A flux feeding apparatus and flux optimization selection method

Abstract

A flux feeding apparatus 10 for delivering flux to a mold 13 during a continuous casting process is described. The apparatus comprises: a plurality of silos 20a-20c each containing a different flux or flux component; a receiver 52 for receiving process parameters of the casting process; and a controller 44 which is configured to: analyse the process parameters received by the receiver 52; determine whether a current flux composition is appropriate for the received process parameters; and if the current flux composition is not appropriate for the received process parameters, change the delivery of flux or flux components from the plurality of silos to provide a required flux composition to the mold 13 for the received parameters. A corresponding method is also described.

1 . A flux feeding apparatus for delivering flux to a mold during a continuous casting process, the apparatus comprising:
 a plurality of silos each containing a different flux or flux component;   a receiver for receiving process parameters of the casting process; and   a controller which is configured to:
 analyse the process parameters received by the receiver; 
 determine whether a current flux composition is appropriate for the received process parameters; and 
 if the current flux composition is not appropriate for the received process parameters, change the delivery of flux or flux components from the plurality of silos to provide a required flux composition to the mold for the received process parameters. 
   
     
     
         2 . A flux feeding apparatus as claimed in  claim 1 , wherein the process parameters include user-input parameters and sensed parameters. 
     
     
         3 . A flux feeding apparatus as claimed in  claim 1 , wherein the process parameters include one or more of: the grade of metal being cast, casting rate/speed, flux consumption rate, heat transfer rate, slag temperature, metal temperature, thickness, width, section size, taper. 
     
     
         4 . A flux feeding apparatus as claimed in  claim 1 , wherein the controller selects a plurality of the silos so as to form a mixture of the individual fluxes or flux components. 
     
     
         5 . A flux feeding apparatus as claimed in  claim 1 , wherein the controller selects one of the silos so as to deliver the flux contained therein to the mold. 
     
     
         6 . A flux feeding apparatus as claimed in  claim 1 , further comprising a feed head which is connected or connectable to the plurality of silos, wherein the controller is configured to supply the feed head with flux or flux components from one or more of the plurality of silos so as to deliver the required flux composition to the mold. 
     
     
         7 . A flux feeding apparatus as claimed in  claim 6 , wherein the feed head is connected to the silos via a manifold and one or more valves which selectively couple the silos to the feed head. 
     
     
         8 . A flux feeding apparatus as claimed in  claim 7 , wherein the one or more valves are metering valves. 
     
     
         9 . A flux feeding apparatus as claimed in  claim 6 , wherein one or more mixing devices are provided to mix the flux or flux components prior to or in the feed head. 
     
     
         10 . A flux feeding apparatus as claimed in  claim 6 , further comprising an intermediate hopper and a transfer apparatus for transferring mold flux from the silos to the intermediate hopper, wherein the feed head is connected to a feed hopper which is configured to receive flux from the intermediate hopper. 
     
     
         11 . A flux feeding apparatus as claimed in  claim 10 , wherein the transfer apparatus includes a vacuum for transferring flux from the silos to the intermediate hopper, and wherein the controller is further configured to control the operation of the vacuum. 
     
     
         12 . A flux feeding apparatus as claimed in  claim 11 , 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. 
     
     
         13 . A flux feeding apparatus as claimed in  claim 12 , wherein the valve is a flapper valve having a counter weight. 
     
     
         14 . A flux feeding apparatus as claimed in  claim 1 , further comprising a venturi pump to supply the flux to the feed head. 
     
     
         15 . A flux feeding apparatus as claimed in  claim 1 , wherein, if the current flux composition is not appropriate for the received process parameters, the controller generates an alert for an operator. 
     
     
         16 . A flux feeding apparatus as claimed in  claim 15 , wherein in response to the alert, the operator instructs the controller to change the delivery of flux or flux components from the plurality of silos to provide a required flux composition to the mold for the received process parameters. 
     
     
         17 . A flux feeding apparatus as claimed in  claim 1 , further comprising one or more sensors for determining the process parameters, the one or more sensors being connected to the receiver. 
     
     
         18 . A continuous casting apparatus comprising a flux feeding apparatus as claimed in  claim 1 . 
     
     
         19 . A method for delivering flux to a mold during a continuous casting process, the method comprising:
 receiving process parameters of the casting process at a controller;   analysing the process parameters using the controller;   determining whether a current flux composition delivered to the mold from a plurality of silos each containing a different flux or flux component is appropriate for the received process parameters; and   if the current flux composition is not appropriate for the received process parameters, changing the delivery of flux or flux components from the plurality of silos so as to provide a required flux composition to the mold for the received process parameters.