Continuous Measurement of Liquid Steel Temperature and Chemistry

液态钢的处理在超过1500 ℃的温度下以数百吨的批量进行，但目标成分和温度规格分别有ppm和个位数的温度窗口。这是一个令人兴奋和具有挑战性的工作领域。斯旺西大学先前的研究描述了氧气转炉（BOF）中气体搅拌系统的功效。气体搅拌使熔炉中的材料均匀化，这提高了金属的净化效率。对输送气体的端口（称为风口）的事后分析显示，其表面存在金属堆积物，这对搅拌和工艺效率产生负面影响[1]。进行了实验室水模拟研究，以验证这些观察结果，并设计了一个搅拌器，将提供最佳的搅拌效率。这与最初的观察结果相结合，确定了一种获得专利的全耐火设计[3]。虽然这为提高工艺效率提供了机会，但监测这些改进仍然是一个挑战。目前，该过程是化学和热监测离散在长时间间隔使用一次性探头。如果可以对过程进行连续测量，那么它将在效率和产品质量方面彻底改变炼钢过程，并可能被认为是炼钢的圣杯。以前的尝试已经通过液体线以下的气体端口通过光学光谱技术来做到这一点，但这些测量的稳定性很差，因为端口一直被吸积物堵塞。上述开发的技术为规避这些挑战提供了机会。保守的计算预测，每个工厂每年的净节省约为450万英镑。这相当于10亿美元。该项目将专注于开发能够实时监控熔融金属炉中化学成分和温度的技术，从而实现炼钢生产率的飞跃。令人惊讶的是，尽管有上述需求和好处，但没有这样的商业系统存在。因此，为了实现这一机会，将采用独特的变革性方法，适应并联合收割机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.