Electric Arc Furnace Melt Temperature Prediction
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Solution Overview
Problem
Current methods for determining the tapping time of a metal melt in an electric arc furnace are inefficient, requiring multiple temperature measurements, posing risks to operators and leading to increased energy consumption and production delays due to non-uniform temperature readings and the presence of slag and smoke layers.
Innovation Solution
A system and method utilizing an electromagnetic stirrer to mix the metal melt uniformly, combined with a non-contact temperature measuring device and a dedicated lance unit to continuously measure and clear slag and smoke, allowing for accurate temperature profiling and prediction of tapping time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple temperature measurement trials are carried out using a cartridge, then the temperature measurement can be obtained, but the process time is postponed and the cost of consumable probes increases
Solution Approach 1:
The patent replaces the mechanical cartridge-based temperature measurement system with a non-contact optical measurement system. The non-contact sensor measures temperature remotely without physical contact, eliminating the need for consumable cartridges and the time-consuming insertion/removal operations, thus resolving the contradiction between measurement accuracy and process time loss.
Solution Approach 2:
The patent uses optical radiation (infrared or visible light) as a copy or representation of the thermal energy to measure temperature. Instead of directly contacting the hot metal with a physical probe, the system captures the thermal signature remotely and converts it into temperature data, avoiding the time and resource costs of physical measurement trials.
2Measurement precision
If multiple temperature measurement trials are carried out using a cartridge, then the temperature measurement can be obtained, but the cost of consumable probes increases
Solution Approach 1:
The non-contact optical measurement system replaces the mechanical cartridge system, eliminating the need for repeated measurement trials. This reduces the total energy consumption associated with multiple measurement operations and the production/disposal of consumable probes, while maintaining measurement accuracy.
3Measurement precision
If temperature measurement is performed with a cartridge, then temperature data can be obtained, but the operator faces high temperature in a harsh environment
Solution Approach 1:
The patent replaces the manual cartridge insertion operation with an automated non-contact optical measurement system. The sensor measures temperature from a safe distance without requiring the operator to approach the high-temperature zone, completely eliminating the safety hazard while preserving measurement capability.
Solution Approach 2:
The optical radiation field serves as an intermediary between the measurement system and the hot metal. Instead of direct physical contact or close proximity measurement, the system uses light/infrared radiation to transmit temperature information across a gap, protecting the operator from thermal exposure.
4Reliability
If slag and smoke layers are present on the metal melt surface, then the melt can be protected, but accurate temperature measurement becomes difficult
Solution Approach 1:
The patent uses a gas stream (pneumatic action) to blow away the slag and smoke layers from the metal melt surface. This creates a clear optical path for the non-contact sensor to measure the temperature of the bare metal surface accurately, while the melt remains protected during the measurement process.
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
Enables precise determination of tapping time, reducing energy consumption and improving operator safety by providing continuous, accurate temperature measurements, leading to increased productivity and uniform melt temperatures.
Implementation Method 1
an electromagnetic stirrer including a stirring coil, a power supply system is operatively connected to the stirrer. The stirring coil is typically mounted outside a steel shell of the furnace. This coil generates a travelling magnetic field to provide stirring forces to the metal melt.
Implementation Method 2
non-contactingly measuring a temperature of the metal melt
Implementation Method 3
blowing away the slag and smoke layers from the surface of the metal melt by a flow of a gas
Data Source
AI summary
A system and a method for determining/predicting a tapping time for a metal melt in an electric arc furnace (EAF), at least one electrode is provided for melting the metal melt until it reach a target tapping temperature, the EAF further includes a slag and smoke layer on the surface of the metal melt, wherein an electromagnetic stirrer is provided for stirring the metal melt.