Charge Material Tracking System for Electric Furnace
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Solution Overview
Problem
Current steel production technologies with continuous material supply to electric furnaces face challenges in accurately verifying the yield and optimizing the composition of the charge material to achieve desired steel quality, due to the complexity and high costs of implementing analysis devices like PGNAA, and the inability of existing systems to determine the typology and yield of progressively supplied materials.
Innovation Solution
A control and tracking system that includes a continuous conveyor with loading, preheating, and introduction sections, equipped with weight detection, identification marking, and speed estimation means, allowing for precise determination of charge material type, weight, and arrival time, enabling flexible management of different qualities and quantities based on predetermined recipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If PGNAA analysis device is implemented to determine charge material composition, then measurement precision of charge material typology is improved, but device complexity and installation costs increase significantly
Solution Approach 1:
The patent uses identification means (marks, tags, or visual identifiers) on charge fractions instead of complex PGNAA analysis devices. The control unit creates a virtual model of the charge composition by detecting and recording these simple identifiers, achieving composition tracking through information copying rather than physical analysis.
Solution Approach 2:
The patent replaces the mechanical/physical PGNAA analysis system with an optical/electronic detection system using cameras, sensors, and image processing. The control unit processes visual information from identification means to determine charge material typology, substituting complex nuclear physics equipment with simpler optical detection.
2Measurement precision
If PGNAA analysis device is implemented to determine charge material composition, then measurement precision of charge material typology is improved, but installation and management costs increase significantly
Solution Approach 1:
The patent uses inexpensive identification means (marks, tags, labels) on charge fractions instead of expensive PGNAA equipment. These simple identifiers can be applied once and read repeatedly by the control unit's detection system, providing continuous composition tracking at minimal cost.
Solution Approach 2:
The system creates information copies of charge material identifiers that can be read multiple times without degradation. The control unit stores and processes these digital representations, eliminating the need for repeated expensive physical analysis while maintaining accurate composition records.
3Productivity
If continuous conveyor is used to supply charge material, then productivity is improved, but ability to verify yield and optimize composition of individual charge fractions deteriorates
Solution Approach 1:
The control unit continuously receives information from detection means about charge fraction identifiers, weights, and positions. It processes this feedback to track the composition and yield of each charge fraction throughout the continuous supply process, enabling real-time verification and optimization while maintaining high productivity.
Solution Approach 2:
The patent introduces identification means as an intermediary between the charge material and the control system. These markers serve as information carriers that allow the control unit to track individual charge fractions through the continuous conveyor without interrupting the flow, bridging the gap between continuous operation and discrete tracking.
4Productivity
If continuous conveyor is used to supply charge material, then productivity is improved, but measurement precision of individual charge fraction characteristics deteriorates
Solution Approach 1:
The patent divides the continuous charge material supply into discrete charge fractions, each marked with unique identification means. The control unit detects and records characteristics (weight, composition, position) for each segmented fraction individually, maintaining measurement precision while enabling continuous high-speed processing through parallel detection and tracking.
Data Source
AI summary
A method, control, and tracking system of a charge of material transported by a continuous supply conveyor of a metallurgical furnace, for example an electric furnace for production of steel. The continuous conveyor includes, in sequence starting from its inlet end towards its outlet end, a loading section of the charge of material to be supplied to the furnace, a preheating section of the charge of material loaded, and an introduction section into the furnace of the preheated charge of material, and along the loading section at least a first loading station of material.