U.S. patent number 3,720,404 [Application Number 05/100,666] was granted by the patent office on 1973-03-13 for system for controlling carbon removal in a basic oxygen furnace.
This patent grant is currently assigned to Westinghouse Electric Corp.. Invention is credited to James T. Carleton, Norman R. Carlson, Richard E. J. Putman.
United States Patent |
3,720,404 |
Carlson , et al. |
March 13, 1973 |
SYSTEM FOR CONTROLLING CARBON REMOVAL IN A BASIC OXYGEN FURNACE
Abstract
Both low and high carbon steels are produced in a basic oxygen
furnace controlled by a system which employs a direct sampler
operated at an adequately early predetermined time during the
oxygen blow. Endpoint carbon level is controlled as a result of
calculations made from the sample carbon level and waste gas
measurements of post sample time carbon removal. The carbon control
is made compatible with other endpoint controls.
Inventors: |
Carlson; Norman R. (Export,
PA), Putman; Richard E. J. (Penn Hills, PA), Carleton;
James T. (Pittsburgh, PA) |
Assignee: |
Westinghouse Electric Corp.
(Pittsburgh, PA)
|
Family
ID: |
26797420 |
Appl.
No.: |
05/100,666 |
Filed: |
December 22, 1970 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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649236 |
Jun 27, 1967 |
3565606 |
|
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Current U.S.
Class: |
266/79; 266/80;
266/86; 266/243; 75/375; 266/83; 266/87 |
Current CPC
Class: |
C21C
5/30 (20130101); G01N 1/125 (20130101) |
Current International
Class: |
C21C
5/30 (20060101); G01N 1/12 (20060101); C21c
005/30 () |
Field of
Search: |
;266/13,15,34R,34L,34LM,35 ;75/60 ;73/23R,354 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
automation, February 1963. TJ 212.A9. pp. 78-82..
|
Primary Examiner: Annear; R. Spencer
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a division of Ser. No. 649,236 now U.S. Pat.
No. 3,565,606 entitled "Method For Controlling Carbon Removal In A
Basic Oxygen Furnace", filed on June 27, 1967 and assigned to the
present assignee.
Claims
What is claimed is:
1. A system for controlling the operation of a basic oxygen furnace
having an oxygen lance operable to decarburize the bath of molten
metal within said furnace, said control system comprising means
associated with said furnace for measuring the instantaneous carbon
level and flow rate of waste gas from the furnace, means for
computing bath carbon removal from said bath in relation to the
waste gas measurements, means for computing an estimated bath
carbon content for said bath in relation to the carbon removal
calculation and an initial carbon content estimate of the charge,
means associated with said furnace for obtaining a sample from the
bath in the furnace prior to a desired process endpoint, means for
operating said sample obtaining means at a predetermined process
time point during the time period of the decarburizing oxygen blow,
means for determining the time point at which the sample is
obtained on the basis of the computed value of said estimated bath
carbon content, means for developing a carbon level signal
representing the carbon level of said sample, means for computing
the bath carbon content at the sampling time point on the basis of
said carbon level signal, and means for computing the bath carbon
content from the sampling time bath carbon content and the carbon
removal computed from the sampling time point.
2. A basic oxygen furnace control system as set forth in claim 1
wherein said process time point is determined in a predetermined
manner in relation to the estimated bath carbon content computation
and the specified endpoint carbon level and wherein said computing
means are included in a programmed digital computer system.
Description
BACKGROUND OF THE INVENTION
In the basic oxygen steelmaking process, a lance is controllably
positioned to feed a controlled amount of oxygen into the basic
oxygen vessel principally for the purpose of heating and
decarburizing the metal bath. Since carbon level significantly
affects the properties of steel product, it is necessary that the
carbon level of steel made in a basic oxygen furnace (BOF) be
controlled as in the case of other types of steelmaking furnaces
and further that the carbon control be compatible with other BOF
controls such as an endpoint temperature control placed on the
bath. By the term carbon level, it is meant herein to refer to the
weight percentage of carbon in a quantity of steel. By the term
carbon content, it is meant herein to refer to the weight of carbon
in a quantity of steel. When the weight of a quantity of steel is
known, the carbon content can readily be determined from the carbon
level and vice versa.
In commercial practice, it is desirable that carbon control be
effective during the BOF steelmaking process to produce specified
carbon level steel accurately at the process endpoint. By the
terminology process endpoint, it is herein intended to refer to a
point in time just prior to vessel turndown. Present practice
typically requires turning the vessel down to its test position
after the oxygen blow and spoon sampling the bath and subsequently
taking post endpoint procedures such as carbocoke adding or renewed
oxygen blowing which may be used to correct a low or high bath
carbon level. The extent to which post process endpoint correction
is required depends on the character of the carbon control itself
as well as any special circumstances which may have affected the
effectiveness of the carbon control as operated for a particular
heat. With efficiency in process carbon control, post process
endpoint carbon correction is minimized or eliminated and maximum
furnace utilization and productivity is made possible in the fast
BOF steelmaking process.
As disclosed in U.S. Pat. No. 3,181,343 entitled Method and
Arrangement for Measuring Continuously the Change of the Carbon
Content of a Bath of Molten Metal and issued to J. D. Fillon on May
4, 1965, one means for effecting carbon control is to collect the
process waste gas in a hood over the BOF vessel and then determine
the amount of carbon contained in the outflow gas since it is known
that the carbon in the gaseous products of the vessel reactions is
substantially equal to the carbon removed from the steel bath by
the oxygen blow. Typically, the waste gas flow rate and the
instantaneous carbon level of a sample flow are determined before
the waste gas is depolluted and released to the atmosphere.
The total gaseous carbon outflow in any selected time interval is
calculated by integration of the instantaneous gaseous carbon
outflow rate over the time interval. The carbon integration is
normally started when the oxygen blow is initiated, and the
integral is subtracted from an estimated initial carbon content of
the steel bath to provide updated bath carbon content values
subject to a measurement delay (usually about 40 seconds). When the
estimated residual carbon in the bath reaches the specified value,
the oxygen blow and the decarburizing reaction are substantially
simultaneously terminated.
Another carbon control method is the oxygen balance technique. In
this approach, a calculation is made of the total oxygen required
to oxidize predetermined quantities of carbon, silicon, manganese,
phosphorus, sulfur and slag in the bath. The oxygen blow is
terminated when the total blown oxygen equals the calculated
value.
Both of the foregoing methods are characterized with endpoint
carbon accuracy problems since both depend upon an initial and
often relatively inaccurate estimate of carbon content in the steel
bath. The accuracy of the initial carbon estimate is adversely
affected by factors including: (1) scrap of unknown carbon content
is usually charged in the BOF vessel; (2) it is typically difficult
to obtain a meaningful sample of molten iron for chemical analysis
before the iron is poured from the ladle into the BOF vessel; (3)
during pouring of the molten iron, an unknown quantity of carbon is
lost in graphitic or other form.
One recently developed BOF process improvement for low carbon heats
involves an empirically determined dynamic relationship between the
path carbon removal rate and the bath carbon level. Generally,
under controlled oxygen blow conditions, the carbon removal rate
tends to be constant until the carbon level has dropped to or near
a predetermined value such as about 45 points (0.45% C). Carbon
removal then characteristically decelerates, that is the carbon
removel rate decreases.
From the dynamic carbon level removal rate relationship, the bath
carbon level is relatively accurately determined independently of
the initial carbon estimate during the decelerating part of the
decarburizing process and the specified endpoint carbon level is
usually reached with substantially improved accuracy. However, the
dynamic control is characterized with decreasing accuracy with
increasing endpoint carbon level specifications. Further, endpoint
carbon control above 25 points is virtually impossible because of
restrictions imposed by the carbon level location of the knee of
the carbon removal rate curve in combination with the time delay
associated with waste gas measurements. Accordingly, although the
dynamic control method can in general produce more accurately low
carbon steels than can the initial carbon estimate methods, none of
these methods are adaptable to reliable production of relatively
accurate higher carbon steels such as structurals (about 30 points
C or more) or railing (about 100 points C or more).
SUMMARY OF THE INVENTION
In accordance with the broad principles of the present invention,
an improved BOF carbon control system includes means for detecting
the amount and rate of carbon removed in the form of gaseous
products from the bath in a BOF vessel during oxygen blow and means
for computing bath carbon content and if desired other process
variables from the carbon removal and other input data. A direct
sampler is operated preferably during the decarburizing oxygen blow
at an adequately early sampling time point to produce a sample for
analysis.
On the basis of the sampling time and the sample carbon level data,
the computing means makes predetermined calculations for highly
accurate bath carbon removal control. When the bath carbon level
reaches the specified value within a wide range of selectable
values including low and high carbon values, the decarburizing
oxygen blow is terminated unless endpoint temperature or other
endpoint conditions require its continuance.
Reference is also made to the following issued U.S. patents
assigned to the present assignee:
1. U.S. Pat. No. 3,503,259 entitled A Direct Sampler Adapted For
Use In a Basic Oxygen Furnace, filed by J.T. Carleton, N.R.
Carlson, and R.E.J. Putman on June 27, 1967;
2. U.S. Pat. No. 3,540,879 entitled Improved Method For Controlling
Phosphorus Removal In a Basic Oxygen Furnace, filed by N.R. Carlson
on June 27, 1967.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a basic oxygen furnace with an oxygen lance and a
direct sampler provided therein; and
FIG. 2 shows a BOF control system arranged in accordance with the
principles of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
More specifically, there is shown in FIG. 1 a basic oxygen furnace
10 including a refractory lined vessel 12 which is trunnion
supported for rotation from the illustrated vertical position to
various inclined positions or the horizontal position about a
reference axis 14. When the vessel 12 is to be charged at the
startup of a heat, it is tilted to a predetermined extent and scrap
metal scheduled for the heat is placed therein. Next, a preselected
amount of molten iron is poured from a ladle through a mouth 16 of
the vessel 12.
Considerations of thermochemical balance enter into choosing the
ratio of scrap to molten metal to be used in charging the BOF 10.
In a typical case, the total charge might be about 66 percent hot
metal and about 28 percent scrap. In this manner, conditions are
established which enable the bath to be controlled more easily to
reach the specified endpoint chemistry and endpoint temperature at
the same time. Basic slag forming materials such as lime as well as
other preselected materials are usually placed in the vessel 12
just after it has been uprighted and the oxygen blow has been
started. Charge calculation duties would normally be assigned to
the computer.
When the vessel 12 is charged and located in its upright position,
it is disposed under a hood 18 which acts as a collecting agent for
gases emitted from the interior of the vessel 12 during processing
of the bath. A suitable clearance such as a foot or so is provided
for vessel rotation relative to the hood 18. Collected gases are
directed through ducting 20 or the like for eventual discharge to
the atmosphere. Instrumentation for the outflow gases is
appropriately mounted in relation to the gas outflow path.
An oxygen lance 22, cooled by water or other coolant flow in a
conventional lance coolant system, is disposed for vertical
movement through the hood 18 so that the lance tip 24 can be
disposed at various vertical positions within the vessel 12. A
conventional cable hoist operated by a motor driven drum and a
positioning control system (not indicated in FIG. 1) are provided
for raising and lowering the oxygen lance 22.
Present BOF operating practice typically includes positioning the
oxygen lance tip 24 about 5 feet or so above the quiescent slag
surface during full blow conditions in order to produce a direct
decarburizing oxygen supply at a predetermined rate (such as 25,000
cubic feet per minute per 350 tons of bath). Simultaneously, other
elements such as silicon, phosphorus, manganese and sulfur are
oxidized and removed by accumulation in the slag or by gas outflow.
The total processing time from charging to the process endpoint
typically would be about 25 minutes.
When a soft blow is to be effected for some predetermined purpose,
the oxygen flow is materially cut back and the lance tip 24 may be
placed at the full blow position but it is usually raised to some
higher position. For example, if it is desired to increase the
amount of iron oxide in the slag, the oxygen flow would be cut back
and the lance tip 24 would be placed at a predetermined soft blow
position between the slag surface and the vessel mouth 16 where it
creates a swirling oxygen atmosphere above the bath. The quantity
of oxygen flow in any particular lance position is controlled as
described in connection with FIG. 2.
In the full blow lance operation, direct decarburization occurs as
already indicated. In soft blow or raised lance operation,
decarburization can occur indirectly. In any case, the terminology
decarburizing oxygen blow is herein intended to include the full
blow and other blow operations in which direct decarburization
occurs. Indirect decarburizing blows such as slag building soft
blows or slag building high lance-full flow blows are thus excluded
from the definition.
There is also included in the BOF 10 a secondary lance or a direct
sampler lance 26 which is operated through the hood 18 in
accordance with the principles of the present invention by a cable
hoist from a motor driven drum and a positioning control (not
indicated in FIG. 1). A sampler tip 28 of the sample lance 26 is
controllably positioned at an appropriate location within the bath
where an in process sample of the molten metal is obtained at a
predetermined process time point and quickly withdrawn for
analysis. In this manner, a bath carbon content or level
determination can be directly made as opposed to the indirect
determination made from analysis of outflow gases through the hood
18. Further, the direct carbon determination can be and preferably
is made during full oxygen blow conditions to provide a basis for
accurate endpoint control of the steel heat and maximized
productivity.
To function as described, the sampler lance 26 must be operable to
withstand a flaming atmosphere temperature of 3500.degree. F. or
more and immersion in molten slag and molten steel at about
2900.degree.F. for a period as great as one-half minute or more.
Operability requires that the sampler lance 26 be withdrawn intact
and that a withdrawn sample contained in the sampler tip 28 be
solidified without oxidation. A sampler lance and sampler tip or
device adequate for the purposes described is disclosed in the
previously referenced BOF sampler copending application. Other
suitable sampler lances and devices can also be employed if
desired.
In FIG. 2 there is shown a control system 30 arranged to operate
the BOF 10 with accurate endpoint carbon control in accordance with
the principles of the invention. It includes a conventional digital
computer system 32 which is provided with a programming system
adapted to provide the data processing required for controlled
operation of the BOF 10. Suitable display and print out equipment
is provided as indicated and data input equipment 34 including for
example a teletypewriter is provided for manual entry of data as
required.
Prior to charging the BOF vessel 12, an estimate is made of the
initial carbon content of at least the molten metal to be processed
and the estimate is placed in the computer memory. Usual estimating
calculation procedures are employed, including for example the
taking of a sample of the molten iron, analyzing the iron sample
for carbon level, determining the total weight of the molten iron,
and computing the result from the sample and weight data. When a
scrap estimate procedure is employed, the scrap carbon estimate is
added to the molten iron carbon estimate.
After furnace charging, the oxygen lance 22 is lowered to its full
blow position under the control of a position control 36. Start and
stop oxygen lance operation and position setpoint control for the
position control 36 is provided by the digital computer system 32,
or these controls can be provided manually as indicated. An oxygen
flow control 38 regulates the rate at which oxygen flows through
the lance 22, and it is also controlled by the digital computer
system 32, or if desired by manual operation as indicated.
When the oxygen lance 22 starts full blow decarburizing operation,
the carbon integration is begun. Shortly thereafter, any additional
charge materials are entered into the vessel 12 from a hopper
19.
A conventional gas sampling system 40 draws a sample flow from the
outflow gas stream and a conventional carbon detector 42 operates
on the sample flow to indicate continuously the instantaneous
sample carbon level for entry into the computer system 32. Another
conventional detector 44 employing a suitable stack mounted orifice
plate or other means continuously determines the flow rate of the
outflow gas for computer entry. The computer system 32 processes
the sample carbon level and flow rate data to calculate the carbon
integral with a suitable deduction made for aspirant air flowing
into the hood 18. The programming system ordinarily would provide
for the integration to be updated periodically, such as every 5
seconds.
Since the carbon integral equals the amount of carbon removed from
the metal bath, subtraction of the carbon integral from the
estimated initial carbon content provides an updated estimate of
the bath carbon content. However, the time at which the updated
estimate is determined occurs subsequently to the process time
point to which the estimate applies. The time delay is due
principally to the time involved in collecting, sampling, and
measuring the waste gases. As already indicated the measurement
time delay typically is about 40 seconds. Thus, a current estimate
of the bath carbon content is obtained by subtracting from the
updated estimate a predicted amount of carbon removed during a time
period equal to the measurement time delay at the carbon removal
rate characteristic of the time part of the process involved.
When the bath carbon content or level estimate reaches a
predetermined value, a steel sample is obtained from the bath by
operation of the direct sampler lance 26 preferably during the
continuation of the full decarburizing oxygen blow operation of the
oxygen lance 22. A sampler position control 46 is operated by the
computer system 32 for start and stop functions and for the
establishment of position setpoints. The position control 46 can
also be operated manually as indicated.
As soon as the steel sample is obtained, it is withdrawn from the
BOF vessel 12 by raising the sampler lance 26 through the hood 18.
The sample is then placed in an analyzer 48, such as a spectrometer
or a Leco analyzer, and a carbon level analog signal is developed
and entered into the computer as indicated by the reference
character 50. In other cases, the results of analysis may be
visually determined and manually entered into the computer through
the data input 34.
The point in time at which the bath sampling is made is adequately
early in the decarburizing oxygen blow to allow time for analysis
of the sample, processing of the sample results, and initiation and
completion of control actions which might be required before the
process endpoint. In a typical BOF process, the full oxygen blow is
continuously maintained until the carbon endpoint is reached. Under
continuous full blow operation, about 90 carbon points are removed
per five minutes of full oxygen blow when the bath carbon level is
above the knee of the previously mentioned carbon removal rate
curve. Since a time period of about 5 minutes between bath sampling
and the estimated carbon endpoint time is ordinarily more than
adequate to meet the process control needs, the bath sampling time
can be and, where simplified programming is desired, preferably is
fixed to correspond to the point in time at which the estimated
bath carbon content is a fixed number of points (such as 90 points)
above the specified endpoint carbon level.
Generally, however, there is an allowable time range during which
the sample can be taken to provide timely results for process
control, and the computer can therefore be programmed with a fixed
sampling time as just indicated or it can be programmed in
accordance with preselected constraints and rules which define the
point in time at which the bath sample is drawn within the allowed
time period. In any case, the sample time point definition is
preferably somewhat conservatively drafted thereby allowing for
possible overestimation of initial carbon content.
If the oxygen flow rate or the oxygen lance position is varied for
some control purpose or other reason during the decarburization of
the bath by the lance 22, the decarburization process is slowed
down or interrupted. The computer can be programmed to take such
effects into account automatically in defining the sampling time
point.
At the instant the steel sample is drawn by the sampler lance 26, a
timing switch 52 is operated to provide an accurate definition of
the sampling time point for the computer. The switch 52 can be
actuated by the closing of two contacts included in the sampler
lance tip 28 as indicated in the aforementioned BOF sampler
copending application.
The carbon integration is restarted at the sampling time point,
and, with the steel sample carbon level data entered into the
computer, the bath carbon content is thereafter accurately
determined by subtraction of the new carbon integral from the bath
carbon content at the sampling time. When the calculated bath
carbon content or level (including the allowance for measurement
time delay) reaches the specified endpoint value, the decarburizing
oxygen blow is terminated.
Endpoint temperature control is made compatibly with the endpoint
carbon control described herein. For example, a detector 54 such as
a device known in the trade as a bomb thermocouple can be dropped
into the metal bath to produce a real temperature reading for
computer entry at a process time point during the oxygen blow
corresponding to that at which the bath is about 27 carbon points
above its specified end-point carbon level. This point in time is
selected since it allows ample time for insertion of coolant such
as scrap if it is required prior to termination of the
decarburizing oxygen blow.
The programmed computer calculates the expected bath temperature
rise during the continuation of the decarburizing oxygen blow up to
the carbon endpoint time projected from the post sampling carbon
content calculation. If the projected endpoint temperature is too
high, a demand for coolant is signalled and scrap or other coolant
is entered into the BOF vessel 12 in the required amount. If the
projected endpoint temperature is too low, it is then necessary to
provide decarburizing or soft oxygen blow beyond the carbon
endpoint until the endpoint temperature is reached. The heat can
then be accepted at the resulting carbon level, or partial or full
correction of a resulting low carbon heat can be made by
introduction of carbocoke or the like into the molten metal when it
is tapped into a ladle.
Any other required additives such as ferromanganese, aluminum or
ferrophosphorus are also added at tapping. If a sampler lance 26
similar to that described in the aforementioned copending BOF
sampler application is employed, the actual bath temperature
reading to be used for predicting the endpoint temperature can be
obtained by the sampler lance 26 at the bath sampling time point
and the described bomb thermocouple procedure is eliminated.
By use of the control system of the invention, accurate carbon
endpoint levels are realized for low and/or high carbon BOF heats
prior to process endpoint thereby effecting improved efficiency and
productivity. Sole reliance on estimated initial carbon contents in
controlling the BOF process is eliminated since an accurate in
process bath carbon content reference point is established through
the controlled operation of the sampler lance 26.
* * * * *