Hot Direct Reduced Iron Charging Stand with Load Cell Control
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Solution Overview
Problem
Existing methods for charging hot direct reduced iron (HDRI) from hot transport vessels into a melter or finisher lack precise control over feed rate, result in heat loss and dust emissions, and are limited by the need for manual crane operation, which restricts the volume of HDRI that can be charged.
Innovation Solution
A method and apparatus featuring a charging stand with load cells and a programmable logic controller to control the feed rate of HDRI from hot transport vessels, using telescoping seals to minimize heat loss and dust emissions, and accommodating various hot transport vessel types, including invertible and non-invertible designs, to ensure continuous and controlled feeding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual crane operation is used to hold the HTV in position while charging the HDRI into the EAF, then the charging process can be performed, but the annual volume of HDRI that may be charged is limited
Solution Approach 1:
The system uses load cells to automatically measure the weight of HDRI in the HTV and controls the feed rate automatically without requiring manual crane operation or intervention, allowing the system to serve itself and maximize productivity
Solution Approach 2:
The manual mechanical crane operation is replaced with an automated control system that uses load cells and programmable logic to automatically regulate the feeding process, substituting human operation with automated mechanical and electronic systems
2Measurement precision
If existing HTV procedures are used for charging HDRI, then the charging process can be completed, but the feed rate of HDRI charged cannot be accurately controlled
Solution Approach 1:
Load cells are used to measure the actual weight of HDRI being fed and provide feedback to the control system, which adjusts the feed rate in real-time to maintain accurate control, creating a closed-loop feedback mechanism
Solution Approach 2:
The mechanical feeding process is replaced with an automated control system that uses sensors and programmable logic to precisely regulate feed rate, substituting mechanical control with electronic and computational systems
3Loss of energy
If HDRI is charged from hot transport vessels into the melter or finisher, then energy consumption is reduced, but heat loss and dust emissions occur
Solution Approach 1:
The charging system creates a controlled atmosphere that prevents air contact with the hot HDRI, using the enclosed charging structure and controlled airflow to maintain an inert environment that prevents oxidation and reduces dust emissions
Solution Approach 2:
The system introduces intermediary elements such as controlled airflow and enclosed charging structures that act as mediators between the hot HDRI and the external environment, preventing direct contact and reducing harmful emissions
Data Source
AI summary
The present invention provides a method and apparatus for charging hot direct reduced iron (HDRI) from hot transport vessels (HTVs) into a melter or finisher. In general, the apparatus includes a charging stand including a plurality of bays for receiving and supporting a plurality of HTVs. Each HTV includes at least an outlet port. This outlet port is configured to engage an inlet port of one of the plurality of bays of the charging stand via a telescoping seal that provides a substantially air-tight seal. A feed device is provided that moves the HDRI disposed within the HTVs from the outlet port/inlet port interface to a melter or finisher, such as an electric arc furnace (EAF) or the like. The charging stand also includes one or more load cells operable for weighing the HTVs and the HDRI disposed therein, such that a computer or other logic may be used to control the feed rate of the HDRI charged into the melter or finisher.