Claims:WE CLAIM:
1. A breakout detection system (100) for activation of granulation system, the system comprising of:
a processing module (101) coupled to a processor unit (102) configured to receive:
level of liquid steel inside a mould () (input 1),
mode of operation for casting (Input 2) and
speed of casting (Input 3), and
generate a pattern based on input1, input 2 and input 3;
an identification module (103) coupled to the processor unit (102) and a memory (104), the identification module (103) being configured to compare the generated pattern with a logic derived on plurality of pre-stored historic breakout patterns; and
a Granulation system activation module (105) configured to activate a Granulation System (106) based on the affirmative match.
2. The breakout detection system (100) as claimed in claim 1, wherein processor unit (102) has a microcontroller or a microprocessor.
3. The breakout detection system (100) as claimed in claim 1, wherein the system (100) further comprises of an alarm module (107) to raise an alarm when there is an affirmative match.
4. The breakout detection system (100) as claimed in claim 1, wherein the alarm is audio, visual or both.
5. A method for activation of a granulation system, the method comprising:
receiving plurality of inputs, by a processing module (101), coupled to a processor unit (102), to generate a pattern based on plurality of inputs;
comparing the generated pattern by an identification module, coupled to a processor unit (102) and a memory (104), with a logic derived on plurality of pre-stored historic breakout patterns; and
activating the granulation system (106), by a granulation system activation module (105), when there is an affirmative match.
6. The method for activation of granulation system as claimed in claim 5, wherein the plurality of inputs is level of liquid steel inside a mould () (input 1), mode of operation for casting (Input 2) and speed of casting (Input 3).
7. The method for activation of granulation system as claimed in claim 5, wherein an alarm is raised, by the alarm module (107), when there is an affirmative match.
The method for activation of granulation system as claimed in claim 7, wherein the alarm is audio, visual or both.
, Description:A BREAKOUT DETECTION AND GRANULATION SYSTEM AND A METHOD THEREOF
FIELD OF INVENTION:
[001] The present subject matter described herein, relates to a method and a system to activate a granulation system during breakout of the liquid steel while continuous casting of steel. The present subject matter in particularly relates to a method and a system for determining the rupture during continuous casting of liquid steel causing a breakout and activating the granulation system.
BACKGROUND AND PRIOR ART AND PROBLEM IN PRIOR ART:
[002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[003] Breakout of liquid steel is one of the catastrophic process failures that occur during the process of continuous casting of steel. Breakout occurs when solidifying strand steel shell ruptures or tears beneath or around the casting mould. There are several reasons due to which the solid shell of the strand breaks and allows the still liquid steel contained within it to spill out and damage the equipment of Continuous Casting machine.
[004] A breakout is the most detrimental incident associated with the process of continuous casting. Breakout of liquid steel is not only very costly but is also a serious safety hazard for the operators of the Continuous Casting machine. Breakout leads to a shutdown of the strand and results in the loss of production time along with significant drop in the yield. Hence each breakout causes a significant direct economic loss. For the restoration of the Continuous Casting machine strand, it typically requires an extended turnaround involving removal of the spilled steel material from within the strand equipment and/or replacement of the damaged part of the equipment.
[005] A breakout is normally due to the steel shell wall being too thin to support the liquid steel column above it. This is caused due to a condition which has several root causes often associated with the phenomena of heat transfer. Any disturbance in heat transfer mechanism, arising due to mould lubrication failure or Improper cooling water flow tor d any physical damage to mould etc can lead to inadequate heat removal from the solidifying liquid steel, causing the solid shell not strong enough to sustain ferro static pressure at the exit of the mould and hence causing breakage of newly formed shell and hence spillage of liquid steel.
[006] At present, After breakout caster remains down for 10-24 hours for restoring machine condition. During breakout if liquid steel falls over accumulated water, it will lead to explosion. Also cleaning of spilled steel after breakout is hazardous process as it involves, person entering in narrow passage and performing gas cutting operation. Rescue of such person always remains challenge if any mishap happen
[007] To address the above issues a new method and system has been established to mitigate the consequences of breakout of liquid steel. The present subject matter discloses a system and method for breakout detection and activation of granulation system. Granulation system cools down the falling liquid steel and convert it into granules of steel. Cooled granules are more easy to clean and does not possess safety hazards to the operators or continuous casting machines.
[008] The information disclosed in this background of the disclosure section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
OBJECTS OF THE INVENTION:
[009] It is therefore the object of the invention to overcome the aforementioned and other drawbacks in prior method/product/apparatus.
[0010] The principal objective of the present invention is to develop a method and system to detect breakout in casting to activate granulation system.
[0011] Another object of the present invention is to develop a process and system to mitigate the consequences of breakout of liquid steel.
[0012] Another object of the present invention is to develop a process and system to reduce safety hazards during breakout of liquid steel.
[0013] Yet another object of the present invention is to develop a process and system to reduce loss of production time.
[0014] Yet another object of the present invention is to provide a process and a system to avoid damage to the equipment’s of the continuous casting machine during breakout of liquid steel, so that breakout revival time can be minimized
[0015] These and other objects and advantages of the present subject matter will be apparent to a person skilled in the art after consideration of the following detailed description taken into consideration with accompanying drawings in which preferred embodiments of the present subject matter are illustrated.
SUMMARY OF THE INVENTION:
[0016] One or more drawbacks of conventional method for detection of breakout and activation of granulation system and additional advantages are provided through the method as claimed in the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be a part of the claimed disclosure.
[0017] The present subject matter relates to a method and system to detect the breakout and activate the granulation system based on the pre-stored historic breakout patterns. The pre-stored historic breakout patterns take into account parameters such as level of liquid steel inside a mould, mode of operation for casting and speed of casting. These primary parameters are determined at real time and compared with logic derived on the basis of the pre-stored historic breakout patterns. Granulation system is activated if there is an affirmative match.
[0018] In an embodiment, the present subject matter discloses a method for activation of granulation system during breakout of liquid steel while continuous casting of steel. According to the method disclosed processing module received plurality of inputs, which is processed by the processing unit coupled with processing module. The processing unit is configured to receive the plurality of inputs and generate a pattern based on those inputs. The generated pattern is then compared to the pre-stored historic breakout patterns stored in the memory, by the identification module. The identification module in turn activate the granulation system if there is an affirmative match.
[0019] Yet another embodiment of the present subject matter discloses a system comprising a processing module coupled with processing unit to generate a pattern based on the received inputs, an identification module coupled with processor unit and a memory to compared the generated pattern with a plurality of pre-stored historic breakout patterns stored in the memory and a granulation system to be activated if there is an affirmative match with the pre-historic breakout patterns.
[0020] In an embodiment, an alarm module is coupled with identification module, to raise the alarm when there is an affirmative match. The alarm module can raise audio, visual or both kind of alarm.
[0021] In an aspect, the received inputs are level of liquid steel inside a mould (input 1), mode of operation for casting (Input 2) and speed of casting (Input 3).
[0022] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.
[0023] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:
[0025] Fig. 1 illustrates a breakout detection system for activation of granulation system according to an embodiment of present invention;
[0026] Fig. 2 illustrates a breakout detection system for activation of granulation system according to another embodiment of present invention;
[0027] Fig. 3 illustrates flow diagram of method for activation of granulation system according to present invention.
[0028] Fig. 4 illustrates flow diagram of method for activation of granulation system according to another embodiment of the present invention.
[0029] Fig. 5 illustrates granulation nozzle headers deployed in segment bender
[0030] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DESCRIPTION OF THE PREFERRED EMBODIMENTS:
[0031] While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.
[0032] The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusion, such that a device, system, assembly that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such system, or assembly, or device. In other words, one or more elements in a system or device proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or device.
[0033] The present subject matter relates to a method and a system to detect breakout and to activate granulation system during breakout of liquid steel while continuous casting of steel.
[0034] It should be noted that the description and figures merely illustrate the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present subject matter. It should also be appreciated by those skilled in the art that by devising various arrangements that, although not explicitly described or shown herein, embody the principles of the present subject matter. Furthermore, all examples recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the inventor(s) to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. The novel features which are believed to be characteristic of the present subject matter, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures.
[0035] These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
[0036] Reference may be made to Figure 1 illustrating block diagram of breakout detection system. The present breakout detection system for activation of granulation system comprises a processing module 101 coupled with a processor unit 102, an identification module 103 coupled to the processor unit 102 and a memory 104, a granulation system activation module 105 coupled with a granulation system 106.
[0037] The breakout detection system 100 includes a processing module 101 coupled with processor(s) unit 102, an identification module 103 coupled with the processor unit 102 and a memory 104, a granulation system activation module 105 coupled with granulation system 106 to activate the granulation system 106 when there is an affirmative match. The identification module 103 may be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, central processing units, logic circuitries, and/or any devices that manipulate data based on operational instructions. Among other capabilities, the identification module 103 is configured to fetch and execute computer-readable instructions and one or more routines stored in the memory 104. The memory 104 may store historic breakout patterns which then the identification module 103 compares to the generated pattern and one or more computer-readable instructions or routines, which may be fetched and executed to give instructions to granulation system activation module 105. The memory 104 may include any non-transitory storage device including, for example, volatile memory such as RAM, or non-volatile memory such as EPROM, flash memory, and the like.
[0038] The processing module 101 receive plurality of inputs such as level of liquid steel inside mould (input 1), mode of operation for casting (input 2) and speed of casting (input 3). These plurality of inputs are processed in processor unit 102 to generate a pattern. The identification module compares the generated pattern with a plurality of pre-stored historic breakout patterns stored in the memory 104. The pre-stored historic patterns stored in the memory 104 are the patterns shown by the continuous casting machine during breakout of liquid steel in past. The past breakout pattern also generated by taking into account level of liquid steel inside mould (input 1), mode of operation for casting (input 2) and speed of casting (input 3).
[0039] The identification module 103 compares and identifies if there is any instance in past when the currently generated pattern leads to breakout of liquid steel. The granulation system activation module 105 is configured to activate granulation system 106 in case there is an affirmative match.
[0040] Referring to Figure 2 illustrating another embodiment of present invention. An alarm module 107 is provided coupled with the identification module 103 to raise an alarm when there is an affirmative match. The alarm can be audio, visual or both.
[0041] Referring to Figure 3 illustrating flow diagram of method according to present invention.
[0042] At Step 301, plurality of inputs is received at processing module 101 coupled with processor unit 102. The inputs received includes level of liquid steel inside mould (Input 1), mode of operation for casting (Input 2) and speed of casting (Input 3).
[0043] At step 302, the processing module 101 coupled with processor unit 102 is configured to generate a pattern based on the received plurality of inputs.
[0044] At step 303, the pattern generated by processing module 101 coupled with processor unit 102, is compared with logic derived on plurality of pre-stored historic breakout patterns stored in the memory 104 by the identification module 103. The identification module checks if there is any incident in past when the generated pattern results in breakout of liquid steel.
[0045] At step 304, the granulation system 106 is activated by the granulation system activation module 105, when the generated pattern matches with at least one of the pre-stored historic breakout patterns.
[0046] In one of the embodiments, at step 305, an alarm module 107, coupled with the identification module 103, is activated by the identification module 103, which is coupled with the processor unit 102, to raise an alarm when there is an affirmative match. The alarm can be audio, visual or both.
[0047] The activation of granulation system 106 will cool down the falling liquid steel and convert them into steel granules before falling on the casting machines. These steel granules pose less safety hazard for operators and reduce the damage to the components of the continuous casting machines. With present system consequences of breakout of liquid steel can be mitigated which result in more production time which leads to increase in yield. Also, it is easier to clean granules of steel which falls on the continuous casting machines after cooling and granules cause less damage to the equipment’s of continuous casting machine.
[0048] Granulation system is designed to provide high volume of water from both side of segment, it is combination of headers and nozzles in casting direction
[0049] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
[0050] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present invention contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. The present invention also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.
[0051] Although embodiments for the present subject matter have been described in language specific to structural features, it is to be understood that the present subject matter is not necessarily limited to the specific features described. Rather, the specific features and methods are disclosed as embodiments for the present subject matter. Numerous modifications and adaptations of the system/component of the present invention will be apparent to those skilled in the art, and thus it is intended by the appended claims to cover all such modifications and adaptations which fall within the scope of the present subject matter