A system for producing double-folded cored wire with inert gas

Abstract

The invention relates to a system for the production of double-folded cored wire with inert gas. The invention particularly relates to a system for the production of double-folded inert gas-filled cored wires injected into liquid steel for alloying in ladle furnaces, which prevents oxidation by reducing the moisture content in the wire, extends the shelf life of the wires thanks to the protective effect of inert gases, and increases the mechanical strength with its double-folded structure, thus optimizing the alloying efficiency in liquid steel.

Description

[0001] A SYSTEM FOR PRODUCING DOUBLE-FOLDED CORED WIRE WITH INERT GAS

[0002] Field of the Invention

[0003] The invention relates to a system for the production of double-folded cored wire with inert gas.

[0004] The invention particularly relates to a system for the production of double-folded inert gas-filled cored wires injected into liquid steel for alloying in ladle furnaces, which prevents oxidation by reducing the moisture content in the wire, extends the shelf life of the wires thanks to the protective effect of inert gases, and increases the mechanical strength with its double-folded structure, thus optimizing the alloying efficiency in liquid steel.

[0005] State of the Art

[0006] The method commonly used today for the production of cored wire is based on the process of placing various core materials in a sheath made of high quality steel strips and then closing this sheath by means of roller systems. In this method, alloying elements such as Ca, Ca-rod, CaSi, CaFe, C, S, FeTi, FeB are generally used. These core materials are used to obtain the desired chemical composition of the steel by alloying them when they come into contact with liquid steel. This production technique makes it possible to produce cored wires in desired lengths and has an important place in steel production. Cored wire serves as a critical component in steelmaking processes such as ladle furnaces, enabling the controlled addition of alloying elements into liquid steel.

[0007] In current technologies, the production and usage process of cored wire faces some significant challenges. In these traditional methods used in the production of cored wire, after the core materials are placed inside the sheath, these materials begin to come into contact with air. Core materials that come into contact with air are subject to adverse chemical reactions such as dehumidification, oxidation and corrosion. In particular, moisture absorption and oxidation are factors that seriously reduce the quality of cored wire and shorten the shelf life of the wire. These processes prevent the alloying elements from dissolving properly in the liquid steel, reducing the effectiveness of the core materials. As a result of oxidation, the formation of metal oxides and the onset of corrosion are factors that reduce the efficiency of the wire and lead to economic losses. In addition, moisture in materials that come into contact with air reduces the durability of the cored wire, which limits the life of the wire.

[0008] The efficiency of cored wire decreases over time compared to its efficiency at the time of production. This reduction is particularly relevant to shelf life, making it difficult to use cored wire efficiently during steelmaking. Although cored wires with a short shelf life start with high efficiency at the beginning of the production process, they lose their efficiency over time due to factors such as oxidation and corrosion. These types of cored wires create difficulties in obtaining the desired chemical properties in steel production and negatively affect the process efficiency.

[0009] These difficulties existing in the technical field directly affect the efficiency and costeffectiveness of the steel production process in particular. In this context, various solutions are being sought to extend the shelf life of cored wire and increase its efficiency. However, these solutions are generally temporary and limited methods of improving the shielding properties of the cored wire. Existing solutions are generally limited to protective coatings applied to the outer surface of the wire, but these methods generally cannot prevent oxidation and moisture absorption that occur as a result of contact of the alloying substances in the wire with air. In addition, these methods cannot sufficiently improve the mechanical properties and durability of the wire.

[0010] The efficiency of cored wire used in steel production depends mainly on the quality of the materials used and the processing methods of the wire. However, with current techniques, the difference between the yield at the time of production and the yield after the product can lead to serious economic losses. The loss of effectiveness of cored wire over time causes steel producers to use more material and labor, which increases production costs. Additionally, shorter shelf life can lead to restricted use of the product, thus disrupting the steelmaking process.

[0011] Solving problems such as moisture and oxidation that occur as a result of the contact of cored wires with air is of critical importance for the efficiency of steel production. Therefore, the development of new technologies that will eliminate these problems has great potential for optimizing industrial production processes.

[0012] As a result, the process of producing and using cored wire in current techniques faces some significant efficiency and durability issues. The most important of these problems is the absorption of moisture, oxidation and corrosion of the cored wire. This situation negatively affects the effectiveness and shelf life of the cored wire used in steel production, thus reducing the efficiency of steel production processes. Therefore, it is of great importance to develop solutions for the production of more durable and long-lasting cored wires in this field.

[0013] As a result, due to the abovementioned disadvantages and the insufficiency of the current solutions regarding the subject matter, a development is required to be made in the relevant technical field.

[0014] Object of the Invention

[0015] The present invention aims to solve the above-mentioned drawbacks, and it is inspired by the current situation

[0016] The object of the present invention is to prevent negative chemical reactions such as moistening and oxidation by minimizing the contact of the core substances (Ca, Ca-rod, CaSi, CaFe, C, S, FeTi, FeB etc.) in the sheaths made of steel strip with air. In this way, the shelf life of the cored wire used in steel production processes will be extended and its efficiency will be increased. The invention will begin with the injection of inert gases into the sheath made of steel strip during wire production. Inert gases protect the contents of the wire and prevent the risks of oxidation and moisture absorption. Then, the produced cored wire will be enclosed in a second sheath and protected with inert gases. This double layer protection method will completely eliminate the contact of the wire content with air, preventing problems such as oxidation and moisture, thus ensuring that the cored wire can be used effectively for a longer period of time. This innovative approach will enable higher efficiency and durability in production processes, especially by improving the quality of cored wires used in steel production.

[0017] In order to fulfil the above-mentioned purposes, the invention is a system for the production of double-folded inert gas-filled cored wires, comprising:

[0018] • first steel strip inlet and second steel strip inlet, which allow the steel strips to be taken into the system, a first inert gas tunnel, which carries out the first folding process of the steel strips in an oxygen-free environment, the inner surface of which is designed with a coating material suitable for the passage of inert gases and equipped with leakproof covers,

[0019] • a core material inlet to allow the injection of inert gases into the first inert gas tunnel,

[0020] • a second inert gas tunnel, which carries out the second folding process of the cored wire in an oxygen-free environment after the first folding process is completed, and whose inner surface is designed with a coating material suitable for the passage of inert gases and equipped with leak-proof covers,

[0021] • a spraying system equipped with nozzles that ensure the spraying of the inert gas into the tunnel, positioned to ensure the homogeneous distribution of the inert gas within the first inert gas tunnel and the second inert gas tunnel,

[0022] • high precision gas measurement sensors integrated on the first inert gas tunnel and second inert gas tunnel to determine oxygen and inert gas ratios,

[0023] • electronic gas valves with electronic adjustment feature that precisely control the inert gas flow between the first inert gas inlet and first air outlet positioned for the first inert gas tunnel and the second inert gas inlet and second air outlet positioned for the second inert gas tunnel, and perform regulation in case the gas quantities go out of the reference value,

[0024] • double-layer roller groups performing the first folding of the steel strip in the first inert gas tunnel and single-layer roller groups performing the second folding of the steel strip in the second inert gas tunnel,

[0025] • a wire outlet where the cored wire exits the system.

[0026] The structural and characteristic features of the present invention will be understood clearly by the following drawings and the detailed description made with reference to these drawings and therefore the evaluation shall be made by taking these figures and the detailed description into consideration.

[0027] Figures Clarifying the Invention

[0028] Figure 1 is a front view of the system of the present invention.

[0029] Figure 2 is a rear view of the system of the present invention. Figure 3 is the view of the double-layer roller group.

[0030] Figure 4 is the view of the single-layer roller group.

[0031] Figure 5 is a view of the spraying system.

[0032] Part References

[0033] 1 Observation glasses

[0034] 2 Core material inlet

[0035] 3 First steel strip inlet (first layer)

[0036] 4 Second steel strip inlet (second layer)

[0037] 5.1 First tunnel

[0038] 5.2 Second tunnel

[0039] 6 Gas measurement sensors

[0040] 7 Wire output

[0041] 8 First inert gas inlet

[0042] 9 Electronic gas valve

[0043] 10 First air outlet

[0044] 12 Second inert gas inlet

[0045] 14 Second air outlet

[0046] 16 Spraying system

[0047] 17 Double-layer roller group

[0048] 18 Single-layer roller group

[0049] Detailed Description of the Invention

[0050] In this detailed description, the preferred embodiments are described solely for the purpose of a better understanding of the subject matter.

[0051] The present invention relates to an inert gas double-folded system for preventing undesirable reactions such as oxidation, humidification and corrosion during the production of cored wire, and aims to extend the shelf life and increase the efficiency of the product by minimizing the contact of the core materials (Ca, CaSi, CaFe, C, S, FeTi, FeB etc.) placed in the argon gas tunnel with air. In the invention, during the production of cored wire, steel strips are wound in two layers and injected with inert gases between the two layers. The first folding process takes place in the first inert gas tunnel (5.1 ), while the second folding process takes place in the second inert gas tunnel (5.2). The double-layered structure provides additional protection against external factors, and in particular, by preventing the wire from coming into contact with the external environment, reactions such as oxidation and moisture are prevented.

[0052] In the invention, the high-quality steel strips from the first steel strip inlet (3) and the second steel strip inlet (4) enter the first inert gas tunnel (5.1 ), and the steel strips coming out of the first inert gas tunnel (5.1 ) enter the second inert gas tunnel (5.2). In the twolayered flux cored wire production system, double-layered roller groups (17) are used in the first inert gas tunnel (5.1 ); and single-layered roller groups (18) are used in the second inert gas tunnel (5.2). The wire folding process is carried out by the mentioned roller groups. During these folding processes, the protection of the wire and core materials is ensured and an extra layer of protection against external factors is added

[0053] During the folding process, inert gases are injected into the first inert gas tunnel (5.1 ) from the core material inlet (2) to fill the spaces around the wire and the core materials. This process prevents oxygen from entering the outer surface of the wire, eliminating the risks of oxidation and corrosion.

[0054] In the invention, the amounts of oxygen and inert gas in the tunnel are continuously monitored by using gas measurement sensors (6) positioned on the first inert gas tunnel (5.1 ) and the second inert gas tunnel (5.2). Gas measurement sensors (6) regulate the system by means of electronic gas valves (9) located on the first inert gas tunnel (5.1 ) and the second inert gas tunnel (5.2) in case the gases rise to a level outside the reference values.

[0055] In the invention, the first inert gas tunnel (5.1 ) comprises two electronic gas valves (9) and one of said electronic gas valves (9) is connected with a first inert gas inlet (8) and the other with a first air outlet (10). Similarly, the second inert gas tunnel (5.2) comprises two electronic gas valves (9) and one of said electronic gas valves (9) is connected with a second inert gas inlet (12) and the other with a second air outlet (14). The mentioned first inert gas inlet (8) and first air outlet (10) ensure that the gas flow in the first inert gas tunnel (5.1 ) is smooth and controlled, while the second inert gas inlet (12) and second air outlet (14) ensure that the gas flow in the second inert gas tunnel (5.2) is smooth and controlled. For example, if the oxygen level drops below 4% or rises above 6%, the system intervenes immediately and brings the gas values back to the reference range. Likewise, if the inert gas ratio falls below 94% or rises above 96%, the system makes the necessary adjustments to ensure the desired gas balance. The injection of inert gases into the first inert gas tunnel (5.1 ) and the second inert gas tunnel (5.2) is carried out by a spraying system (16). This process ensures that the gases are spread into the tunnel in the right amount and at an angle of 180 degrees. In this way, the entire surface of the wire is protected equally and negative factors such as oxidation and moisture are prevented.

[0056] In the invention, the cored wire coming out of the system comes out through a wire outlet (7) located on the second inert gas tunnel (5.2) after the applied process.

[0057] Observation glasses (1 ) enable visual monitoring of the condition of the wire and the folding processes in the first inert gas tunnel (5.1 ) and the second inert gas tunnel (5.2). The closed tunnel system allows for the control of gases and safe monitoring of the condition of the wire.

[0058] This invention offers an innovative solution developed to prevent negative factors such as oxidation and moisture during the production of cored wire, to extend the shelf life of the product and to increase efficiency. The double-layered wire structure protected by inert gases provides extra security against external factors during production, while continuous monitoring of the gas balance with gas sensors and automatic valves ensures that the system operates efficiently and safely.

[0059] The working principle of the invention is based on a double-layer protection system designed to prevent oxidation, moisture and other undesirable effects in the production of cored wire. This process begins with the use of inert gases in a closed tunnel system and continuous monitoring of the amounts of these gases. The basic steps and active elements in the process are as follows:

[0060] A. Starting production after determining the amount of gas in the closed tunnel and reaching the reference values: The production process begins with the determination of the gas ratios in the first inert gas tunnel (5.1 ) and the second inert gas tunnel (5.2). In this step, the oxygen and inert gas rates in the tunnel are continuously monitored using gas measurement sensors (6). These sensors ensure that the gas balance within the tunnel reaches certain reference values. When the reference value of 5% oxygen and 95% inert gas is reached, the production process is started.

[0061] B. Injecting inert gases at a 180 degree angle in a closed tunnel: During the production process, inert gases are injected into the first inert gas tunnel (5.1 ) and the second inert gas tunnel (5.2) at an angle of 180 degrees. This process is carried out using a special spraying system (16). The spraying system (16) ensures that the gases are distributed homogeneously within the tunnel and eliminates the risk of oxidation on the surface of the wire, ensuring that the wire is protected for a longer period of time.

[0062] C. Regulation process in case the gas amounts in the closed tunnel go out of the reference value: If the gas quantities in the first inert gas tunnel (5.1 ) and the second inert gas tunnel (5.2) fall outside the reference values, the gas flow is automatically regulated. This is done by means of electronic gas valves (9). In line with the data received from the gas measurement sensors (6), the oxygen and inert gas rates in the tunnel are automatically adjusted and kept between reference values. This regulation process ensures that the system operates correctly and efficiently, thus maintaining the gas balance necessary to protect the wire.

[0063] D. Ensuring the protection of the main cored wire against possible impacts from the external environment by folding it for the second time: Additional protection of the cored wire against external factors is achieved through a second folding process. During the first folding process, the wire is protected in the first inert gas tunnel (5.1 ). The second folding is performed with a high-quality steel strip inlet (4) placed inside the tunnel, thus protecting the wire from impacts that may occur from the external environment. This additional layer further protects the outer surface of the wire and prevents reactions such as oxidation and moisture.

[0064] All of these steps ensure that the wire is safely protected, increasing its resistance to adverse factors such as oxidation, corrosion and moisture. Throughout the process, gas flow and wire condition are constantly monitored and controlled by gas sensors, electronic gas valves and spraying system. In this way, high quality cored wire production is ensured.

Claims

CLAIMS1. A system for the production of double-folded inert gas-filled cored wires injected into liquid steel for alloying in ladle furnaces, which prevents oxidation by reducing the moisture content in the wire, extends the shelf life of the wires thanks to the protective effect of inert gases, and increases the mechanical strength with its double-folded structure, thus optimizing the alloying efficiency in liquid steel, characterized by comprising:• first steel strip inlet (3) and second steel strip inlet (4), which allow the steel strips to be taken into the system,• a first inert gas tunnel (5.1 ), which carries out the first folding process of the steel strips in an oxygen-free environment, the inner surface of which is designed with a coating material suitable for the passage of inert gases and equipped with leakproof covers,• a core material inlet (2) to allow the injection of inert gases into the first inert gas tunnel (5.1 ),• a second inert gas tunnel (5.2), which carries out the second folding process of the cored wire in an oxygen-free environment after the first folding process is completed, and whose inner surface is designed with a coating material suitable for the passage of inert gases and equipped with leak-proof covers,• a spraying system (16) equipped with nozzles that ensure the spraying of the inert gas into the tunnel, positioned to ensure the homogeneous distribution of the inert gas within the first inert gas tunnel (5.1 ) and the second inert gas tunnel (5.2),• high precision gas measurement sensors (6) integrated on the first inert gas tunnel (5.1 ) and second inert gas tunnel (5.2) to determine oxygen and inert gas ratios, electronic gas valves (9) with electronic adjustment feature that precisely control the inert gas flow between the first inert gas inlet (8) and first air outlet (10) positioned for the first inert gas tunnel (5.1 ) and the second inert gas inlet (12)and second air outlet (14) positioned for the second inert gas tunnel (5.2), and perform regulation in case the gas quantities go out of the reference value,• double-layer roller groups (17) performing the first folding of the steel strip in the first inert gas tunnel (5.1 ) and single-layer roller groups (18) performing the second folding of the steel strip in the second inert gas tunnel (5.2),• a wire outlet (7) where the cored wire exits the system.

2. The system according to claim 1 , characterized by comprising observation glasses (1 ) mounted in the first inert gas tunnel (5.1 ) and the second inert gas tunnel (5.2) for visually monitoring the folding operations and the condition of the wire in the first inert gas tunnel (5.1 ) and the second inert gas tunnel (5.2).

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