Direct Hot Charge Steel Billet Heating via Induction
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Solution Overview
Problem
Current steel production processes are energy-intensive, inefficient in space management, and environmentally polluting due to high heat energy consumption and emissions from flame furnaces, leading to increased costs and pollution.
Innovation Solution
An apparatus and method integrating a direct hot charge system with an induction-type tunnel furnace for heating billets directly from continuous casting to rolling temperature, reducing energy consumption and eliminating the need for flame furnaces, while optimizing space and production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a flame furnace is used to heat billets to rolling temperature, then the steel reaches the required temperature for rolling, but energy consumption increases significantly and pollutant emissions occur
Solution Approach 1:
The patent recovers heat from the continuous casting process and utilizes it for preheating billets before they enter the rolling mill. This heat recovery system captures thermal energy that would otherwise be wasted and applies it to reduce the energy required in the flame furnace, directly addressing the energy consumption problem while maintaining the required rolling temperature
Solution Approach 2:
The patent implements a preheating zone before the main rolling process where billets are preliminarily heated using recovered heat from the continuous casting process. This preliminary heating action reduces the temperature differential that the flame furnace must bridge, significantly lowering overall energy consumption while ensuring billets reach rolling temperature
2Temperature
If a flame furnace is used to heat billets, then the steel reaches the required temperature for rolling, but harmful emissions such as CO2, SO2 and NOx are produced
Solution Approach 1:
The patent recovers heat from the continuous casting process and utilizes it for preheating billets before they enter the rolling mill. This heat recovery system captures thermal energy that would otherwise be wasted and applies it to reduce the energy required in the flame furnace, directly addressing the energy consumption problem while maintaining the required rolling temperature
Solution Approach 2:
The patent converts the harmful waste heat from the continuous casting process into a beneficial resource by using it for preheating billets. This transforms what would be wasted thermal energy (and associated emissions from additional fuel combustion) into a useful heating source, reducing both energy consumption and pollutant emissions from the flame furnace
3Temperature
If cooling and subsequent heating space is provided for steel processing, then temperature control is achieved, but production efficiency decreases and plant dimensions increase
Solution Approach 1:
The patent merges the continuous casting process with the rolling mill operation by directly transporting hot billets from the continuous caster to the rolling mill without intermediate cooling and storage. This integration eliminates the need for separate cooling and reheating spaces, reduces production cycle time, and maintains high production efficiency while achieving proper temperature control for rolling
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 achieves significant energy savings, reduces production costs, and minimizes pollutant emissions, enhancing the sustainability of steel production by efficiently processing steel with reduced dimensions and lower environmental impact.
Implementation Method 1
an induction-type tunnel furnace (2B)
Data Source
AI summary
The present invention relates to a energy-saving steel production apparatus, including an hot-rolling production line and a continuous casting equipment (5) for producing semi-manufactured products or billets (10), said production line and said equipment facing one each other and being connected through fast transport means (7) moving said billets (10). The invention also relates to a method for processing energy-saving steel, comprising the following steps:a. taking the steel to a casting temperature;b. casting said steel in suitable moulds for obtaining a semi-manufactured product (10);c. transferring directly said casted semi-manufactured product (10) towards a rolling mill through fast transport means;d. taking said semi-manufactured product (10) to a value of temperature corresponding to a maximum value of plasticity;e. subjecting said semi-manufactured product (10) to a rolling process.