Claims:We Claim:
1. A Flux Reactivity measurement Apparatus for measuring the Reactivity of Calcined Lime and Calcined Dolomite, comprising

a steel structural frame assembly supporting a horizontal platform movable vertically up and down by the action of a cooperative hydraulic cylinder/lifting jack powered by a hydraulic power pack;

a stainless steel container removably placed on said vertically movable platform for holding water and flux therein for conducting reactivity measurement of flux;

a hopper and a chute (metal feeder) for flux addition with water inside said container,
an electrically operated mechanical geared stirrer mounted at top of the setup assembly/frame for homogenization of the water temperature during its reaction with flux;
a load cell placed at the bottom of the moving platform for the measurement of weight of empty container, weight of water and weight of flux;

a RTD (Resistance temperature detector) sensor installed in the setup assembly which is placed parallel to the stirrer and dipped into the water, for continuous and precise measurement of water temperature.

a control unit comprising a programmable logic controller (PLC) with installed programme logic for easy conduction of flux reactivity experiment, controlling measurement of temperature and weight data for estimation of flux reactivity; and a touch screen / display panel comprising graphical user interface (GUI) screen installed for data input, display of recorded data and for display of test results.

2. A Flux Reactivity measurement Apparatus as claimed in claim 1 wherein said stainless steel container comprising a thermally isolated double layer stainless steel (SS) container having a layer of heat insulator (glass wool) put between the two layers of container to reduce the heat loss.

3. A Flux Reactivity measurement Apparatus as claimed in anyone of claims 1 or 2 wherein a holding arrangement has been provided at the top of the apparatus for holding said geared stirrer, hopper and chute, control units and RTD sensor.

4. A Flux Reactivity measurement Apparatus as claimed in anyone of claims 1 to 3 wherein upward and downward movement of platform on which the container is placed is controlled using an inching switch such that the platform movement is controlled by a hydraulic jack and its movement is carried out using said inching button for small and steady movement of the platform to avoid spillage of liquid, having Guide rolls provided for smooth vertical movement of the platform.

5. A Flux Reactivity measurement Apparatus as claimed in anyone of claims 1 to 4 wherein the movement of container is restricted such that the stirrer and RTD sensor do not touch the bottom of the container and upward movement of container is stopped at a place where stirrer and RTD sensors (fixed) are immersed inside water present in the SS container but the bottom of the stirrer and the RTD sensor do not touch the bottom of container and remain 30 cm above the bottom.

6. A Flux Reactivity measurement Apparatus as claimed in anyone of claims 1 to 5 wherein the platform containing the container is moved downward after completion of an experiment, so that sufficient gap between the top of the container and the bottom part of stirrer is maintained for ease of container removal for cleaning.
7. A Flux Reactivity measurement Apparatus as claimed in anyone of claims 1 to 6 wherein an execution button has been provided to start the experiment with input of starting weight of flux and water (Manual / automatic entry).

8. A Flux Reactivity measurement Apparatus as claimed in anyone of claims 1 to 7 wherein said GUI displays the real time data for temperature (RTD measurement), weight (Load cell measurement) and displays reaction time (using a stop watch) and having one pop up screen in which graph is drawn indicating temperature change and weight directly in real time, plotting of said graph starts with start of experiment on pressing of execution button.
9. A Flux Reactivity measurement Apparatus as claimed in anyone of claims 1 to 7 wherein results of the experiment are displayed on the second screen (GUI) and measured data for temperature and weight against time are stored in the PLC / HMI.

10. A method for Flux Reactivity measurement using the Flux Reactivity measurement Apparatus as claimed in claims 1 to 9 comprising

(i) lowering the platform by operating the hydraulic jack;
(ii) placing the stainless steel container on platform and fillig appropriate volume of water therein;
(iii) weight of empty container and added water displayed on GUI screen;

(iv) Raising the platform upward by operating the hydraulic jack so that flux feeding chute and RTD sensor are immersed in water at desired depth above bottom of container;

(v) gradually adding flux through hopper and chute with water inside container;

(vi) putting on the execution switch on control panel with input of initial weight of water and flux;
(vii) carrying out flux reactivity measurements based on the developed co-relation implemented through programme logic on the installed (PLC) comprising
(a) displaying the real time data for temperature (RTD measurement), weight (Load cell measurement) and displays reaction time (using a stop watch) on GUI screen;
(b) displaying results of the experiment on the second screen (GUI) and obtaining graph plot indicating temperature change and weight directly in real time on pop up screen;
(c) storing measured data for temperature and weight against time n the PLC / HMI.
(viii) moving the platform downward again by operating the hydraulic jack after the experiment/test is over to remove the SS container for cleaning.

11. A method as claimed in claim 10 wherein ratio of water to flux used during experimentation is pre determined in the range of 3 to 4.

12. A method as claimed in claim 10 or 11 wherein the water used is simple tap water and flux sample may be taken directly from the desired location in bulk without needing sizing or screening of sample.

Dated this the 27th day of December, 2018
Anjan Sen
Of Anjan Sen & Associates
(Applicants Agent)
IN/PA-199

, Description:FIELD OF THE INVENTION

The present invention relates to an Flux Reactivity measurement Apparatus for measuring reactivity of fluxes i.e. calcined lime and calcined dolomite used in various steelmaking processes like Basic oxygen furnace, ladle furnace, electrical arc furnace, CONARC, hot metal de-sulphurisation, calcinations kiln etc. More particularly, the present invention relates to an experimental setup that was conceptualized, designed, developed and fabricated for measuring reactivity of calcined lime and calcined dolomite which have various applications in industry, particularly in steel plants as flux material. The system may be utilized to conduct the reactivity tests of samples of fluxes at the shop floor or at any other convenient location and can be easily and effortlessly used to obtain the reactivity values of fluxes in a very short span of time (~ 5 minutes). The reactivity values that are obtained by using this equipment denote the quality of calcined flux which may be gainfully used by the Basic Oxygen Furnace operator to make necessary modifications and adjustments in the steelmaking process to enhance process efficiency.

BACKGROUND OF THE INVENTION

The various processes that are a part of steelmaking are Basic Oxygen Furnace (BOF), Ladle Heating Furnace (LHF), Electrical Arc Furnace (EAF), CONARC process, Hot Metal De-Sulphurisation (HMDS) etc; where calcined lime and calcined dolomite are used as fluxing materials. Calcined lime and calcined dolomite are obtained by calcination of limestone and dolomite respectively in calcining kilns. The reactivity of these calcined fluxes is important since they determine quick dissolution of fluxes which leads to early formation of slag during steelmaking processes. The primary function of addition of calcined lime in steelmaking vessel is to make a slag that is basic in nature that facilitates removal of impurities of liquid steel / metal like sulphur and phosphorus. The key function of calcined dolomite is to reduce chemical erosion of the MgO-C refractory used in steelmaking process. It is well recognized that the dissolution rate of lime in molten slags increases the reaction kinetics between the liquid steel and slag.
The quality of the calcined flux that comes out from the kiln depends on several factors like type of kiln, the operating parameters of the kiln, stability of kiln operation, size of flux, formation of flux fines etc. It has been observed that the quality of flux after calcination varies from kiln to kiln. Moreover, there is a variation in the quality of flux obtained from the same kiln owing to change in the kiln operating parameters. Thus, it is imperative to be aware of the reactivity value of flux prior to charging in steelmaking.

OBJECTS OF THE INVENTION

The basic object of the present invention is directed to provide a Flux Reactivity Apparatus which is developed as an experimental testing setup for measuring the flux reactivity.
A further object of the present invention is directed to develop a Flux Reactivity Apparatus for implementing a convenient, reliable and quick testing process which can be located at any desired place like calcining kiln or near steelmaking vessel for quality evaluation and classification of the calcined product.
A still further object of the present invention is directed to develop the formulation of a testing procedure involving said apparatus in which flux sample in as received condition can be analyzed for reactivity while eliminating process of sample preparation like crushing, grinding or screening.
Another object of the present invention is directed to provide said Flux Reactivity Apparatus wherein a bulk quantity of flux sample can be tested in order to obtain test results reliably and quickly.
Yet another object of the present invention is directed to provide said Flux reactivity Apparatus comprising a thermally isolated container/reactor in which reactions are carried out between water and flux by choosing a suitable water and flux ratio.
A further object of the present invention is directed to provide said Flux Reactivity Apparatus wherein the water temperature which rises on reacting with flux is measured accurately and precisely using a resistance thermometer/resistance temperature detector (RTD) at regular interval.
A still further object of the present invention is directed to provide said Flux Reactivity Apparatus wherein the process of reactivity measurement includes developing a co-relation to estimate the flux reactivity based on the measured temperature, which can be compared and validated with results obtained using the conventional method of sample preparation and titration.
A still further object of the present invention is directed to provide said Flux Reactivity Apparatus wherein a programmable logic controller(PLC) has been incorporated in the equipment including installed hardware and software and a display screen that shows all the relevant parameters and results.
SUMMARY OF THE INVENTION

The basic aspect of the present invention is directed to a Flux Reactivity measurement Apparatus for measuring the Reactivity of Calcined Lime and Calcined Dolomite, comprising

a steel structural frame assembly supporting a horizontal platform movable vertically up and down by the action of a cooperative hydraulic cylinder/lifting jack powered by a hydraulic power pack;

a stainless steel container removably placed on said vertically movable platform for holding water and flux therein for conducting reactivity measurement of flux;

a hopper and a chute (metal feeder) for flux addition with water inside said container,
an electrically operated mechanical geared stirrer mounted at top of the setup assembly/frame for homogenization of the water temperature during its reaction with flux;
a load cell placed at the bottom of the moving platform for the measurement of weight of empty container, weight of water and weight of flux;

a RTD (Resistance temperature detector) sensor installed in the setup assembly which is placed parallel to the stirrer and dipped into the water, for continuous and precise measurement of water temperature.

a control unit comprising a programmable logic controller (PLC) with installed programme logic for easy conduction of flux reactivity experiment, controlling measurement of temperature and weight data for estimation of flux reactivity; and a touch screen / display panel comprising graphical user interface (GUI) screen installed for data input, display of recorded data and for display of test results.

A further aspect of the present invention is directed to a Flux Reactivity measurement Apparatus wherein said stainless steel container comprising a thermally isolated double layer stainless steel (SS) container having a layer of heat insulator (glass wool) put between the two layers of container to reduce the heat loss.

A still further aspect of the present invention is directed to a Flux Reactivity measurement Apparatus wherein a holding arrangement has been provided at the top of the apparatus for holding said geared stirrer, hopper and chute, control units and RTD sensor.

A still further aspect of the present invention is directed to a Flux Reactivity measurement Apparatus wherein upward and downward movement of platform on which the container is placed is controlled using an inching switch such that the platform movement is controlled by a hydraulic jack and its movement is carried out using said inching button for small and steady movement of the platform to avoid spillage of liquid, having Guide rolls provided for smooth vertical movement of the platform.

A still further aspect of the present invention is directed to a Flux Reactivity measurement Apparatus wherein the movement of container is restricted such that the stirrer and RTD sensor do not touch the bottom of the container and upward movement of container is stopped at a place where stirrer and RTD sensors (fixed) are immersed inside water present in the SS container but the bottom of the stirrer and the RTD sensor do not touch the bottom of container and remain 30 cm above the bottom.

Another aspect of the present invention is directed to a Flux Reactivity measurement Apparatus wherein the platform containing the container is moved downward after completion of an experiment, so that sufficient gap between the top of the container and the bottom part of stirrer is maintained for ease of container removal for cleaning.
Yet another aspect of the present invention is directed to a Flux Reactivity measurement Apparatus as claimed in anyone of claims 1 to 6 wherein an execution button has been provided to start the experiment with input of starting weight of flux and water (Manual / automatic entry).

A further aspect of the present invention is directed to a Flux Reactivity measurement Apparatus wherein said GUI displays the real time data for temperature (RTD measurement), weight (Load cell measurement) and displays reaction time (using a stop watch) and having one pop up screen in which graph is drawn indicating temperature change and weight directly in real time, plotting of said graph starts with start of experiment on pressing of execution button.
A further aspect of the present invention is directed to a Flux Reactivity measurement Apparatus wherein results of the experiment are displayed on the second screen (GUI) and measured data for temperature and weight against time are stored in the PLC / HMI.

A still further aspect of the present invention is directed to a method for Flux Reactivity measurement using the Flux Reactivity measurement Apparatus comprising

(i) lowering the platform by operating the hydraulic jack;
(ii) placing the stainless steel container on platform and filling appropriate volume of water therein;
(iii) weight of empty container and added water displayed on GUI screen;

(iv) Raising the platform upward by operating the hydraulic jack so that flux feeding chute and RTD sensor are inserted at desired depth above bottom of container;

(v) addition of flux through hopper and chute with water inside container;

(vi) putting on the execution switch on control panel with input of initial weight of water and flux;
(vii) carrying out flux reactivity measurements based on the developed co-relation implemented through programme logic on the installed (PLC) comprising
(a) displaying the real time data for temperature (RTD measurement), weight (Load cell measurement) and displays reaction time (using a stop watch) on GUI screen;
(b) displaying results of the experiment are displayed on the second screen (GUI) and obtaining graph plot indicating temperature change and weight directly in real time on pop up screen;
(c) storing measured data for temperature and weight against time n the PLC / HMI/GUI.
(viii) moving the platform downward again by operating the hydraulic jack after the experiment/test is over to remove the SS container for cleaning.

A further aspect of the present invention is directed to said method wherein ratio of water to flux used during experimentation is pre determined in the range of 3 to 4.

A further aspect of the present invention is directed to a method wherein the water used is simple tap water and flux sample may be taken directly from the desired location in bulk without needing sizing or screening of sample.

The above and other objects and advantages of the present invention are described hereunder in greater details with reference to the following accompanying non limiting illustrative drawing.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1: shows the schematic front view and side view of the Flux Reactivity measuring apparatus according to present invention wherein all the components have been marked with respective reference number.
Figure 2: shows Comparative time – temperature plot for flux samples differing in reactivity.

DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS
The present invention is directed to provide a Flux Reactivity Apparatus as an experimental setup that can be used for measuring flux reactivity of fluxes used in steel manufacturing. Moreover, the equipment can be placed at desired location in the steel plant. The testing procedure has been simplified for easy operation and for obtaining results quickly. The entire experiment can be conducted within 05 minutes and flux reactivity value can be obtained within this time. The equipment can be easily and effortlessly used to obtain the reactivity values of fluxes in a very short span of time (~ 5 minutes). The calcined flux has various usage in steelmaking processes like Basic oxygen furnace, ladle furnace, electrical arc furnace, CONARC, hot metal de-sulphurisation etc. Beside this, the equipment is capable of classifying the calcinations product at calcinations kiln.

A user friendly, simple procedure of testing has been adopted to measure flux reactivity of calcined lime and calcined dolomite used as fluxing materials in steel manufacturing. The hardware and software of the system has been selected to make the system stable, robust, reliable and easy to handle. Broadly the system of the apparatus has three parts:
a) Mechanical part: It involves the overall structure(1) of the setup assembly which is mounted on castor wheels(11). A thermally isolated double layer stainless steel (SS) container(5) has been fabricated. The main structure of the equipment consists of a vertically moving platform(3), a metal feeder(9) having a hopper and a chute for flux addition, a stirrer(6), hydraulic power pack(2) operatively connected to hydraulic jack(10) for lifting the platform(3), a RTD sensor(7) system for measuring the water temperature and control units/panel(8) etc.
• Setup assembly: A light weight, robust and stable structural assembly(1) has been made of stainless steel and mild steel to hold the entire equipment as shown in Figure 1 of flux reactivity test apparatus. It is kept compact, light in weight, rigid and is easy to handle in which experiments pertaining to reactivity tests can be carried out easily and quickly. At the top of the equipment, a holding arrangement has been provided for holding the geared stirrer(6), material feeder(9) with a hopper & chute, control units(9) and RTD sensor(7).
• Double layer stainless steel container: The container(5) is only removable part in the system. This is the reactor to conduct the reaction of flux sample with tap water. To make the container(5) thermally isolated, a double layer design has been selected. A layer of heat insulator (glass wool) has been put between the two layers of container to reduce the heat loss. The container(5) is made of stainless steel and is placed on the moving platform(3) for conducting the experiment. A schematic diagram for the proposed container is given in the Sketch. The top opening between the two walls of the container are properly welded and sealed.
• Hydraulic Jack and platform: An electrically operated hydraulic jack(10) has been installed in the setup assembly for upward and downward movement of the platform(3) on which the SS container(5) is placed using a switch which allows inching movement. Guide rolls have been provided for smooth vertical movement of the platform(3). The platform(3) movement is controlled by a hydraulic jack(10) and its movement is carried out using an inching button for small and steady movement of the platform(3) to avoid spillage of liquid. It has been designed to restrict the movement of container(5) such that the stirrer(6) and RTD sensor(7) do not touch the bottom of the container(5). During the upward movement, the container(5) stops moving upward at a place where stirrer(6) and RTD sensors(7) (fixed) are immersed inside water present in the SS container(7) but the bottom of the stirrer(6) and the RTD sensor(7) do not touch the bottom of container(5) and remain 30 cm above the bottom. After completion of an experiment, the platform(3) containing the container(5) is moved downward and is taken out for cleaning. There is sufficient gap between the top of the container(5) and the bottom part of stirrer(6) for ease of container removal.
• Stirrer: A heavy duty, electrically operated mechanical stirrer(6) has been mounted in the setup assembly. This is required for homogenization of the water temperature during its reaction with flux.

b) Measuring system: A load cell(4) has been placed at the bottom of the moving platform(3) for the measurement of weight of empty container(5), weight of water and weight of flux. A RTD (Resistance temperature detector) sensor(7) is installed in the setup assembly which is placed parallel to the stirrer(6) and is used for continuous and precise measurement of water temperature.
• Temperature measuring system (RTD Probe): Real-time measurement of water temperature is carried out during experiment. A RTD (Resistance thermometer/ resistance temperature detector) probe/sensor(7) is fixed at the top of the equipment assembly and is dipped into the water as shown in Figure 1. The measured temperature is continuously monitored and displayed on the PLC screen.
• Load cells: Load cells(4) have been placed at the bottom of the moving platform(3) for the measurement of weight of empty container(5), water and flux. By using the installed load cells(5), accurate weighment of flux and water can be made.

c) Electrical part: Various control units, switches etc. have been provided in the control panel(8) of the equipment assembly.

d) The software parts: A touch screen / display panel has been installed for data input, display of recorded data and for display of test results. The necessary graphical user interface (GUI) screen has been designed and incorporated. The programme logic on the installed (PLC) has been used for easy conducting of experiment and for estimation of flux reactivity.
• PLC, software & GUI: Measurement of temperature and weight are controlled using installed PLC. The measured values are displayed on the GUI screen. For this, a touch screen panel has been installed in the control unit(8). The programme which is essential for carrying out the reactivity test has been written in the installed software. The inputs are displayed on the screen. The outputs including real time measurements (load cell and RTD) and test results are displayed. The following measures are taken for the development of GUI screens:
o Input information: Weight of flux and water (Manual / automatic entry). An execution button has been provided to start the experiment.
o Online measurement of time, temperature & weight: GUI displays the real time data for temperature (RTD measurement), weight (Load cell measurement) and displays reaction time (using a stop watch). There is one pop up screen in which graph is drawn indicating temperature change and weight directly in real time. The plotting of graph starts with start of experiment (pressing of execution button).
o Outputs: The results of the experiment are displayed on the second screen (GUI).
o Storage of data: The measured data for temperature and weight against time are stored in the PLC / HMI.

The testing procedure has been simplified for easy operation and for obtaining results quickly. The entire experiment can be conducted within 05 minutes and flux reactivity value can be obtained within this time.

The method of obtaining the Flux Reactivity of calcined lime and/or calcined dolomite as achieved through the apparatus and procedure according to present invention is illustrated through the following example I:

Example I:

• Collect the bulk quantity sample from bunker or transferring belt.
• The sample will be weighed by putting it on platform and placed in the hopper. The reading will be fed to the system for calculating and display the weight of required water.
• Place the empty container and add the required water as displayed on GUI screen.
• Move the platform upward so that RTD sensor and mechanical rotor will be immersed in water at desired depth and above bottom of container
• Start the execution switch on control panel after feeding of initial weight of water and flux. Immediately, flux will be released from the hopper to react with water.
• The water temperature will increase gradually and it will be continuously monitored by the RTD sensor. The graphs for the increase in water temperature is shown in Figure:2
• The value of the flux reactivity will be calculated from the co-relation as installed in the programmed logic. The reactivity value is co-related by following method:

Flux Reactivity = ƒ (?T, Wwater , Wflux , t)
Where,
?T : Rise in water temperature
Wwater : Weight of water taken
Wflux : Weight of flux taken
t : Reaction time

• The value of the flux reactivity as measured by the apparatus has been validated by measuring it using the traditional titration method as given in Table: 01.

Table 1: Flux reactivity as obtained by conventional titration method and those obtained from new methodology

Flux Reactivity Value Expt 01 Expt 02 Expt 03 Expt 04 Expt 05 Expt 06 Expt 07
Conventional Method 346 386 386 314 366 305 297
New Methodology 357 372 368 324 328 315 312

The main advantages of the innovative process implemented through the Flux Reactivity apparatus developed according to present invention are as follows:
• Cumbersome chemical laboratory is not required. No chemical reagent other than water is required.
• No time consuming sample preparation is required. The sample may be taken directly from the desired location in bulk. No sizing or screening of sample is required.
• The testing can be conducted using normal tap water.
• A ratio of water to flux of 3 to 4 is pre determined and used during experimentation.
• The reactivity analysis can be carried out at shop floor near to steelmaking furnace.
• The operator of the steelmaking furnace may conduct the experiment and obtain reactivity values within 5 minutes.
• Due to ease in conducting the testing, multiple analyses can be carried out depending upon the requirement.
• The measurement of flux reactivity prior to its addition in steelmaking process may help the operator in taking necessary corrective steps for steelmaking.
• No skilled manning is required for conducting experiments with the present setup whereas chemical titration and analysis is needed to be done by a skilled personnel in the conventional method

The present invention thus relates to conceptualization, design and development of a flux Reactivity apparatus as an experimental apparatus for measuring reactivity of fluxes i.e. calcined lime and calcined dolomite used in steel manufacturing process. This apparatus has great industrial applicability in steel industry and in calcinations plants. The calcined flux has various usage in steelmaking processes like Basic oxygen furnace, ladle furnace, electrical arc furnace, CONARC, hot metal de-sulphurisation etc. Beside this, the equipment is capable of classifying the calcinations product at calcinations kiln. The experiments may be conducted for as received sample of fluxes in bulk quantity at convenient location like calcinations kiln or steel processing unit by reacting it with normal tap water in a specially designed double layer stainless steel container. The weight of flux & water and increase in water temperature due to chemical reaction are measured precisely and accurately to calculate the flux reactivity based on the developed co-relation. The procedure is simple and user friendly that can be used to conduct experiments within a short span of time ~ 5 minutes. The measurement of real time flux reactivity will be helpful to the operator in taking necessary corrective steps for steelmaking. The invented process eliminates the requirement of skilled man power and chemical laboratory. The installed software, PLC, hydraulic jack etc makes the system independent and complete in all respect.