Light-guide temperature control of metal melts directly in metallurgical aggregates
Light-guide thermometric system (LGТS)
The LGTS is purposed for the technical realization of continuous light-guide temperature control technologies of closed objects. For example, LGTS provides continuous, during lining life, temperature control and regulation of metal melts under slag in metallurgical furnaces and aggregates. The LGTS can also be used for temperature control of salt and ceramic melts, gaseous media and lining, the boundary of liquid and solid metal and other technological parameters.
2. Operation principle
It is based on the light-guide generation and transmission through the aggregate lining (wall) of heat radiation, which has thermometric characteristics synonymously coherent with the temperature of the controlled object. The light-guide unit, stationary mounted in aggregate lining (wall) performs generation and transmission of heat radiation.
3. Main tеchnical characteristics
Range of measuring temperatures, ºС
Measurement error, %
As a distinct from known solutions, LGTS, for the first time in world practice, provides continuous high-accuracy temperature control of closed type objects, including metal melts under slag in metallurgical furnaces and aggregates. For example, the errors of liquid metal temperature control in the induction crucible and channel melting, holding and pouring furnaces do not exceed 6,4; 4,9 and 4,3 °C, respectively within the temperature range from 1260 to 1600 °C.
5. Теchnical-economic efficiency
The LGTS provides continuous control and optimal operation of technological processes temperature regimes, including metallurgical processes of liquid metal obtaining, treatment and pouring. Using such control for induction furnaces it is possible to reduce power consumption (30-70 %) and waste of charge materials (20-30 %), to exclude spoilage and failures, originating because of temperature regimes violation (40-100 %) and to enlarge lining life duration (50-140 %), as well as productivity (20-30 %) of metallurgical and heating furnaces and other thermal-technical aggregates. For example, during LGTS application on the industrial furnaces ICHT-10, we achieved a remarkable practically double reduction of the energy consumption to 434 kW*h for melting and overheating to 1400 °C of 1 t of cast iron.
6. Patent protection
Protected by copyright certificates and patents, as well as by 29 patents in Australia, Bulgaria, Germany, Great Britain, Canada, USA, Sweden and Japan.
TECHNICAL-ECONOMIC INDICES OF CONTINUOUS LIGHT-GUIDE TEMPERATURE CONTROL USE IN METALLURGY
1. Continuous temperature control of liquid metal in induction channel melting, holding and pouring furnaces
On the base of modern optoelectronic, fiber, microprocessor and computer technologies, as well as new ceramic materials the light-guide thermometry technologies have been developed. The technologies are purposed for continuous control, registration and regulation of the metal melts temperature in the induction crucible and channel melting, holding and pouring furnaces.
Light-guide thermometric systems are included in construction of induction furnaces. Developed on the basis of continuous temperature control processes and algorithms for receipt and processing liquid cast iron, algorithms and principles of management of the melting, mixering and pouring of metal are used by machine building branches in production control system (PCS) "Electrosmelting". Developments are used in branch instructions, which represent automatic production lines, specialized shops and technological processes of receipt, processing and pouring of liquid cast iron in foundry production.
Economy is achieved mainly due to the reduction of spoilage level and consumption of electricity, fuel and charge materials, increasing lining life duration of metallurgical equipment, exception of failures caused by uncontrolled overheating or overcooling of metal.
2. Continuous temperature control of steel in tundish (according to the data of TATA Steel – Great Britain)
3. Continuous temperature control of converter process (project offer)
In terms of technical-economic efficiency and complexity, the TOP-application of continuous temperature control in metallurgy is the converter process. According to estimates of Western and Japanese experts, 1,5-2,0 billion USD has already been spent in the world on the development of continuous temperature control of the converter process. Nevertheless, this problem has not yet been solved. According to the same information, our light-guide technology is the closest, among all known developments, to solution of this global metallurgical problem. The main part of light-guide technology (optoelectronics, algorithms of primary pyrometric information processing and auxiliary devices) has undergone extensive tests under metallurgical conditions and is ready for continuous temperature control of the converter process. To use this technology on the converter, they are to adapt light-guide unit to the converter process conditions on base of modern thermal insulation materials, ceramics and nanoceramics.