Continuous Measurement of Liquid Steel Temperature and Chemistry

钢水加工在超过1500摄氏度的温度下进行，批量大小为数百吨，但目标成分和温度规格分别有ppm和个位数度数窗口。这是一个令人兴奋和具有挑战性的工作领域。斯旺西大学之前的研究对碱性氧气炉(BOF)中气体搅拌系统的功效进行了表征。气体搅拌使熔炉中的材料均匀，从而提高了金属的净化效率。对输送气体的端口(称为Tuyeres)的尸检分析显示，其表面存在金属附着物，这对搅拌和工艺效率有负面影响[1]。进行了实验室水模型研究，以验证这些观察结果，并设计出可提供最佳搅拌效率的风口。这与最初的观察结果相结合，定义了一种获得专利的全耐火设计[3]。虽然这提供了一个提高工艺效率的机会，但监控这些改进仍然是一个挑战。目前，使用一次性探头对这一过程进行长时间间隔的化学和热监测。如果能够对过程进行连续测量，它将在效率和产品质量方面给炼钢过程带来革命性的变化，并可能被视为炼钢的圣杯。以前曾尝试通过光学光谱学技术通过液线以下的气体端口进行测量，但这些测量的稳定性很差，因为端口一直被吸积物堵塞。上述开发的技术提供了绕过这些挑战的机会。保守的计算预测，每座工厂每年可净节省约450万GB。据推算，这相当于全球转炉钢产量的一半，相当于惊人的10亿美元。该项目将专注于开发能够实时监控金属熔炉中的化学成分和温度的技术，从而实现炼钢生产率的阶段性变化。令人惊讶的是，尽管有上述需要和好处，但并不存在这样的商业系统。因此，为了实现这一机会，将实施独特和变革性的方法，以适应和结合耐火材料制造和激光计量的最新进展。

Liquid steel processing occurs in batch sizes of hundreds of tonnes at temperatures in excess of 1500oC, but the target composition and temperature specifications have ppm and single digit degree windows respectively. This is an exciting and challenging area to work in. Previous research at Swansea University characterised the efficacy of gas stirring systems in the basic oxygen furnace (BOF). Gas stirring homogenises the material in the furnace which enhances the efficiency of purification of the metal. Post mortem analysis of the ports that delivered the gas (called Tuyeres) revealed the presences of metallic accretions on their surface which have a negative effect on stirring and hence process efficiency [1]. Laboratory water modelling research was conducted to validate these observations and also to design a tuyere that would deliver optimum stirring efficiency. This was combined with the initial observations to define an all refractory design which was patented [3].Whilst this presents an opportunity to enhance the efficiency of the process, monitoring these improvements remains a challenge. Currently the process is chemically and thermally monitored discretely at long intervals using disposable probes. If continuous measurement of the process were possible it would revolutionise the steelmaking process both in terms of efficiency and product quality and might be considered somewhat of a holy grail of steelmaking. Previous attempts have been made to do this via optical spectroscopy techniques through gas ports below the liquid line, but the stability of these measurements was poor because the port kept being blocked by accretions. The technology developed above offers an opportunity to circumvent these challenges. Conservative calculations predict a net saving per plant is ~£4.5m p.a. Extrapolated to half of globally produced BOF steel this equates to a staggering $1bn.The project will focus on the development of technology that enables real-time monitoring of chemical composition and temperature in molten metal furnaces, delivering a step-change in steelmaking productivity. Surprisingly, no such commercial system exists despite the need and benefits outlined above. Hence to realise this opportunity, unique and transformative approaches will be implemented that adapt and combine the latest advancements in refractory manufacturing and laser metrology.