Steam Condensation in DC Casting Pits for Cooling Water Recovery

Solution Overview

Problem

Steam generated during metal processing, such as direct chill casting, poses safety hazards, reduces visibility, and leads to equipment degradation, while requiring costly make-up water to compensate for lost water due to steam venting.

Innovation Solution

A steam condensation system that condenses steam into recycled water, which is then reused for cooling, reducing the need for new water intake and minimizing environmental venting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If steam is vented to the environment during metal processing, then safety hazards and visibility reduction are avoided, but water is lost requiring costly make-up water and environmental pollution occurs

Engineering Contradiction:

ImprovesafetyVSAvoidwater loss

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent converts the harmful steam byproduct into beneficial recycled water. The steam condensation system captures steam that would otherwise be vented and condenses it back into liquid water, which is then reused in the cooling system. This transforms a harmful waste product into a valuable resource, eliminating water loss while maintaining safety.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent implements a steam recovery system that captures and recycles water from steam that would traditionally be discarded. The condensation system recovers the water contained in steam, returning it to the cooling water supply, thereby preventing water loss and reducing the need for make-up water.

Inventive Principle:

Principle #34Discarding and recovering

2Duration of action of stationary object

If steam is vented to the environment, then equipment degradation from condensation is avoided, but costly make-up water must be continuously introduced

Engineering Contradiction:

Improveequipment life cycleVSAvoidwater consumption

Core Design Contradiction:

Duration of action of stationary objectVSQuantity of substance

Solution Approach 1:

The patent converts the harmful steam byproduct into beneficial recycled water. The steam condensation system captures steam that would otherwise be vented and condenses it back into liquid water, which is then reused in the cooling system. This transforms a harmful waste product into a valuable resource, eliminating water loss while maintaining safety.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent establishes a continuous water recycling loop where steam is continuously condensed and returned to the cooling system. This continuous recovery process ensures that water is constantly reused rather than lost, maintaining both equipment protection and water conservation over extended operational periods.

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If water is directed onto metal ingot for cooling, then metal processing is achieved, but steam is generated creating safety hazards and visibility reduction

Engineering Contradiction:

Improvemetal processing efficiencyVSAvoidsteam generation

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful steam byproduct into beneficial recycled water. The steam condensation system captures steam that would otherwise be vented and condenses it back into liquid water, which is then reused in the cooling system. This transforms a harmful waste product into a valuable resource, eliminating water loss while maintaining safety.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent introduces a steam condensation system as an intermediary between the cooling process and the environment. This intermediary system captures steam before it can create safety hazards or visibility issues, condensing it into water that can be reused. The condensation system acts as a mediator that eliminates the harmful effects of steam generation while maintaining the beneficial cooling function.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The system effectively recycles water, reducing costs and resource consumption by reusing condensed steam as coolant, thereby enhancing safety and equipment longevity.

Implementation Method 1

a steam condensation system for condensing steam generated during metal processing of the metal substrate

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 2

spraying water relative to a direction of the flow of the steam

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS20250381596A1Systems and methods for steam condensation in aluminum direct chill casting pit

Publication Date: 2025.12.18 NOVELIS INC(US)

AI summary

A direct chill (DC) casting system may be used to cast a metal ingot from a molten metal such as aluminum or aluminum alloys. The DC casting system includes a steam condensation system that condenses steam generated during a DC casting process as recycled water. The recycled water may be used for subsequent cooling of the metal ingot during the DC casting process.