steel semi-product according to claim 9, wherein said installation further comprises a means for retrieving gas from the furnace (5) to be used again to heat the steel semi-product (6).1 1 ) An installation for heating a steel semi-product according to claim 10, wherein said installation further comprises a mixing station (8) able to mix said retrieved gas with the entry gas flow before being introduced into said at least one device for heating gas (1 ).12) An installation for heating a steel semi-product according to any of claim 9 to 11 , wherein said installation comprises several feeding pipes (7) arranged to feed the inner volume of the furnace (5).13) An installation for heating a steel semi-product according to claim 12, wherein at least one device for heating gas is connected to each of said feeding pipes (7).14) An installation for heating a steel semi-product according to any of claim 9 to 13, wherein said insert (3) is designed to have an exchange surface with the gas to be heated that ranges from 0.5m2to 100m2by meter of pipe (2).15) An installation for heating a steel semi-product according to any of claim 9 to 14, wherein said insert (3) shape is designed to provide a turbulent flow to the gas flowing into the pipe (2).

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