Angled Flow Surface for Solid Water Separation in Continuous Casting
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Solution Overview
Problem
In continuous casting operations, the presence of particles in the cooling medium complicates accurate monitoring of its properties, leading to clogging issues and impaired measurement accuracy, which affects the quality of the resulting metal and operational efficiency.
Innovation Solution
A separation device with an angled flow surface is used to separate fine particles from the cooling medium, allowing only fluid and fine particles to pass through to a monitor, preventing clogs and enabling continuous monitoring of the medium's properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If particles are present in the cooling medium for sampling, then the monitoring can detect real cooling medium properties, but the particles will block piping and damage monitors
Solution Approach 1:
The system divides the cooling medium into separate streams: one for monitoring that has been filtered of particles, and another that remains in the spray chamber. This segmentation allows the monitoring function to operate reliably without particles while the main cooling function continues with all its components intact.
Solution Approach 2:
A sampling system acts as an intermediary between the particle-filled cooling medium and the monitor. The sampling system includes filtration components that remove particles from the sample stream before it reaches the monitor, protecting the monitor while still allowing accurate measurement of the cooling medium's chemical and physical properties.
2Reliability
If all particles are removed from the cooling medium sample, then the monitor is protected from damage, but the sample no longer represents the true composition of the cooling medium
Solution Approach 1:
Different parts of the cooling medium are treated differently: the main cooling medium retains all particles to maintain its true composition and cooling effectiveness, while the sampled portion is selectively filtered to protect the monitoring equipment. This local differentiation allows both goals to be achieved simultaneously.
Solution Approach 2:
A representative sample of the cooling medium is taken and processed separately from the main stream. This copy contains the same chemical and physical properties as the original, allowing accurate monitoring while the sample can be filtered and treated differently without affecting the main cooling medium's performance.
3Productivity
If cooling medium is continuously monitored in real-time, then operational efficiency is improved, but particles in the medium will clog the monitoring system
Solution Approach 1:
Particle filtration is performed in advance of the monitoring measurement on the sample stream. By removing particles beforehand, the monitoring system can operate continuously without clogging, maintaining real-time monitoring capability and operational efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for real-time, accurate monitoring of the cooling medium's properties, reducing corrosion risks and maintaining operational efficiency by preventing clogs and ensuring reliable data collection, thereby improving the quality of the metal casting process.
Implementation Method 1
Large particles in the medium do not pass through but rather slide down and off the angled flow surface thereby inhibiting the formation of clogs over the surface
Data Source
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AI summary
The invention is directed towards methods and apparatus for improving the accuracy of monitors measuring the property of spray water used to cool a molten metal strand in a continuous casting operation. The method utilizes a highly effective slid-sieve to remove particles from sample water that would otherwise jam the monitor or would break the monitor. This particle removal results in the monitor providing more accurate measurements which in turn results in lower operating expenses, reduced maintenance costs, and production costs.