Flume Mill Scale Separation Before Oil Contamination

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Solution Overview

Problem

Hot rolling mills and basic oxygen furnaces face challenges in separating mill scale from wastewater due to oil contamination, which hinders recycling and increases treatment and landfill costs, as existing methods are inefficient and energy-intensive.

Innovation Solution

Implementing grit separators or continuous deflective separation (CDS) units in the flumes of hot rolling mills and basic oxygen furnaces to separate mill scale particles from wastewater while it is flowing at high speeds, reducing oil contamination and allowing for the collection of clean, recyclable mill scale.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If conventional separation methods are used to separate mill scale from wastewater, then mill scale can be recovered, but the mill scale becomes heavily contaminated with oil requiring disposal in landfills

Engineering Contradiction:

Improvemill scale recoveryVSAvoidoil contamination

Core Design Contradiction:

Loss of substanceVSObject-affected harmful factors

Solution Approach 1:

The separator is positioned to capture mill scale particles from the flume water before the particles can become contaminated with oil that accumulates in the pit. By performing the separation action preliminarily, before the harmful oil contamination occurs, the mill scale remains clean and recyclable

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The separator extracts mill scale particles from the flowing flume water, removing them from the water stream before it reaches the pit where oil accumulates. This extraction prevents the mill scale from being contaminated with oil, allowing it to be recycled rather than disposed of in landfills

Inventive Principle:

Principle #2Taking out (Extraction)

2Quantity of substance

If mill scale is collected from pits after water slows down, then separation occurs, but oil contamination increases and recycling becomes impossible

Engineering Contradiction:

Improvemill scale collectionVSAvoidrecyclability

Core Design Contradiction:

Quantity of substanceVSAdaptability or versatility

Solution Approach 1:

The separator performs mill scale collection preliminarily, while the water is still flowing rapidly in the flume. This preliminary collection happens before the water slows down in the pit and before oil contamination can occur, preserving the mill scale's recyclability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The separator acts as an intermediary device between the flowing flume water and the pit. It captures mill scale particles from the water stream before the water enters the pit environment where oil accumulates, thereby preserving the mill scale for recycling

Inventive Principle:

Principle #24Intermediary (Mediator)

3Loss of substance

If existing separation methods are used, then mill scale can be separated, but additional energy and environmental protection measures are required

Engineering Contradiction:

Improvemill scale separationVSAvoidenergy consumption

Core Design Contradiction:

Loss of substanceVSUse of energy by moving object

Solution Approach 1:

The separator utilizes the existing kinetic energy of the rapidly flowing flume water to perform the separation. The water's own motion provides the force needed to carry particles through the separator, eliminating the need for additional pumps or energy-intensive processing equipment

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The separator converts the potentially harmful rapid flow of flume water into a beneficial force that enhances the separation process. The high-velocity water flow provides the necessary energy to move particles through the separator efficiently, eliminating the need for additional energy input

Inventive Principle:

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

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 method effectively reduces oil concentration in collected mill scale, making it suitable for recycling, decreases treatment costs, and eliminates the need for additional energy or environmental protection measures, resulting in cleaner mill scale with lower operational and landfill expenses.

Implementation Method 1

The CDS units deflect the fluid stream inflow into a separation chamber. The screen removes the pollutants and allows the fluid to return to the stream. Floatable solids are kept in motion in the separation chamber so they do not clog the screen. Heavy solids settle to the bottom of the sump in the chamber.

Methodology Applied

Scientific EffectContinuous deflective separation: Flow Separation

Implementation Method 2

Heavy solids settle to the bottom of the sump in the chamber.

Methodology Applied

Scientific EffectSedimentation: Sedimentation

Implementation Method 3

The screen removes the pollutants and allows the fluid to return to the stream.

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS11839838B2Method for separating mill scale from wastewater

Publication Date: 2023.12.12 ARCELORMITTAL SA

AI summary

A method for collecting mill scale from a hot rolling mill is provided. The hot rolling mill includes a flume. The method includes transporting mill scale particles in wastewater, retrieving the wastewater from a flume of the hot rolling mill and separating the mill scale particles from the wastewater using a separator. A hot rolling mill and a method for retrofitting a hot rolling mill are also provided.