Electric Thick Slab Heating for Uniform Hot Rolling
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Solution Overview
Problem
Existing methods for heating thick slabs for hot-rolling are inefficient, requiring high fuel quantities and leading to long heating times and high CO2 emissions, while also failing to achieve uniform heating across the slab.
Innovation Solution
A system and method utilizing an electric heating device arranged in the transport direction in front of the hot-rolling mill, which heats thick slabs over their entire surface to a hot-rolling temperature, enabling individual temperature control and maximizing the utilization of casting heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gas-powered heating devices are used to heat thick slabs from room temperature to hot-rolling temperature, then the slabs can be heated to the required temperature, but high fuel quantities and long heating times are required along with high CO2 emissions
Solution Approach 1:
The patent applies preliminary action by utilizing the casting heat that is already present in the thick slabs immediately after casting. The electric heating device is positioned to heat the slabs directly in the casting area before they are transported to the rolling mill, thereby preserving and maximizing the use of the residual casting heat rather than heating from room temperature
Solution Approach 2:
The patent replaces the gas-powered heating system with an electric heating device. This substitution eliminates the need for fossil fuel combustion and associated CO2 emissions while providing more efficient and controllable heating of the thick slabs to the required hot-rolling temperature
2Temperature
If gas-powered heating devices are used to heat thick slabs, then the slabs can be heated to the required temperature, but long heating times are required
Solution Approach 1:
The electric heating device performs heating action preliminarily in the casting area while the slabs still retain significant casting heat. This preliminary heating approach reduces the total heating time required compared to heating from room temperature after slab storage
Solution Approach 2:
The system creates an optimized heating process model where thick slabs are heated efficiently using electric heating elements positioned in the transport direction, replicating and improving upon conventional gas heating methods with faster heating rates and better temperature control
3Temperature
If inductive edge heaters are used to heat the edges of thick slabs, then the edges can be heated to hot-rolling temperature, but the entire thick slab cannot be heated uniformly
Solution Approach 1:
The patent transitions from one-dimensional edge heating (inductive edge heaters) to three-dimensional volumetric heating by positioning electric heating devices that can heat the entire slab cross-section. The heating devices are arranged to provide uniform temperature distribution throughout the thick slab, not just at the edges
Solution Approach 2:
The electric heating device provides localized heating zones that can be independently controlled to achieve uniform temperature distribution across the entire thick slab. Different regions of the slab can be heated with appropriate intensity to ensure overall temperature uniformity
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 approach allows for efficient heating of thick slabs to uniform temperatures, reducing energy consumption by over 70% compared to conventional methods, and improving the quality and output of flat rolled products.
Implementation Method 1
at least one electric heating device for a direct hot charging process arranged in the transport direction in front of the hot-rolling mill, in particular in the transport direction in front of the pre-rolling train, by means of which at least those thick slabs which come from the continuous casting device arranged in the common transport line can be heated over their entire surface to a hot-rolling temperature
Data Source
AI summary
A system for producing flat rolled products from thick-cast metal slabs includes: a continuous casting device, by which a flat continually cast product with a thickness of at least 160 mm can be continually cast; a separating device, arranged so as to adjoin the continuous casting device for separating the flat continually cast product into individual thick slabs; a hot-rolling mill, by which the thick slabs can be rolled to form the flat rolled product; a thick slab supplying device arranged transversely to the transport direction and positioned between the separating device and the rolling train; and an electric heating device arranged in front of the hot-rolling mill, for a direct hot charging process, said electric heating device allowing at least the thick slabs coming from the continuous casting device arranged in the common transport line to be heated to a hot-rolling temperature.