Patent Application
20220275936
Example embodiments generally relate to a cooling system for cooling or reducing the temperate of exhaust gases created within a steel production system.
A system used for the production of steel may include several components, such as a furnace and ductwork, that are water cooled in order to extend the operating life of the respective component. In this regard, the components in the system operate under high temperatures and extreme mechanical stress. Thus, in order to extend the operating life of the system, the components may be or have portions that are water-cooled to reduce or prevent thermal, chemical, and mechanical stress of the components.
The cooling system described herein may be configured to provide water to water-cooled components of a steel production system. In this regard, a furnace of the steel production system produces exhaust gases during operation, and these exhaust gases are exhausted to components of the steel production system such as an exhaust hood, a dropout box, and a hot gas duct. These exhaust gases need to be cooled in order to reduce stress on the steel production system and to allow for the exhaust gases to be filter effectively by filter components of the steel production system. In order to cool exhaust gases produced by a furnace of the steel production system, a cooling system may be configured to supply water for cooling exhaust gases received by components of the steel production system. The cooling system may also be configured to maintain a defined temperature of the water that ensures the efficient and effective cooling of the exhaust gases. The cooling system is designed to also reduce erosion and corrosion that may occur to the components of the steel production system.
Thus example embodiments may provide a cooling system configured to cool exhaust gases exiting a furnace of a steel production system through an exhaust hood, a dropout box, and a hot gas duct of the steel production system. The cooling system may include an inlet configured to receive water from a water system The outlet configured to route the water from the cooling system. The cooling system may further include a first water line configured to supply the water to the exhaust hood of the steel production system for cooling the exhaust gas received therein, and a second water line configured to supply the water to the dropout box of the steel production system for cooling the exhaust gas received therein. The cooling system may also include a third water line configured to supply the water to the hot gas duct of the steel production system for cooling the exhaust gas received therein, and each of the first water line, the second water line, and the third water line may be operably coupled between the inlet and the outlet of the cooling system. The cooling system may also include a controller configured to control flow returning to the water system and maintain a defined temperature of the water circulating within the cooling system.
A further example embodiment may provide a method of cooling exhaust gases received by components of a steel production system. The method may include causing water to circulate within water lines of a cooling system for the steel production system in order to cool the exhaust gases received by the components. The method may also include monitoring operating parameters of the cooling system to ensure a defined temperature of the water circulating within the water lines is achieved. The method may additionally include executing a program to adjust or maintain the operating parameters of the cooling system to achieve the defined temperature.
Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
Some example embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all example embodiments are shown. Indeed, the examples described and pictured herein should not be construed as being limiting as to the scope, applicability or configuration of the present disclosure. Rather, these example embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like reference numerals refer to like elements throughout. Furthermore, as used herein, the term “or” is to be interpreted as a logical operator that results in true whenever one or more of its operands are true.
Steel can be made by either refining liquid iron or is produced by melting and refining iron and steel scrap.
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Due to the high temperature under which the furnace 20 operates and the composition of the exhaust gases from the furnace 20, the furnace 20 and other components of the system 10 (e.g., exhaust hood 30, exhaust duct 40, dropout box 50, and hot gas duct 60) may be subject to thermal, chemical, and mechanical stresses. As mentioned above, the exhaust gases may have a high temperature, include chemical elements, and contain particles. Thus, the exhaust gas from the furnace 20 may lead to corrosion, erosion, and general stress on the components of the system 10. In order to extend the operational life of the furnace 20 and the other components of the system 10 and reduce the stress experienced by the system 10, components of the system 10 may be configured to receive a heat transfer fluid (e.g., water) in order to cool the stream of exhaust gases exiting the furnace and thereof reduce the stress caused by the exhaust gases on the components of the system 10 while not compromising the intent of filter components 70.
In this regard, the furnace 20, the exhaust hood 30, the exhaust duct 40, the dropout box 50, and the hot gas duct 60 may be or include components that are cooled (e.g. water) or a heat transfer fluid. While water is described herein as the medium used for cooling, other heat transfer fluids known in the art of cooling the gasses may also be used in a similar manner as described herein.
Each of the furnace 20, the exhaust hood 30, the exhaust duct 40, the dropout box 50, and the hot gas duct 60 may include or be formed from plates or pipes that are configured to receive water in order to effectively cool the exhaust gases received by the respective component. Thus, the water may flow through the pipes and plates of each of the furnace 20, the exhaust hood 30, the exhaust duct 40, the dropout box 50, and the hot gas duct 60 in order to reduce the temperature of the exhaust gases exiting the furnace 20. For example, the components of the furnace 20 located above the smelting area 24 (i.e., the side panels 26 and the roof 28 of the shell 22) of the furnace 20 may be water cooled by plates or tubes configured to receive cooling water. Similar to the side panels 26 and the roof 28 of the furnace 20, the exhaust hood 30, the exhaust duct 40, the dropout box 50, and the hot gas duct 60 may also include a plurality of plates or tubes to receive and direct the water around the respective component to control the temperature to a design within the system 10.
Notwithstanding that water-cooled components within system 10 have reduced failure caused by the temperature and composition of the exhaust gases leaving the furnace 20, systems for supplying cool water to these cooling plates and tubes are known by one of ordinary skill in the art for being unable to maintain a consistent defined temperature that efficiently and effectively reduces operational stress on the system 10 due to the exhaust gases released from the furnace 20. Furthermore, the exhaust gases have been known by one of ordinary skill in the art to also cause failure of the plates and tubes due to the cooling water received therein being unable to effectively cool the exhaust gases. When the plates or tubes configured to transport the water fail, water may then leak into the component that the plates or tubes are cooling. Furthermore, the plates and tubes downstream in the water circuit, beyond the location of leakage, do not receive the water to the designed criteria. In particular, the variable temperature ranges of the water received via the plates or tubes may lead to problems such as wear, corrosion, and other damage on the plates and tubes themselves.
Accordingly, example embodiments described herein may include a cooling system 100 that is configured to supply cooling water to the system 10 at a defined, maintainable temperature. Water temperatures of known cooling systems typically have a high variability due to, for example, a water pump's distance from the system 10 and the batching of the steel making process. When the water supplied to the system 10 is too cool, condensation can build up on the plates and tubes. The condensation creates acidic conditions, such as sulphuric and chloric acids, beneath dust deposits that adhere to the tubing and plates. Corrosion then gradually attacks the tubing or plates, resulting in tube or plate failures and insertion of water directly into the exhaust gas stream causing safety issues for the system 10. Additionally, when the water is too hot, superheated vapors can form thereby creating a laminar flow on a surface of the plates or tubing and reducing the effectiveness of the cooling capabilities of the respective plates or tubes. Accordingly, the cooling system 100 further described herein reduces the fluctuations in the water temperature of the water supplied to the plates and tubes thereby reducing corrosion and erosion and further extending the operational life of the components of the system 10.
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The exhaust hood water line 106 may be configured to supply water to the furnace 20, the exhaust hood 30, the exhaust duct 40, or combination thereof in order to effectively and efficiently cool exhaust gases received therein. As shown in
In some cases, each of the water lines 106, 107, 108 may include one or more check valves disposed therein to allow water flow through a respective water line 106, 107, 108 in one direction and prevent flow from returning in the opposite direction thereby preventing the backflow of water in the cooling system 100 towards inlet 102.
As mentioned above, the cooling system 100 may be configured to maintain the water temperature of the cooling system 100 at defined temperature (e.g., 60-70° C.) suitable for cooling the exhaust gases and reducing or preventing corrosion and erosion of the plates and tubes of each of the components of the system 10. In order to maintain a defined water temperature, the cooling system 100 may also include a recirculating pump 120 and one or more flow control valves 130. The recirculating pump 120 may be located on a pump water line 109. The pump water line 109 may be operably coupled to the hot gas duct water line 109. In this regard, a first end of the pump line 109 may be operably coupled to a portion of the hot gas duct water line 108 located between the inlet 102 of the cooling system 100 and the water inlet 62 of the hot gas duct 60. A second end of the pump line 109 may be operably coupled to a portion of the hot gas duct water line 108 between the outlet 104 of the cooling system 100 and the water outlet 64 of the hot gas duct 60. Under certain circumstances defined herein, the recirculating pump 120 may be configured to recirculate water received from the water lines 106, 107, 108. Similar to water lines 106, 107, 108, the pump line may also include one or more check valves 110. Moreover, it should be appreciated that water may be introduced to other portions of the system 10 as well in alternative embodiments. In this regard, cooling may be provided at any location where acid may be formed as a chemical reaction in the system 10.
The cooling system 100 may also include one or more flow control valves 130. As shown in
Furthermore, the cooling system 100 may include sensors configured to monitor flow rate, temperature, pressure, or any combination thereof of the water in the cooling system 100. In this regard, the sensors may be configured to monitor the operating parameters of the cooling system 100. In this regard, to monitor the water or heat transfer fluid circulating in the cooling system 100, a sensor assembly 140 may be located at a location in the cooling system 100 to monitor one or more of the temperature, the pressure, or the flow rate of the water circulating within the cooling system 100. As shown in
The cooling system 100 may also include a controller 200 configured to monitor operational parameters under which the cooling system 100 is operating.
The controller 200 may include processing circuitry 210 (e.g., a processor 212 and memory 214) configured to store instructions and execute the same in order to control the cooling system 100. In this regard, the processing circuitry 210 to may be configured to process data generated by and relating to the cooling system 100 in conjunction with operating conditions of furnace 20 (e.g., operational parameters or sensor information). In some cases, the processing circuitry 210 may be configured to perform data processing, control function execution, or other processing and management services according to an example embodiment. However, in other examples, the processing circuitry 210 may be configured to manage extraction, storage, or communication of data received at the processing circuitry 210. Thus, for example, the controller 200 may be understood to execute one or more algorithms or programs defining a cooling process of the cooling system 100. The controller 200 may be configured to receive inputs from an operator of the cooling system 100 regarding desired operational parameters of the cooling system 100 (e.g., temperature, pressure, flow rate) in order to provide instructions or controls to the components of the cooling system 100.
In some cases, the controller 200 may include a user interface 220 that allows for the operator of the cooling system 100 to program the desired or defined parameters of the cooling system 100. Thus, the user interface 220 may be in communication with the processing circuitry 210 to receive an indication of a user input at the user interface 220 or to provide an audible, visual, tactile or other output to the user. As such, the user interface 220 may include, for example, a display, one or more switches, lights, buttons or keys (e.g., function buttons), or other input/output mechanisms.
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Each of the system manager 234 and the communications manager 232 may employ or utilize components or circuitry that act as a device interface 230. The device interface 230 may include one or more interface mechanisms for enabling communication with other devices (e.g., the recirculating pump 120, the flow control valve 130). In some cases, the device interface 230 may be any means such as a device or circuitry embodied in either hardware, or a combination of hardware and software that is configured to receive or transmit data from/to components in communication with the processing circuitry 210.
In some embodiments, the system manager 234 may be any means such as a device or circuitry embodied in either hardware, or a combination of hardware and software that is configured to receive or transmit cooling system data (e.g., operational parameters). The system manager 234 may monitor the operational parameters of the cooling system 100 and enable the system manager 234 to implement operational, safeguard, or protective functions as appropriate. These functions may be implemented based upon examination of cooling system data and comparison of such data to various defined thresholds or limits. Thus, the cooling system data may, in some cases, be acted upon locally by the system manager 234.
The system manager 234 may receive the cooling system data (e.g., operation parameters) from the sensor assemblies 140, the flow control valve 130, the recirculating pump 120, or combination thereof. The cooling system data may include, for example, information indicative of temperature, pressure, or flow rate of the water circulating within the cooling system 100 or the status of the flow control valve 130 or the recirculating pump 120 at discrete intervals, continuously, or at discrete times.
Thus, it should be understood that the controller 200 may be configured to receive inputs descriptive of the desired or defined temperature, flow rate, or pressure of the cooling system 100 (e.g., via the user interface 220) in order to provide instructions or controls to the components of the cooling system 100 to effectively control the cooling of the components of the system 10. For example, the controller 200 may be configured to execute various programs in order to ensure that the temperature of the cooling system 100 is maintained at the desired temperature. Accordingly, the controller 200 may execute a cooling program, a heating program, or a maintenance program in order to maintain the defined water temperature of the cooling system 100, or in other words, to facilitate effective cooling of the exhaust gases from the operating conditions of furnace 20. Therefore, the controller 200 may be understood to execute one or more algorithms defining the cooling process for the cooling system 100.
If the controller 200, based on data received from the sensor assemblies 140, determines the temperature of the water within the cooling system 100 needs to be increased in order to achieve or maintain the defined temperature of the cooling system 100, the controller 200 may be configured to run the heating program. In the heating program, the controller 200 may be configured to cause the flow control valve 130 of the cooling system 100 at 108 to fully close and the recirculating pump 120 to become operational. When the flow control valve 130 is closed and the recirculating pump 120 is operational, the water in the cooling system 100 at 108 is prevented from leaving the cooling system 100 via the outlet 104. Rather, the water recirculates causing the temperature of the water to increase. In some cases, the controller 200 may be configured to start the cooling system 100 in the heating program in response to the cooling system 100 initially receiving water from the water pump 150.
Furthermore, based on the operational data or parameters received from the cooling system 100 (e.g., data from the sensor assemblies 140), the controller 200 may determine the temperature of the water needs to be decreased in order to achieve or maintain the defined temperature of the cooling system 100 at 108. Thus, in this case, the controller 200 may be configured to run the cooling program. In the cooling program, the controller 200 may be configured to cause the flow control valve 130 to fully open and also restrict the operation of the recirculating pump 120. In this case, cold water will enter via the inlet 102 from the water pump 150 and hot water will leave by the outlet 104.
Additionally, based on the operational data or parameters received from the cooling system 100 (e.g., data from the sensor assemblies 140), the controller 200 may determine the temperature of the water needs to maintained or held at the defined temperature of the cooling system 100. Thus, in this case, the controller 200 may be configured to run the maintenance program. In the maintenance program, the controller 200 may be configured to cause the flow control valve 130 to partially open and also restrict the operation of the recirculating pump 120. In this case, cold water will gradually enter via the inlet 102 from the water pump 150 and hot water will gradually leave by the outlet 104. In this regard, by controlling the position of the flow control valve 130, the controller 200 is causing the water to more slowly enter and leave the cooling system 100, in contrast to the cooling program where water enters and leaves the cooling system 100 more quickly.
Therefore, it should be understood that the controller 200 may be configured to control the position of the flow control valve 130 or the mode of operation of the recirculating pump 120 if the controller determines that water should leave the cooling system 100 more slowly or quickly. Accordingly, the controller 200 may be configured to monitor the data received from the sensor assemblies 140 in order to ensure that the defined temperature of the water in the cooling system 100 is maintained. Furthermore, it should be understood that the programs executed by the controller 200 mentioned herein are merely exemplary, and the controller 200 may be configured to execute additional programs to control the temperature of the water in the cooling system 100. Specifically, the controller 200 may be configured to control flow rate, pressure, etc. of the water to achieve the defined temperature set by the operator.
Accordingly, example embodiments described herein may provide for a cooling system configured to cool exhaust gases exiting a furnace of a steel production system through an exhaust hood, a dropout box, and a hot gas duct of the steel production system. The cooling system may include an inlet configured to receive water from a water pump for cooling the exhaust gases, and an outlet configured to exhaust the water from the cooling system. The cooling system may further include a first water line configured to supply the water to the exhaust hood of the steel production system for cooling the exhaust gas received therein, and a second water line configured to supply the water to the dropout box of the steel production system for cooling the exhaust gas received therein. The cooling system may also include a third water line configured to supply the water to the hot gas duct of the steel production system for cooling the exhaust gas received therein, and each of the first water line, the second water line, and the third water line may be operably coupled between the inlet and the outlet of the cooling system. The cooling system may also include a controller configured to control and maintain a defined temperature of the water circulating within the cooling system.
The cooling system may include various modifications, additions or augmentations that may optionally be applied. Thus, for example, in some cases, the cooling system may further include a sensor assembly disposed on one of the first water line, the second water line, or the third water line for monitoring the temperature of the water flowing therein, and the controller may be configured to receive temperature data from the sensor assembly in order to control and maintain the defined temperature of the water based on the temperature data. Alternatively or additionally, the sensor assembly may include a first sensor assembly, a second sensor assembly, and a third sensor assembly. The first sensor assembly may be disposed on the first water line, the second sensor assembly may be disposed on the second water line, and the third sensor assembly may be disposed on the third water line. The controller may be configured to receive the temperature data from each of the first sensor assembly, the second sensor assembly, and the third sensor assembly. Alternatively or additionally, the sensor assembly may further include a fourth sensor assembly disposed proximate the inlet of the cooling system, and the controller may be further configured to receive the temperature data of the fourth sensor. Alternatively or additionally, the cooling system may further include a flow control valve and a recirculating pump, and the recirculating pump may be disposed on a pump line of the cooling system. Alternatively or additionally, the flow control valve may be disposed on the hot gas duct line. Alternatively or additionally, the controller may be configured to execute a program in order to control and maintain the defined temperature of the water. Alternatively or additionally, the program may be one of a cooling program, a maintenance program, or a heating program. Alternatively or additionally, the heating program may be executed in response to the temperature of the water circulating within the cooling system being less than the defined temperature. The heating program may include directing the flow control valve to fully close and the recirculating pump to be operational in order to prevent the water leaving the cooling system via the outlet thereby allowing the water within the cooling system to recirculate thereby increasing the temperature of the water to the defined temperature. Alternatively or additionally, the controller may be configured to execute the heating program in response to the water initially entering the cooling system via the inlet upon start-up of the cooling system. Alternatively or additionally, the cooling program may be executed in response to the temperature of the water circulating within the cooling system being hotter than the defined temperature. The cooling program may include directing the flow control valve to fully open and the recirculating pump to stop operation in order to allow the water to leave the cooling system via the outlet and new water from the water pump to enter via the inlet decreasing the temperature of the water to the defined temperature. Alternatively or additionally, the maintenance program may be executed in response to the temperature of the water being at the defined temperature. The maintenance program may include directing the flow control valve to partially close in order to allow the water to gradually leave the cooling system via the outlet and new water from the water pump to gradually enter via the inlet. Alternatively or additionally, the pump line of the cooling system may be operably coupled to the hot gas duct line. Alternatively or additionally, the defined temperature may be set by an operator of the cooling system.
Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although the foregoing descriptions and the associated drawings describe exemplary embodiments in the context of certain exemplary combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, different combinations of elements and/or functions than those explicitly described above are also contemplated as may be set forth in some of the appended claims. In cases where advantages, benefits or solutions to problems are described herein, it should be appreciated that such advantages, benefits and/or solutions may be applicable to some example embodiments, but not necessarily all example embodiments. Thus, any advantages, benefits or solutions described herein should not be thought of as being critical, required or essential to all embodiments or to that which is claimed herein. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
