SBIR Phase II: On-Line Optoelectronic Sensing of Molten Metal Chemistry

这个小型企业创新研究（SBIR）二期项目将开发一种高度创新的高速光电传感器系统，能够在铸造和熔化过程中连续监测熔融金属合金成分。目标是设计和构建一个商业上可行的传感器系统，能够在激进的工业环境中对熔融铝合金成分进行高度精确的定量测量。这种传感器的开发是金属铸造行业和铝行业在其未来行业路线图中确定的最优先的技术需求之一。为了有效地竞争，美国金属工业必须增加低成本废料的使用，还必须找到提高生产效率的方法。该传感器获取关键成分数据的速度比目前的商业方法快数千倍，并且可以实时运行，而无需将传感器与熔融金属接触。在这样的速度下，熔炼车间每天可以多生产一批金属（“热”），从而使生产率提高15%。这种创新的光电传感器系统的结合将导致生产效率的巨大提高，提供15%的生产力增益。因此，300亿美元的铝冶炼行业可以实现45亿美元的产量增加，除了传感器系统的成本之外，很少或没有额外的资本投资。事实上，由于生产率的提高，拟议的活动最直接的影响将是提高美国铝铸造和冶炼厂的竞争力。此外，所建议的技术将对过程控制和质量保证产生重大的积极影响，从而提供进一步的竞争优势。通过缩短融化周期减少排放和节约能源，也将对我们的社会产生更广泛的影响。锌、铜、黄铜、青铜、铁、陶瓷和玻璃行业也可能有类似的改进，这些行业也需要类似的连续传感器系统来实时监测和控制成分和质量。

This Small Business Innovation Research (SBIR) Phase II project will develop a highly innovative, high-speed optoelectronic sensor system capable of continuously monitoring molten metal alloy compositions during casting and melting operations. The goal is to design and construct a commercially-viable sensor system capable of performing highly-accurate quantitative measurement of molten aluminum alloy compositions in an aggressive industrial setting. Development of this sensor is among the highest priority technology needs identified by both the metal casting industry and the aluminum industry in their industry roadmaps of the future. In order to effectively compete, U.S. metal industries must increase their use of low cost scrap and must also find ways to increase production efficiency. The proposed sensor will acquire critical compositional data thousands of times faster than current commercial methods and will operate on a real-time basis without the need to place the sensor in contact with the molten metal. At these speeds, a melt shop could produce one extra metal production batch ('heat') per day, resulting in a 15% increase in productivity.The incorporation of this innovative optoelectronic sensor system will result in a tremendous increase in production efficiency, providing for a 15% gain in productivity. Thus, the $30 billion aluminum smelting industry could realize a $4.5 billion increase in production output with little or no additional capital investment other than the cost of the sensor system. In fact, the most immediate broader impact of the proposed activity will be to enhance U.S. competitiveness of aluminum casters and smelters because of this productivity improvement. In addition, the proposed technology will have a significant positive effect on process control and quality assurance, thereby providing further competitive advantages. Broader impact to our society will also be brought about through reduced emissions and energy savings resulting from shorter melting cycles. Similar improvements would be possible for zinc, copper, brass, bronze, iron, ceramic and glass industries that also have need for a similar continuous sensor system to monitor and control composition and quality on a real-time basis.