Graphite Ferrule Assembly for Tundish Nozzle Inclusion Reduction
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Solution Overview
Problem
Existing methods for controlling small-sized inclusions in steel during continuous casting face challenges due to low current intensity and complex operations, particularly with non-contact electric fields, leading to inefficient inclusion removal.
Innovation Solution
A ferrule device comprising a ferrule, ferrule base, and wire, made of graphite with good electrical conductivity, is used to create a stable gradient electric field by forming a closed circuit, facilitating easy installation and change, and reducing inclusions through a detachable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a groove is set on the surface of the original immersion nozzle with metal wires sealed by high-temperature cement and heat resistant cotton, then the electrical conductivity is improved, but the device complexity and operation difficulty increase
Solution Approach 1:
The device is segmented into three main components: the immersion nozzle, the ferrule (with wire hole), and the ferrule base (with through wire hole). This segmentation allows each component to have a specific function - the ferrule and ferrule base provide dedicated pathways for current-carrying wires, eliminating the need to modify the nozzle surface with grooves and seals, thus reducing device complexity while maintaining electrical conductivity.
Solution Approach 2:
The ferrule and ferrule base act as intermediary components between the power supply and the steel liquid in the tundish. These intermediaries provide a structured way to introduce current into the system through the immersion nozzle, serving as mediators that simplify the overall device architecture compared to direct surface modification of the nozzle.
2Manufacturing precision
If aluminum-carbon compound pulse electrodes are inserted into the tundish by holding device, then the inclusion distribution is adjusted, but the current intensity is low due to complicated operation and complex device
Solution Approach 1:
The device is segmented into the immersion nozzle, ferrule, and ferrule base components, allowing the current-carrying wires to be installed through predetermined holes in the ferrule and ferrule base rather than requiring complex insertion operations into the tundish. This segmentation simplifies the installation process while maintaining the ability to control inclusion distribution through the electric field.
Solution Approach 2:
The patent replaces the mechanical insertion method of aluminum-carbon compound electrodes through holding devices with an electrical field-based approach. Current-carrying wires are installed through the ferrule and ferrule base, and the electric field generated by these wires directly influences inclusion distribution, eliminating the need for complex mechanical insertion and holding mechanisms.
3Force
If stable forward current is applied to the inner wall of immersion nozzle, then repulsion force between charges is formed, but the actual current intensity is low due to bad electrical conductivity of the nozzle
Solution Approach 1:
The ferrule and ferrule base serve as intermediary components that provide dedicated pathways for current-carrying wires. These intermediaries have good electrical conductivity and are designed to efficiently transmit current from the power supply through the immersion nozzle into the steel liquid, overcoming the poor conductivity issue of the original nozzle material while maintaining the charge repulsion force for inclusion removal.
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 ferrule device effectively decreases inclusions by 28% or more in continuous casting samples by generating a stable electric field, ensuring fluent electric circuits without disrupting the continuous casting process.
Implementation Method 1
The ferrule device comprises a ferrule, ferrule base, and wire, made of graphite with good electrical conductivity, is used to create a stable gradient electric field by forming a closed circuit
Implementation Method 2
generate a stable gradient electric field, control inclusion movement of the tundish, which results to decreasing amount of the inclusions in the tundish
Data Source
AI summary
A ferrule device of tundish nozzle for reducing inclusions in steel contains a ferrule, a ferrule base and a wire. Structure of the ferrule is circular cylinder; inner diameter of the ferrule is same to outer diameter of matched immersion nozzle. A ferrule wire hole is set on bottom of the ferrule. The ferrule is detachably connected with the top of the ferrule base. A base wire hole throughout top surface and bottom surface of the ferrule base is set on the ferrule base. The diameter of the base wire hole is same to the diameter of the ferrule wire hole. The ferrule device of the present disclosure is easy to install and change. Installing and change process and filling of refractory material of the tundish process can be carried out simultaneously. Continuous casting process is not influenced.