System and method for monitoring mold flux consumption

Abstract

A system for monitoring the consumption of mold flux in a continuous casting apparatus including a transfer apparatus for transferring mold flux from a bulk source to an intermediate hopper; a feed control apparatus for controlling the transfer of mold flux from the transfer apparatus to the intermediate hopper, the feed control apparatus including at least one load cell for weighing the intermediate hopper and the mold flux within the intermediate hopper over a period of time, the feed control apparatus further including a controller receiving input from the at least one load cell and for controlling the operation of the transfer apparatus based on the input; and a delivery apparatus for receiving mold flux from the intermediate hopper and delivering the mold flux to a mold, the delivery apparatus pneumatically feeding the mold flux to the mold.

What is claimed is: 
     
         1 . A continuous casting apparatus comprising;
 a transfer apparatus for transferring mold flux from a bulk source to an intermediate hopper;   a feed control apparatus for controlling the transfer of mold flux from the transfer apparatus to the intermediate hopper, the feed control apparatus including at least one load cell for weighing the intermediate hopper and the mold flux within the intermediate hopper over a period of time, the feed control apparatus further including a controller receiving input from the at least one load cell and for controlling the operation of the transfer apparatus based on the input from the at least one load cell; and   a delivery apparatus for receiving mold flux from the intermediate hopper and delivering the mold flux to a mold, the delivery apparatus including a feed hopper configured to receive mold flux from the intermediate hopper, at least one outlet, and a delivery tube connected to each outlet for pneumatically feeding the mold flux to the mold.   
     
     
         2 . The apparatus of  claim 1 , wherein the transfer apparatus includes a vacuum for transferring mold flux from the bulk source to the intermediate hopper, and wherein the feed control apparatus controls the operation of the vacuum. 
     
     
         3 . The apparatus of  claim 2 , wherein the transfer apparatus further comprises a valve which is operable between a first closed position which prevents mold flux from transferring to the intermediate hopper when the vacuum is on, and a second open position which allows mold flux to transfer to the intermediate hopper when the vacuum is off. 
     
     
         4 . The apparatus of  claim 3 , wherein the valve is a flapper valve having a counter weight. 
     
     
         5 . The apparatus of  claim 1 , wherein the controller is a programmable logic controller. 
     
     
         6 . The apparatus of  claim 5 , wherein the programmable logic controller is operable to turn on the transfer apparatus to transfer mold flux from the bulk source and to turn off the transfer apparatus to transfer mold flux from the transfer apparatus to the intermediate hopper. 
     
     
         7 . The apparatus of  claim 6 , wherein the transfer apparatus includes a vacuum for transferring mold flux from the bulk source to the intermediate hopper, and wherein the programmable logic controller is operable to turn the vacuum on and off. 
     
     
         8 . The apparatus of  claim 5 , wherein the programmable logic controller includes an operator touch screen adaptable for receiving input from an operator for controlling mold flux feed rate. 
     
     
         9 . The apparatus of  claim 5 , wherein the programmable logic controller includes a receiver and a wireless remote in communication with the receiver adaptable for receiving input from an operator for controlling mold flux feed rate. 
     
     
         10 . The apparatus of  claim 1 , wherein each outlet includes a venturi pump. 
     
     
         11 . A method for monitoring the consumption of mold flux in a continuous casting apparatus comprising:
 transferring mold flux from a bulk source to an intermediate hopper using a transfer apparatus;   weighing the intermediate hopper and the mold flux within the intermediate hopper over a period of time;   controlling the operation of the transfer apparatus based on the weight of the intermediate hopper and the mold flux within the intermediate hopper;   transferring mold flux from the intermediate hopper to a feed hopper; and   pneumatically feeding the mold flux from the feed hopper to a mold.