Ferritic Hot-Rolled Strip Inductive Skin Heating Before Final Rolling
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Solution Overview
Problem
The energy-intensive process of producing ferritic hot-rolled strips in integrated casting-rolling plants results in high energy consumption, despite achieving good metallurgical properties and surface quality, as the intermediate strip is heated to a high temperature and then cooled intensively.
Innovation Solution
The process involves heating only the surface layers of the intermediate strip to ≥1000°C using high-frequency alternating current inductive surface heating modules, followed by descaling and final rolling without further cooling, allowing the strip to enter the finishing stand at an average temperature of 775-900°C, thereby reducing energy consumption while maintaining quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the intermediate strip is heated to a high temperature of ≥1070°C and then cooled intensively for descaling and final rolling, then good metallurgical properties and surface quality are achieved, but energy consumption is significantly increased
Solution Approach 1:
The patent applies local quality by heating only the surface layers of the intermediate strip to ≥1000°C using inductive surface heating modules, while the core temperature remains lower. This localized heating approach enables effective descaling of the surface without the need for intensive cooling of the entire strip, thereby maintaining good surface quality and metallurgical properties while significantly reducing energy consumption compared to heating the entire strip uniformly to high temperatures.
2Manufacturing precision
If the entire intermediate strip is heated uniformly to high temperature for descaling, then thorough descaling is achieved, but energy consumption increases and cooling time is extended
Solution Approach 1:
The patent applies local quality by heating only the surface layers of the intermediate strip to ≥1000°C using inductive surface heating modules, while the core temperature remains lower. This localized heating approach enables effective descaling of the surface without the need for intensive cooling of the entire strip, thereby maintaining good surface quality and metallurgical properties while significantly reducing energy consumption compared to heating the entire strip uniformly to high temperatures.
Solution Approach 2:
The patent replaces conventional thermal heating methods with inductive surface heating modules that use high-frequency alternating current (≥20 kHz) to generate eddy currents within the strip surface. This electromagnetic induction method directly heats only the surface layers through induced eddy currents, achieving thorough descaling while minimizing energy consumption and eliminating the need for extensive cooling operations.
3Use of energy by moving object
If high-frequency alternating current inductive surface heating modules are used to heat only surface layers, then energy consumption is reduced and processing time is shortened, but uniform heating of the entire strip is not achieved
Solution Approach 1:
The patent applies local quality by heating only the surface layers of the intermediate strip to ≥1000°C using inductive surface heating modules, while the core temperature remains lower. This localized heating approach enables effective descaling of the surface without the need for intensive cooling of the entire strip, thereby maintaining good surface quality and metallurgical properties while significantly reducing energy consumption compared to heating the entire strip uniformly to high temperatures.
Solution Approach 2:
The patent applies preliminary action by performing surface heating and descaling before final rolling operations. The intermediate strip enters the finishing stand with an average temperature of 775-900°C without requiring further cooling after descaling, which prepares the strip in advance for the final rolling process and maintains temperature uniformity appropriate for ferritic hot-rolling while minimizing energy consumption.
4Use of energy by moving object
If the intermediate strip enters the finishing stand at lower temperature without intensive cooling, then energy consumption is reduced, but control over the rolling process becomes more challenging
Solution Approach 1:
The patent applies preliminary action by performing surface heating and descaling before final rolling operations. The intermediate strip enters the finishing stand with an average temperature of 775-900°C without requiring further cooling after descaling, which prepares the strip in advance for the final rolling process and maintains temperature uniformity appropriate for ferritic hot-rolling while minimizing energy consumption.
Solution Approach 2:
The patent applies feedback by using pyrometers to measure the surface temperature of the partially finished intermediate strip and transmitting signals to a temperature regulator, which adjusts the heating power of inductive heating modules to maintain the desired temperature range. This feedback control system ensures precise temperature management during the heating and rolling process, facilitating ease of operation despite the reduced temperature margin.
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 significantly reduces energy consumption by heating only the surface layers, ensuring thorough descaling and maintaining good metallurgical properties and surface quality, with the hot-rolled strip achieving a high coiler temperature without additional heating or reheating, thus enhancing energy efficiency.
Implementation Method 1
heating of the broad sides of the intermediate strip by one or preferably more inductive surface heating modules to a surface temperature of ≥1000° C.
Implementation Method 2
the surface heating module is operated using an alternating current having a first frequency f1
Implementation Method 3
heating only the surface layers of the intermediate strip to ≥1000°C using high-frequency alternating current inductive surface heating modules
Data Source
AI summary
Energy-efficient production of a ferritic hot-rolled strip (6) in an integrated casting-rolling plant (1), which modifies the known processes for producing a ferritic hot-rolled strip (6) in an integrated casting-rolling plant (1) so that the ferritic hot-rolled strip (6) can be produced significantly more energy-efficiently but nevertheless has good metallurgical properties and a good surface quality.