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 - 19 . (canceled) 
     
     
         20 . 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, wherein the process parameters include a flux consumption rate, a heat transfer rate, and/or a thickness of a layer of flux on molten metal in the mold; 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. 
   
     
     
         21 . A flux feeding apparatus as claimed in  claim 20 , wherein the flux consumption rate is measured using load cells. 
     
     
         22 . A flux feeding apparatus as claimed in  claim 21 , wherein the flux feeding apparatus further comprises an intermediate hopper and a transfer apparatus for transferring mold flux from the silos to the intermediate hopper, and wherein the load cells support the intermediate hopper. 
     
     
         23 . A flux feeding apparatus as claimed in  claim 22 , wherein the flux feeding apparatus further comprises a feed head that is connected to a feed hopper, wherein the feed hopper is configured to receive flux from the intermediate hopper, and wherein the controller is configured to supply the feed head with flux or flux components from one or more of the plurality of silos via the intermediate hopper and the feed hopper so as to deliver the required flux composition to the mold. 
     
     
         24 . A flux feeding apparatus as claimed in  claim 20 , wherein the heat transfer rate is determined by measuring a temperature increase of cooling water used to cool the mold. 
     
     
         25 . A flux feeding apparatus as claimed in  claim 20 , wherein the thickness of the layer of flux on the molten metal is determined using a laser distance measurement device. 
     
     
         26 . A flux feeding apparatus as claimed in  claim 20 , wherein the process parameters include user-input parameters and sensed parameters. 
     
     
         27 . A flux feeding apparatus as claimed in  claim 20 , wherein the process parameters further include one or more of: the grade of metal being cast, casting rate/speed, slag temperature, metal temperature, thickness, width, section size, taper. 
     
     
         28 . A flux feeding apparatus as claimed in  claim 20 , wherein the controller selects a plurality of the silos so as to form a mixture of the individual fluxes or flux components. 
     
     
         29 . A flux feeding apparatus as claimed in  claim 20 , wherein the controller selects one of the silos so as to deliver the flux contained therein to the mold. 
     
     
         30 . A flux feeding apparatus as claimed in  claim 20 , wherein, if the current flux composition is not appropriate for the received process parameters, the controller generates an alert for an operator. 
     
     
         31 . A flux feeding apparatus as claimed in  claim 30 , 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. 
     
     
         32 . A continuous casting apparatus comprising a flux feeding apparatus as claimed in any  claim 20 . 
     
     
         33 . 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, wherein the process parameters include a flux consumption rate, a heat transfer rate and/or a thickness of a layer of flux on molten metal in the mold;   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.   
     
     
         34 . A method for delivering flux as claimed in  claim 33 , wherein the flux consumption rate is measured using load cells. 
     
     
         35 . A method for delivering flux as claimed in  claim 34 , wherein the method comprises a transfer apparatus transferring mold flux from the silos to an intermediate hopper, and wherein the load cells support the intermediate hopper. 
     
     
         36 . A method for delivering flux as claimed in  claim 35 , wherein the method comprises the controller supplying a feed head with flux or flux components from one or more of the plurality of silos via the intermediate hopper and a feed hopper so as to deliver the required flux composition to the mold. 
     
     
         37 . A method for delivering flux as claimed in  claim 33 , wherein the heat transfer rate is determined by measuring a temperature increase of cooling water used to cool the mold. 
     
     
         38 . A method for delivering flux as claimed in  claim 33 , wherein the thickness of the layer of flux on the molten metal is determined using a laser distance measurement device. 
     
     
         39 . A method for delivering flux as claimed in  claim 33 , wherein the process parameters further include one or more of: the grade of metal being cast, casting rate/speed, slag temperature, metal temperature, thickness, width, section size, taper.