Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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PREDICTIVE REFRACTORY PERFORMANCE MEASUREMENT SYSTEM
Field of the Invention
[0001] The present invention relates generally to refractory
analysis and, more specifically, a
system and method for predicting refractory performance.
Background of the Invention
[0002] Industrial processes, such as production of steel and other
processes associated with high-
temperature erosive environments in manufacturing vessels, are supported by
ever-increasing
collections of process data and parameters. Many statistical, analytical, and
data manipulation
solutions can be used to quickly and efficiently analyze process data with the
aim of process
optimization and improved efficiencies. Process optimization systems, composed
of computing
system hardware and software, collect the raw process data and correlate the
raw process data with
changes, modifications, or upgrades to the process. The systems arc capable of
time stamping and
correlating various collected data. In advanced formats, the systems are also
capable of analytical and
statistical correlations of multiple and interdependent parameters. Using
these correlations, the
systems can describe the influences on the process efficiencies. Many of the
collected process
parameters, individually or in correlations, directly influence the
performance of the refractory linings.
[0003] Such systems, as described above, are used in processes
making liquid steel in primary
melting units, such as basic oxygen furnaces and electric arc furnaces. The
systems can also be used
with processes in secondary refining and transport vessels, such as steel
ladles, degassers, argon
oxygen decarburization, vacuum oxygen decarburization furnaces, or similar.
Vessels that contain
liquid steel must contain linings constructed from high temperature refractory
materials resistant to
liquid steel and molten slags. Even so, both liquid, steel and molten slags
serve to corrode the refractory
linings.
[0004] In addition, systems as those described above can be used in
processes making glass,
cement, lime, or other minerals, and in other high temperature units, such as
incinerators and others.
Further systems can also be used in production and refinement of oils, gasses,
chemicals, or similar
materials. Vessels utilized in processes that operate at high temperatures,
such as continuous and
batch glass melters, cement or lime rotary and shaft kilns, or rotary and
shaft kilns processing other
minerals, or preheat towers and coolers, or various petrochemical reformers,
such as primary and
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secondary ammonia reformers, or fluid catalytic cracking units, or thermal
reactors, such as Sulphur
recovery units, or gasifies. fluidized beds, incinerators and the like must
contain linings constructed
from high temperature refractory materials resistant to corrosive and erosive
conditions or non-
metallic liquids or molten slag or coatings. Even so, all of the above
conditions serve to corrode the
refractory linings.
[0005] The level and the progression of the refractory lining
corrosion are conventionally
measured by three widely accepted and currently employed methods: visual
observation, infrared
mapping, and laser scanning. Visual observation of refractory lining corrosion
can be performed
during servicing of the refractory linings. Visual observation of refractory
lining corrosion can also
be performed by physical measurement of the refractory lining remnants after
completion of the useful
life of the refractory lining. The level and the progression of the refractory
lining corrosion in glass
melters can also be measured by radar detections.
[0006] Infrared mapping of refractory lining corrosion is performed
on the outside surfaces of the
lining-equipped vessels that are loaded with liquid steel, glass, cement,
lime, oils, gases, chemicals, or
other minerals or materials at a specific step or time at which liquid steel,
glass, cement, lime, oils,
gases, chemicals, or other minerals or materials are respectively in contact
with the vessels. The
purpose of infrared mapping of refractory lining corrosion is to correlate the
temperature of the outside
surfaces of the loaded vessels with the conditions of the refractory linings
installed in the vessels.
Infrared mapping can be as simple as a visual review of infrared mapping
images. Visual review of
infrared mapping images can be additionally complemented with software
manipulations, advanced
temperature imagery, and data reports.
[0007] Laser scanning of refractory lining corrosion is performed on
inside surfaces of empty, in
some cases on full or partially full, lining-equipped vessels at a specific
process location. The laser
scanning systems can utilize multiple types of hardware and devices therein,
including, but not limited
to, laser time-of-flight cameras. A software package capable of processing
point cloud data into fully
geometrically descriptive images and generating various data reports can be
used to analyze the data
collected from the laser scanning. The purpose of the method is to measure,
within an accuracy of 2
mm, an actual geometry, a remaining thickness, or other detailed parameters of
the refractory lining.
With respect to liquid steel, such parameters may include, but are not limited
to, a condition of
functional parts of the ladle, such as a well block or a taphole, or a sanding
efficiency of the well
blocks or tapholes, or measure a steel yield trapped in the depressions of the
bottom of the ladle, or
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conditions of the passages of the flow control components, which may include,
but are not limited to,
slide gates. With respect to glass, cement, lime, oils, gases, chemicals, or
other minerals or materials,
such parameters may include, but are not limited to, a condition of functional
parts of the respective
vessel in contact therewith, such as, but not limited to, entry or exit ports,
crowns, roofs, or speci tic
functional sections.
[0008] Radar waves can be used for measuring the thickness of the
refractory lining in a glass
melter during the operation thereof by determining, based on a response of the
radar waves, whether
the radar waves entered areas having differing densities. The radar
measurement is performed from
an outer surface of the glass melter.
[0009] Conventionally, the four methods described above are utilized
independently of each other.
The refractory lining corrosion is primarily identified in industrial
processes by visual observation.
However, infrared mapping, radar scanning, and laser scanning are considered
alternate and
independent solutions for refractory linings corrosion evaluation. In fact,
the four methods compete
in the marketplace at significantly diverging costs. The costs of visual
observation are largely related
to overhead. Infrared mapping systems and radar scanning systems, in glass
melters, are less costly
than laser scanning systems.
[0010] However, the use of the methods individually may have
drawbacks in certain situations.
For example, very infrequent visual observation of refractory lining corrosion
does not collaborate
with actual conditions of the refractory linings physically described using
laser scanning after each
heat or process cycle, or, to a lesser extent, infrared mapping. Further,
visual observation does not
allow for the collection of valuable process optimization data that can be
used to calculate predictive
performance of the refractory lining.
[0011] Infrared mapping of refractory lining corrosion is indirect
and judges the conditions of the
refractory lining by observation of the outside surfaces. The temperature
readings collected by the
infrared mapping method are influenced by the flow of heat thru the actual
thickness of the lining.
However, adversely, the temperature readings arc al so influenced by the
temperature of the liquid steel
or the temperature of impregnated lining voids by liquid steel, process
liquids, gasses, solids, or molten
slag or coatings. Such impregnations are common and could generate false
readings using infrared
mapping, thereby leading to a premature replacement of a refractory lining at
a significant cost.
[0012] Laser scanning of refractory lining corrosion is direct and
measures the actual conditions
and thickness of the refractory lining with high precision. However, laser
scanning is incapable of
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measuring the thickness and conditions of the refractory lining if the
refractory lining is coated by
slags or coatings at the time of measurement. In other words, liquid steel, or
other melts such as glass
or molten slags or coatings cannot be present within the ladle or vessel if
accurate results from laser
scanning are to he desired. Laser scanning in those situations can only
measure the actual conditions
and thickness of visually exposed parts of the refractory linings, such as
glass rather crowns. If a
significant flaw in the lining, such as a large crack or insufficient
thickness, were covered by the
temporary slag coating, the laser scan would generate false reports. The
coating could then melt away
during operation, thereby exposing the hidden refractory lining flaw to liquid
steel or a high
temperature process environment involving non-metals. This could lead to a
catastrophic breach of
the refractory lining.
[0013] In addition, radar scanning in glass applications is within
an accuracy of 5 mm and lower
than the high precision of laser scanning. Further, each point must be
measured individually in radar
scanning. As such, radar scanning is time consuming. Only so many points ¨
typically not more than
150 ¨ can be completed throughout the entire scan of the vessel. Similar to
infrared cameras, radar
scanning cannot distinguish between the glass melt or glass infiltrations and
can give false readings if
such infiltrations are behind the refractory lining.
[0014] The present invention has been developed to address these and
other issues by providing a
system by which refractory lining corrosion is identified through both laser
scanning and infrared
mapping, and possibly, in the case of glass melters, radar scanning. In
addition, the present invention
provides a system in which process characteristics and variables can be used
in addition to the data
retrieved by laser scanning, infrared mapping, and radar scanning to predict
the future performance of
the refractory lining in question.
Summary of the Invention
[0015] In accordance with an embodiment of the present invention,
there is provided a
measurement system for predicting a future status of a refractory lining that
is lined over an inner
surface of an outer wall of a manufacturing vessel and exposed to an
operational cycle during which
the refractory lining is exposed to a high-temperature environment for
producing a non-metal and the
produced non-metal. The system includes one or more laser scanners and a
processor. The laser
scanners are configured to conduct one or more pre-operational laser scans of
the refractory lining
prior to the operational cycle to collect data related to pre-operational
cycle structural conditions, and
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one or more post-operational laser scans of the refractory lining after the
operational cycle to collect
data related to post-operational cycle structural conditions of the refractory
lining. The processor is
configured to determine an exposure impact of the operational cycle on the
refractory lining by
comparing the collected pre-operational cycle structural condition data with
the collected post-
operational cycle structural condition data, and predict the future status of
the refractory lining after
one or more subsequent operational cycles based on the determined exposure
impact of the operational
cycle.
[0016] In accordance with another embodiment of the present
invention, there is provided a
method of predicting a future status of a refractory lining that is lined over
an inner surface of an outer
wall of a manufacturing vessel and exposed to an operational cycle during
which the refractory lining
is exposed to a high-temperature environment for producing a non-metal and the
produced non-metal.
The method includes conducting one or more pre-operational laser scans of the
refractory lining prior
to the heat, the conducting prior to the operational cycle to collect data
related to pre-operational cycle
structural condition, conducting one or more post-operational laser scans of
the refractory lining after
the operational cycle to collect data related to post-operational cycle
structural conditions of the
refractory lining, determining, via a processor, an exposure impact of the
operational cycle on the
refractory lining by comparing the collected pre-operational cycle structural
condition data with the
collected post-operational cycle structural condition data, and predicting,
via the processor, the future
status of the refractory lining after one or more subsequent operational
cycles based on the determined
exposure impact of the operational cycle.
[0017] These and other advantages will become apparent from the
following description of a
preferred embodiment taken together with the accompanying drawings and claims.
Brief Description of the Drawings
[0018] The invention may take physical form in certain parts and
arrangement of parts, a preferred
embodiment of which will be described in detail in the specification and
illustrated in the
accompanying drawings which form a part hereof, and wherein:
[0019] FIG. 1 is a schematic view illustrating a first example
predictive refractory performance
measurement system of the present invention;
[0020] FIG. 2 is a schematic view illustrating a first example of a
refractory lining being
respectively lined over an inner surface of an outer wall of an empty
metallurgical vessel and a full
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metallurgical vessel for which a future status of the refractory lining is to
be predicted by the first
example predictive refractory performance measurement system of the present
invention;
[0021] FIG. 3 is a flowchart illustrating a first example method of
the present invention of
predicting a future status of a refractory lining, where the refractory lining
is lined over an inner surface
of an outer wall of a ladle vessel and exposed to a heat during which the
refractory lining is exposed
to molten metal;
[0022] FIG. 4 is a schematic view illustrating a second example
predictive refractory performance
measurement system of the present invention;
[0023] FIG. 5 is a schematic view illustrating an example of a
refractory lining being respectively
lined over an inner surface of an outer wall of a manufacturing vessel for
which a future status of the
refractory lining is to be predicted by the second example predictive
refractory performance
measurement system of the present invention; and
[0024] FIG. 6 is a flowchart illustrating a second example method of
the present invention of
predicting a future status of a refractory lining, where the refractory lining
is lined over an inner surface
of an outer wall of a manufacturing vessel and exposed to an operation cycle
during which the
refractory lining is exposed to a high-temperature environment for producing a
non-metal.
Detailed Description of Preferred Embodiment
[0025] The following detailed description is provided to assist the
reader in gaining a
comprehensive understanding of the methods, apparatuses, and/or systems
described herein. However,
various changes, modifications, and equivalents of the systems, apparatuses
and/or methods described
herein will be apparent to one of ordinary skill in the art. In addition,
descriptions of functions and
constructions that are well known to one of ordinary skill in the art may be
omitted for increased clarity
and conciseness.
[0026] Throughout the drawings and the detailed description, the
same reference numerals refer
to the same elements. The drawings may not be to scale, and the relative size,
proportions, and
depiction of elements in the drawings may be exaggerated for clarity,
illustration, and convenience.
[0027] The features described herein may be embodied in different
forms and are not to be
construed as being limited to the examples described herein. Rather, the
examples described herein
have been provided so that this disclosure will be thorough and complete, and
will convey the full
scope of the disclosure to one of ordinary skill in the art.
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[0028] Initially, for purposes of the discussion herein,
"metallurgical vessel- refers to any
container that can be used within the process for the production or refining
of molten steel. This
includes, but is not limited to, a primary melting unit or second
metallurgical vessels. A primary
melting unit includes, but is not limited to, a basic oxygen furnace or an
electric arc furnace. Secondary
metallurgical vessels include, but are not limited to, a ladle metallurgical
furnace, a degasser. an argon
oxygen decarburization vessel, or a vacuum oxygen decarburization vessel. An
example of a
secondary steelmaking or metallurgical vessel that is tasked with carrying
molten steel is empty ladle
vessel 16 and full ladle vessel 18, which will be described in more detail in
the discussion below.
However, embodiments described herein are not limited thereto, as the use of a
metallurgical vessel is
not limited to use with molten steel, but also can hold other molten metals in
general.
[0029] For purposes of the discussion herein, "manufacturing vessel"
refers to any container that
can be used within the high temperature process for the production or refining
of glass, cement. lime,
chemicals, oils and gasses, or other materials typically called as non-metals.
This includes, but is not
limited to, continuous and batch glass melters, cement or lime rotary and
shaft kilns, or rotary and
shaft kilns processing other minerals, or preheat towers and coolers, or
various petrochemical
reformers, such as primary and secondary ammonia reformers, or fluid catalytic
cracking units, or
thermal reactors, such as sulphur recovery units, or gasifiers, fluidized
beds, incinerators and others.
However, embodiments described herein are not limited thereto, as the use of a
manufacturing vessel
is not limited to use with glass, cement, lime, chemicals, oils and gasses,
but also can hold or process
other non-metals in general.
[0030] Further, steel mill operational parameters that influence the
performance of refractory
linings in metallurgical vessels will be described along with, if applicable,
the variability and the
measuring methods thereof. For example, for purposes of the discussion herein,
a "heat" may refer
to one performance of a steel-making process from beginning to end.
[0031] In addition, operational parameters that influence the
performance of refractory linings in
manufacturing vessels will be described along with, if applicable, the
variability and the measuring
methods thereof. For example, for purposes of the discussion herein, an
"operational cycle" may refer
to one performance of a manufacturing process from beginning to end. An
"operational cycle" may
also refer to a time period between shutdowns, a time period between
inspections, a time period
between maintenance, a time period between repairs, or a time period between
laser scans of the
manufacturing vessel.
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[0032] For purposes of the discussion herein, "scrap or charging mix-
with respect to the process
for the production or refining of molten steel could include batches with
specific proportions of
individual scrap qualities and iron units for the grade of steel to be
produced, including, but not limited
to, ferrous scrap identified by guidelines from the Institute of Scrap
Recycling Industries, which
additionally may include, but is not limited to, heavy melting steel,
busheling, clippings, bundles,
shreddings, turnings, plates, structures, cast iron, mixed heavy melt, rails,
railroad, and can bales, and
could be complemented by other sources of iron units, such as, but not limited
to, pig iron and hot
briquetted iron.
[0033] With respect to "scrap or charging mix" in the process for
the production or refining of
molten steel, there is a large variability of steel scrap qualities and iron
units available for the
steelmaker to utilize in his primary melting process. Physical attributes of
these materials, such as
size, shape, and contaminations, chemical attributes of these materials, such
as composition, rust, and
impurities, and a composition of a "scrap or charging mix" for each heat, have
direct impact on the
efficiency of the melting process, the duration of the refining metallurgy and
the corrosion and erosion
of the refractories. The "scrap or charging mix" is typically a simple
hatching instruction with specific
proportions of individual scrap qualities and iron units. These instructions
are based on the availability
of charging components and grade of steel to be produced.
[0034] Further, for purposes of the discussion herein, "charging
mix" or "continuously fed mix"
with respect to the high temperature process for the production or refining of
glass, cement, lime,
chemicals, oils and gasses, or other materials typically called as non-metals
could respectively include
batches or continuous feed with specific proportions of individual raw and
starting materials for the
grade of the non-metal to be produced.
[0035] With respect to "charging mix" or "continuously fed mix" in
the high temperature process
for the production or refining of glass, cement, lime, chemicals, oils and
gasses, or other materials
typically called as non-metals, there is a large variability of qualities
available for the non-metal maker
to utilize in the manufacturing process. Physical attributes of these
materials, such as size, shape, and
contaminations, along with chemical attributes of these materials, such as
composition and impurities,
and additionally a composition and frequency of a "charging mix" or
"continuously fed mix" for each
operational cycle, have direct impact on the efficiency of the manufacturing
process, the duration of
the operational cycle, and the corrosion and erosion of the refractories. The -
charging mix- is typically
a simple batching instruction with specific proportions of individual
ingredients or additives. The
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"continuously fed mix- is typically a feeding instruction with specific
proportions of individual
ingredients or additives. These instructions arc based on the availability of
charging or continuously
fed mix components and grade of non-metal to be produced.
[0036] Moreover, for purposes of the discussion herein, "steel" and
grades thereof could include,
but are not limited to, carbon steels, nickel steels, nickel-chromium steels,
molybdenum steels,
chromium steels, chromium-vanadium steels, tungsten steels, nickel-chromium-
molybdenum steels,
and silicon-manganese steels. Further, each grade of steel requires some
alternation in the processing
of the steel in a primary melting unit, such as, but not limited to, a basic
oxygen furnace or an electric
arc furnace, and secondary metallurgical vessels, such as, but not limited to,
a ladle metallurgical
furnace, a degasser, an argon oxygen decarburization vessel, or a vacuum
oxygen decarburization
vessel. These specific process requirements, aimed at achieving the required
steel grade, have a
demonstrated effect on refractory lining performance. The amount of residual
carbon, the level of
impurities and the addition of alloying elements are achieved by
decarburization and deoxidation
processes, having distinctive corrosion and erosion effect on refractories.
[0037] Additionally, for purposes of the discussion herein, "non-
metals" and grades thereof could
include, but are not limited to, glass compositions such as soda-lime-silicate
container or flat glasses,
or soda-silicate water glasses, or boro-silicate glasses, or other specialty
glasses, or a variety of other
glass compositions typically called e-glasses, c-glasses, fiberglass, and the
like.
[0038] Moreover, for example, the grades of cement clinkers are many
and have standardized
specifications per ASTM C-150/C-150M-20. The specification lists five types;
Type I is the standard
product, also referred to as "ordinary cement"; Type II possesses moderate
resistance to sulfate attack,
also called moderate-heat cement; Type III is high-early-strength cement; Type
IV is low-heat cement;
and Type V is sulfate-resisting cement with appropriate limits on composition.
In addition, ASTM
C1157 lists further modification, such as Type GU for general use, type HE for
having high early
strength, type MS for having moderate sulfate resistance, type HS for having
high sulfate resistance,
type MI-I for having moderate heat of hydration, and type LH for having low
heat of hydration.
[0039] Similarly, the refining products of oil and gasses, or grades
of other minerals or chemicals
produced within the high temperature environments, have distinctive corrosion
and erosion effects on
refractories. These specific process requirements, aimed at achieving the
required non-metal grade,
have a demonstrated effect on refractory lining performance.
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[0040] Further, for purposes of the discussion herein, -alloying
additions- could include
-deoxidizers" to furnaces or other metallurgical vessels, such as, but not
limited to, aluminum, silicon,
ferro-silicon, calcium, magnesium, calcium carbide, and various deoxidizing
blends, or additions to
ladle manufacturing vessels for secondary steelmaking and refining, such as,
but not limited to, carbon,
manganese, vanadium, molybdenum, chromium, nickel, titanium, boron, niobium,
and other similar
materials known to those having ordinary skill in the art.
[0041] The process of alloying steel is used to change the chemical
composition of steel and alter,
adjust, or improve its properties to suit a specification or application. The
purpose of deoxidizers is
to lower the concentration of oxygen in liquid steels. The additions are added
by weight during the
melting processes and refining processes, and they differ based on the
starting and target parameters
of each individual heat. The quantity and quality of these alloying additions
have significant effect
not only on the quality of the steel, but also on the corrosion of refractory
linings.
[0042] Still moreover, for purposes of the discussion herein, "slag"
with respect to the process for
the production or refining of molten steel could include solutions of molten
metal oxides and fluorides
floating on the top of liquid steel, and could be formed by materials such as,
but not limited to, lime,
dolomitic lime, and magnesia, which are added prior or during the steel-making
and refining processes
and are the basis for the creation of slags. Additionally, for purposes of the
discussion herein, "flux
additions" are added to optimize the fluidity of operating slags, and may
include calcium aluminate,
fluorspar, silica sand, or various blends of synthetic slags.
[0043] "Slags" with respect to the process for the production or refining of
molten steel are primarily
liquid at the temperatures at which steel making and steel refining take
place. They play a role in the
steel making process, absorbing non-metallic compounds from the
decarburization, deoxidation,
desulfurization, and dephosphorization processes. The additions of slag former
and fluxes could vary
from heat to heat and can be as low as few pounds per ton of steel and as high
as several hundred
pounds per ton of steel. The quantity and the quality of these additions have
a direct influence on the
chemical composition of liquid slag and on the corrosion of refractory
linings.
[0044] The typical chemical composition of the -slags" during the
refining processes of molten
steel is identified in Table 1. An out-of-balance slag chemical composition
has a significant negative
impact on the life of a refractory lining. The chemical compositions of a
processed cold sample can
be measured by, for example, an XRF unit, thereby employing an x-ray
fluorescence analytical
technique to determine the chemical composition. While not discussed in detail
below, a unit that can
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measure the chemical composition of a processed cold sample will be referred
to as slag chemistry
measurement apparatus 3.
Ideal Vessel Slag Composition
Component Silicon Aluminum
Killed Killed
CaO 50-60% 50-60%
SiO2 25-30% <8%
MgO 7-10% 7-10%
A1103 <8% 25-30%
Fe0 Mn0 <2% <2%
TABLE 1
Ideal Vessel Slag Composition
[0045] Additionally, for purposes of the discussion herein,
"coatings" with respect to the high
temperature process for the production or refining of glass, cement, lime,
chemicals, oils and gasses,
or other materials typically called as non-metals could include solutions, or
blends of non-metal oxides
and fluorides generated in certain conditions during the operational cycle and
in certain locations of
the manufacturing vessel. The "coatings" adhere to the refractory surface at
the temperatures at which
non-metal making or refining take place. They could have a direct influence on
the corrosion of
refractory linings.
[0046] The temperature of steel is defined as such prior to tapping
(or removal) of the steel from
the primary melter, i.e., the furnace vessel, in the range between 2800 F and
3200 F, or during or
near the end of secondary steelmaking in a ladle vessel in the range between
2700 F and 3000 F.
Temperature is usually measured by thermoelectric thermocouples with
effectiveness within several
degrees F, such as ladle thermocouple 25, which are dipped in the molten
metal or molten steel and
preferably expendable. The application of ladle thermocouple 25 in predictive
refractory performance
measurement system 4, as well as system 4 itself, will be described in further
detail in the following
discussion.
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[0047] The temperature of a manufacturing vessel or the operational
cycle with respect to the high
temperature process for the production or refining of glass, cement, lime,
chemicals, oils and gasses,
or other materials typically called as non-metals is between 2000 F to 3400
F for glass melters,
between 1600 F to 2700 F. for cement kilns, between 600 F to 1600 F for
preheat towers, up to
2200 F for coolers, between 1200 F to 1400 F for fluid catalytic cracking
units, between 2400 F
to 2800 F for thermal reactors, up to 2200 F for ammonia reformers, up to
3000 op for incinerators,
between 2400 F to 3000 F for gasifiers, and between 1500 F to 2200 F for
fluidized beds. Again,
temperature is usually measured by thermoelectric thermocouples with
effectiveness within several
degrees F.
[0048] Additionally, for purposes of this discussion, a "history" of
a metallurgical vessel refers to
a period in which the same refractory lining has been lined over the inner
surface of the outer wall of
the metallurgical vessel. The history is typically recorded through the
collection of various "ladle
tracking parameters", which include, but are not limited to, heats, plate
changes, nozzle changes, and
other events that affect metallurgical vessels during the steel-making process
in such a way that would
affect the life span of refractory linings installed therein. More
specifically, the ladle tracking
parameters identify when the refractory lining of metallurgical vessel is
subjected to repair, change,
or demolition.
[0049] For example, newly installed working refractory lining of a
metallurgical vessel, such as
working refractory lining 34, has zero heats and has initial chemical
compositions, origins, and
physical designs. After service exposure, some of the components of the
metallurgical vessel may
require change or repair. Examples of such changes could be, but are not
limited to a replacement of
the flow control slide gate (after as low as 1 heat and as high as 15 heats),
a replacement of flow control
upper or lower nozzles (after as low as few heat up to 30 heats or higher), a
replacement of a gas
purging cone, a replacement of a well block and pocket blocks ( as low as 15
heats and as high as life
of the ladle), and a replacement of the slag line (as low as 15 heats and as
high as the life of the unit).
[0050] Additionally, for purposes of this discussion, a "history" of
a manufacturing vessel with
respect to the high temperature process for the production or refining of
glass, cement, lime, chemicals,
oils and gasses, or other materials typically called as non-metals refers to a
period in which the same
refractory lining has been lined over the inner surface of the outer wall of
the manufacturing vessel.
The history is typically recorded through the collection of various "process
tracking parameters",
which include, but are not limited to, number of operational cycles, number of
inspections, number of
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preventive or acute maintenance stoppages, and other events that affect
manufacturing vessels during
the non-metal-making process in such a way that would affect the life span of
refractory linings
installed therein. More specifically, the manufacturing vessel tracking
parameters identify when the
refractory lining of manufacturing vessel is subjected to repair, change, or
demolition.
[0051] There are additional repairs possible with respect to the
metallurgical vessel, such as, but
not limited to, a monolithic patch of a bottom of a ladle vessel and a repair
of the ladle vessel lip ring.
The ladle vessel at a final demolition thereof could have exposed working
refractory lining 34 to as
low as a few heats and as high as greater than 200 heats. Variable ladle
tracking parameters have
significant effects on the overall performance of the refractory lining. The
repairs or changes to the
metallurgical vessel typically require the vessel to be taken out of service,
thereby resulting in thermal
shock or thermal gradient damage to the refractory lining positioned therein.
[0052] There are also additional repairs possible with respect to
the manufacturing vessel used for
the high temperature process for the production or refining of glass, cement,
lime, chemicals, oils and
gasses, or other materials typically called as non-metals. These repairs or
changes to the
manufacturing vessel typically require the vessel to be taken out of service,
thereby resulting in thermal
shock or thermal gradient damage to the refractory lining positioned therein.
[0053] Still additionally, for purposes of this discussion,
"preheating" or -heat up" refers to
exposing a metallurgical or a manufacturing vessel to a gas-powered preheater
prior to exposure to
molten metal or steel with respect to the metallurgical vessel or an
operational cycle with respect to
the manufacturing vessel. Specifically, with respect to a metallurgical
vessel, each empty
metallurgical vessel, if in operation, should be kept hot. The preheating or
heat up in both
metallurgical and manufacturing vessels influences the performance of
refractory linings. An example
of the preheating that is used in the process for the production or refining
of molten steel is working
refractory lining 34.
[0054] The preheating temperature may be measured by thet
____________________ mocouples. Examples of this method
of temperature measurement used in the process for the production or refining
of molten steel include
preheater thermocouple 2, which is described in further detail below, or
optical pyrometers. The
preheating temperatures in the process for the production or refining of
molten steel are typically in a
range of 1500 F to 2200 F. However, since working refractory linings used in
the process for the
production or refining of molten steel, such as working refractory lining 34,
usually contain graphite
and carbon, any non-typical preheating exposure has direct impact on the
carbon depletion and
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consequently on the performance of working refractory lining 34. While
necessary, the preheating of
working refractory linings used in the process for the production or refining
of molten steel, such as
working refractory lining 34, predictably shortens the refractory life of the
working refractory linings,
which impacts the future status of the working refractory linings.
[0055] Further, the duration of the preheating or heat up of the
metallurgical or manufacturing
vessel is not predetermined. Instead, the duration is dependent upon the
variables and circumstances
defined in the area, or shop, in which the process takes place. Such variables
and circumstances may
include, but are not limited to, operational inconsistencies, process
backlogs, availability of molten
metal in the case of the metallurgical vessel, availability of charging or
continuously fed mix
ingredients or fuels in the case of the manufacturing vessel, unforeseen
repairs, or emergency
maintenance shutdowns of process equipment. As such, the duration of the
preheating or heat up must
be monitored by a recording mechanism, such as preheating or heat up recording
apparatus 24, which
is described in greater detail below.
[0056] Moreover, for the purposes of this discussion, "residence
time" with respect to the process
for the production or refining of molten steel is defined as the cumulative
contact time of working
refractory lining 34 with molten steel and slags. The residence time is not
predetermined and highly
depends on the variables and circumstances defined in the area, or shop, in
which the process takes
place. For example, the process flow of the steel mill can affect the
cumulative contact time of working
refractory lining 34 with molten steel and slags from as low as 30 minutes to
as high as 10 hours or
more per each heat. As such, the cumulative contact time must be monitored by
a recording
mechanism, such as residence time recording apparatus 23, which is described
in greater detail below.
[0057] Additionally, for the purposes of this discussion, "cycle
time" with respect to the high
temperature process for the production or refining of glass. cement, lime,
chemicals, oils and gasses,
or other materials typically called as non-metals is defined as the cumulative
contact time of refractory
lining with high temperature corrosion and erosion environments. The cycle
time is not predetermined
and highly depends on the variables and circumstances defined in the area, or
shop, in which the
process takes place. For example, the process flow in non-metal mill can
affect the cumulative contact
time of refractory lining and as such, the cumulative contact time must be
monitored by a recording
mechanism, such as cycle time recording apparatus 423, which is described in
greater detail below.
[0058] Further, specifically with respect to the process for the
production or refining of molten
steel, metallurgical vessels are typically equipped with stirring elements
located in the bottom thereof.
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They purge inert gas, such as argon or nitrogen, thru molten steel. The main
purpose of this is to
improve and accelerate desulfurization of the molten steel, but also to
improve alloying efficiency and
temperature homogenization of the molten steel. The stirring pressure is
typically in the range of 120
psi to 180 psi, and the gas volume is typically between 5-50 scfm. The normal
flow volumes are
typically 5-10 scfm for a gentle stir and rinse, 15-25 scfm for a medium stir
during arcing, alloy
addition, and homogenization, and 25-45 scfm for heavy desulfurization. Flows
vary by vessel size,
plug location, and plug conditions. The purging duration during the heat could
be in the range of a
few minutes to 30 minutes or more. The typical life of the purging plug is
between 500 minutes and
2,000 minutes. The stirring pressure, flow, and time influence not only the
life of the plug, but
localized erosion of working refractory lining 34. Thus, as is the case with
the preheating and the
residence time, the parameters related to the stirring of the molten steel are
not predetermined, but are
dependent on the efficiency of the desulfurization of the steel. For example,
the level of sulfur is
measured prior to the tapping of the molten steel. If the target of
desulfurization is not reached,
additional stirring time, increased stirring pressure, and higher flowrate is
applied. Increases and
elevations in these parameters are known to result in a reduced life span of
working refractory lining
34. These parameters can be monitored and recorded in gas stirring control
apparatus 26, which will
be discussed further below.
[0059] In addition, for purposes of this discussion, with respect to
the process for the production
or refining of molten steel, a physical orientation of a metallurgical vehicle
corresponds with the
position of the metallurgical vehicle in relationship to an overall space of
the area in which the
metallurgical vehicle is being used, such as a steel mill or any other
facility dedicated to steel
generation.
[0060] Referring now to the drawings, wherein the showing is for
illustrating a preferred
embodiment of the invention only and not for limiting same, the invention with
respect to the process
for the production or refining of molten steel will be described with
reference to FIGS. 1-3.
[00611 FIG. 1 is a schematic view illustrating an example of
predictive refractory performance
measurement system 4. System 4 is used to predict the future status, or
performance, of refractory
linings that are lined over inner surfaces of outer walls of metallurgical
vessels for handling molten
metal or molten steel. Predictive refractory performance measurement system 4
may be implemented
in a mill, foundry, or other environments known by those of ordinary skill in
the art to be suitable for
the melting, forming, and refining of steel and metal. However, it is
contemplated that a substantial
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portion of system 4 could be implemented in any environment in which surface
analysis, temperature
analysis, process data analysis, and life expectancy calculation arc desired
for refractories.
[0062] The example apparatuses, units, modules, devices, and other
components illustrated in FIG.
1 that make up system 4 and perform the method and operations described herein
with respect to FIGS.
2 and 3 are implemented by hardware components. Examples of hardware
components are not limited
to the above-described example apparatuses, units, modules, and devices and
may include controllers,
sensors, generators, drivers, and any other electronic components known to one
of ordinary skill in the
art. Such components may be variably located according to design needs and may
communicate with
each other through wired or wireless means.
[0063] In the non-limiting example described herein. system 4
includes computing complex 10.
Computing complex 10 may include one or more processors 12 and one or more
means of storage 14,
but is not limited thereto. Processors 12 and storage 14 of computing complex
10 may be oriented,
positioned, or connected in any way to facilitate proper operation of
computing complex 10. This
includes, but is not limited to, wired configurations, wireless
configurations, local configurations, wide
area configurations, and any combination thereof in which communication
therebetween can be
established through compatible network protocol.
[0064] Processor 12 is implemented by one or more processing
elements. Such processing
elements may be as an array of logic gates, a controller and an arithmetic
logic unit, a digital signal
processor, a microcomputer, a programmable logic controller, a field-
programmable gate array, a
programmable logic array, a microprocessor, or any other device or combination
of devices known to
one of ordinary skill in the art that is capable of responding to and
executing instructions in a defined
manner to achieve a desired result.
[0065] For simplicity, the singular term "processor" may be used in
the description of the example
processor 12 described herein, but in other examples multiple processors 12
are used, or processor 12
includes multiple processing elements, or multiple types of processing
elements, or both. In one
example, system 4 of hardware components includes multiple processors 12 in
computing complex
10, and in another example, a hardware component of system 4 includes an
independent processor or
another controller containing a processor, which then communicates data to
receive data from
processor 12 of computing complex 10. Processor 12 of computing complex 10 may
be defined as a
hardware component, along with other components of system 4 discussed below.
Similar to processor
12 and other hardware components containing processing functionality may be
defined according to
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any one or more of different processing configurations, examples of which
include a single processor,
independent processors, parallel processors, single-instruction single-data
(SISD) multiprocessing,
single-instruction multiple-data (SIMD) multiprocessing, multiple-instruction
single-data (MISD)
multiprocessing, and multiple-instruction multiple-data (MIMD)
multiprocessing. Processor 12 may
be connected via cable or wireless network to hardware components to provide
instruction thereto or
to other processors to enable multiprocessing capabilities.
[0066] Instructions or software to control processor 12 or hardware
including processors within
system 4 to implement the hardware components and perform the methods as
described below are
written as computer programs, code segments, instructions or any combination
thereof, for
individually or collectively instructing or configuring processor 12 or
hardware including processors
within system 4 to operate as a machine or special-purpose computer to perform
the operations
performed by the hardware components and the methods as described below. In
one example, the
instructions or software include machine code that is directly executed by
processor 12 or hardware
including processors within system 4, such as machine code produced by a
compiler. In another
example, the instructions or software include higher-level code that is
executed by processor 12 or
hardware including processors within system 4 using an interpreter.
[0067] Programmers of ordinary skill in the art can readily write
the instructions or software based
on the flow chart illustrated in FIG. 3 and the corresponding descriptions
herein, which disclose
algorithms for performing the operations performed by the hardware components
and the methods as
described above.
[0068] Hardware components implemented in system 4, such as
processor 12 or components
linked to processor 12, execute instructions or software. such as an operating
system (OS) and one or
more software applications that run on the OS, to perform the operations
described herebelow with
respect to FIGS. 2 and 3.
[0069] The instructions or software to control processor 12 or
hardware including processors
within system 4 to implement the hardware components and perform the methods
as described below,
and any associated data, data files, and data structures, are recorded,
stored, or fixed in storage 14.
Storage 14 of computing complex 10 generically refers to one or more memories
storing instructions
or software that are executed by processor 12. However, the hardware
components implemented in
system 4, such as processor 12 or components linked to processor 12, may
include local storage or
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access, manipulate, process, create, and store data in storage 14 in response
to execution of the
instructions or software.
[0070] Storage 14 may be represented by on one or more non-
transitory computer-readable storage
media. Storage 14 may be representative of multiple non-transitory computer-
readable storage media
linked together via a network of computing complex 10. For example, non-
transitory computer-
readable storage media may be located in one or more storage facilities or one
or more data centers
positioned remotely from system 4 within computing complex 10. Such a media
may be connected to
system 4 through a network of computing complex 10. The network of computing
complex 10 allows
the non-transitory computer-readable storage media remotely located at the
data center or the storage
facility to transfer data over the network to non-transitory computer-readable
storage medium within
storage 14 of computing complex 10. In addition, storage 14 may be
representative of both remotely
and locally positioned non-transitory computer-readable storage media.
[0071] Examples of a non-transitory computer-readable storage medium
include read-only
memory (ROM), random-access memory (RAM), flash memory, solid state memory, CD-
ROMs, CD-
Rs, CD+Rs, CD-RWs, CD+RWs, DVD-ROMs, DVD-Rs, DVD+Rs, DVD-RWs, DVD+RWs, DVD-
RAMs, BD-ROMs, BD-Rs, BD-R LTHs, BD-REs, magnetic tapes, floppy disks, magneto-
optical data
storage devices, optical data storage devices, hard disks, solid-state disks,
and any device known to
one of ordinary skill in the art that is capable of storing the instructions
or software and any associated
data, data files, and data structures in a non-transitory manner and providing
the instructions or
software and any associated data, data files, and data structures to processor
12 of computing complex
or hardware including processors within system 4 so that processor 12 or
processors can execute
the instructions. In one example, the instructions or software and any
associated data, data files, and
data structures are distributed over network-coupled computer systems so that
the instructions and
software and any associated data, data files, and data structures are stored,
accessed, and executed in
a distributed fashion by processor 12.
[0072] Examples of hardware components in system 4 other than
processor 12 and storage 14 of
computing complex 10 may include terminal 6. Terminal 6 may include a user
input, a display, or a
combination thereof, but is not limited thereto. In FIG. 1, terminal 6 is
illustrated as being connected
to computing complex 10. However, embodiments disclosed herein are not limited
thereto. For
example, terminal 6 may be connected directly to processor 12, directly to
storage 14, to both storage
14 and processor 12, or to any other hardware component of system 4.
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[0073] Terminal 6 may be configured to display information contained
in storage 14 that has been
processed by processor 12 or inputted by a user. Processor 12 is in charge of
determining what should
be displayed on terminal 6. Storage 14 may be configured to store data
generated by processor 12 and
inputted through terminal 6. Applications, user input, and processor
calculations may he stored in
storage 14 for access by processor 12 in order to predict refractory
performance.
[0074] Further examples of the above-referenced hardware in system 4
connected to storage 14
may also include slag chemistry measurement apparatus 3, laser scanner 20,
preheater thermocouple
2, infrared cameras 22, residence time recording apparatus 23, preheating
recording apparatus 24, gas
stirring control apparatus 26, ladle thermocouple 25, and orientation laser
19. Storage 14 may receive
data from these hardware components in any wired or wireless manner known to
those having ordinary
skill in the art and communicate the received and stored data to processor 12
in any wired or wireless
manner known to those having ordinary skill in the art for further processing.
These operational
components will be more particularly described in the discussion below.
[0075] FIG. 2 is a schematic view illustrating an example refractory
lining being lined over an
inner surface of an outer wall of ladle vessels 16 and 18 for which a future
status of the refractory
lining is to be predicted by predictive refractory performance measurement
system 4. Ladle vessel 16
does not contain molten metal or molten steel and, therefore, is referred to
as "empty ladle vessel 16".
Ladle vessel 18 contains molten metal or molten steel and, therefore, is
referred to as "full ladle vessel
18". Ladle vessels 16 and 18 of FIG. 2 are representative of secondary
refining and transport vessels,
such as steel ladles.
[0076] Each of ladle vessels 16 and 18 are lined with the same
refractory. In the examples
illustrated in FIG. 2, backup refractory lining 32 is lined over an inner
surface of an outer wall of ladle
vessels 16 and 18. Working refractory lining 34 is lined over backup
refractory lining 32.
[0077] Since working refractory lining 34 is lined over backup
refractory lining 32, backup
refractory lining 32 typically has a relatively long life span. For example,
backup refractory lining 32
may be able to have a one-year lifespan. On the other hand, during steel-
making heats, working
refractory lining 34 is directly exposed to the molten metal or molten steel
placed within ladle vessels
16 and 18. Thus, working refractory lining 34 typically has a much shorter
life span. Depending on
the severity of the steel-making processes employed during the heats, working
refractory lining 34
may only last for 2 weeks. As such, while working refractory lining 34 of
empty ladle vessel 16 is the
same as working refractory lining 34 of full ladle vessel 18, it is assumed
that, during the heats,
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working refractory lining 34 of full ladle vessel 18 will be affected by the
molten metal or molten steel
contained therein. Therefore, the structural condition of working refractory
lining 34 in empty ladle
vessel 16 prior to a heat being conducted may be significantly different from
the structural condition
of working refractory lining 34 in empty ladle vessel 16 after each heat is
conducted.
[0078] As previously noted. system 4 includes at least one laser
scanner 20. Laser scanner 20 may
be stationary or mobile. Laser scanner 20 is configured to scan working
refractory lining 34 of empty
ladle vessel 16 before and after the heats of handling molten metal or molten
steel. Laser scanner 20
may have a class 1 eye safe laser with the capability to scan with a frequency
of 1,000,000 points in a
second. Laser scanner 20 may also have a scanning speed of 20 seconds and a 1
to 2 mm accuracy.
[0079] Laser scanner 20 is supported by laser support apparatus 21.
Laser support apparatus 21
may be a stationary support if laser scanner 20 is stationary or a mobile
support if laser scanner 20 is
mobile. If laser scanner 20 is mobile, laser support apparatus 21 may be any
means of support known
by those of ordinary skill in the art to be suitable for moving mobile laser
scanner 20. If laser scanner
20 is stationary, laser support apparatus 21 may be any means of fixable
support known by those of
ordinary skill in the art to be suitable for fixing stationary laser scanner
20.
[0080] The functions of scanning performed by laser scanner 20
include, but are not limited to,
collecting structural data related to observations of pre- and post-heat
structural conditions of working
refractory lining 34 in empty ladle vessel 16 respectively before and after
heats in which empty ladle
vessel 16 is filled with molten metal or molten steel, thereby becoming full
ladle vessel 18. This data
is provided to computing complex 10 for safekeeping in storage 14 and/or
consideration by processor
12 regarding the structural conditions of working refractory lining 34.
[0081] System 4 also may include one or more infrared cameras 22
that may conduct one or more
infrared scans of an outer surface of the outer wall of full ladle vessel 18
during the heat to collect data
related to a temperature of the outer surface of the outer wall of full ladle
vessel 18 during the heat.
[0082] In one example, infrared cameras 22 may be placed in several
locations within the process
mill to strategically measure the temperature of the outer surface of the
outer wall of full ladle vessel
18 as full ladle vessel 18 moves from a location in which full ladle vessel 18
is filled with the molten
steel to secondary steelmaking locations throughout the process mill,
including locations in which
refining takes place. In another example, infrared cameras 22 may be placed in
a location within the
process mill to strategically measure the temperature of the outer surface of
the outer wall of empty
ladle vessel 16 before and after the heats of handling molten metal or molten
steel. Thermal
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discrepancies of empty ladle vessel 16 can be identified even when empty ladle
vessel 16 is being
preheated. The temperature data collected from infrared cameras 22 can be
mapped to identify
deteriorating portions of working refractory lining 34 by processor 12.
[0083] Infrared cameras 22 may be any infrared camera known to those
having ordinary skill in
the art to be appropriate to image an outer surface of an outer wall of a
metallurgical vessel when
charged with molten steel. The temperature data can be provided to computing
complex 10 for
safekeeping in storage 14 and/or consideration by processor 12 regarding the
structural conditions of
working refractory lining 34.
[0084] While an analysis utilizing ASTM 680-14 or heat transfer
calculation software developed
for refractory design may be used to calculate the temperature data of empty
ladle vessel 16 or full
ladle vessel 18 obtained by infrared cameras 22 in view of thermal resistivity
and heat fluxes,
embodiments disclosed herein are not limited thereto. For example, any
software or method of
analysis known to one having ordinary skill in the art to be able to calculate
such temperature data can
be utilized.
[0085] Further, the laser scanned data, the temperature data, or a
combination thereof
communicated to computing complex 10 for consideration by processor 12 can be
additionally
considered alongside of other measured and predetermined operational
parameters stored in storage
14 that are awaiting communication to and consideration by processor 12. The
measured operational
parameters may be supplied to computer complex 10 for reference by processor
12 through previously
discussed hardware means, including, but not limited to, slag chemistry
measurement apparatus 3,
preheater thermocouple 2, residence time recording apparatus 23, preheating
recording apparatus 24,
gas stirring control apparatus 26, and ladle thernocouple 25. The
predetermined operational
parameters may be supplied to computer complex 10 through terminal 6 via user
input or historical
data previously processed by processor 12 and stored in storage 14 for future
reference regarding the
future status prediction for working refractory lining 34.
[0086] Predetermined operational parameters may include, but arc not
limited to, historical data
related to one or more refractories applied in one or more historical
refractory linings lined over inner
surfaces of outer walls of historical metallurgical vessels that handled
molten metal or molten steel,
an initial chemical composition and origin of working refractory lining 34, an
initial physical design
of working refractory lining 34, a grade of the steel that is desired to be
produced during the heat from
the molten steel in the metallurgical vessel, physical and chemical attributes
and amounts of charging
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mix components added to the metallurgical vessel during the heat to produce
the desired steel grade
from the molten steel, physical and chemical attributes and amounts of alloys
added to the
metallurgical vessel during the heat for secondary steelmaking and refining,
physical and chemical
attributes and amounts of slag formers added to the molten steel in the
metallurgical vessel during the
heat to form slags that absorb non-metallic components from the molten steel
to produce the desired
steel grade from the molten steel, physical and chemical attributes and
amounts of flux additives added
to the molten steel in the metallurgical vessel to optimize fluidity of the
formed slags to produce the
desired steel grade from the molten steel, a history of the metallurgical
vessel during a period in which
working refractory lining 34 has been lined over the liner surface of the
outer wall of the metallurgical
vessel, or any other relevant predetermined operational parameter identified
in a specific metal
producing operation.
[0087] For purposes of this application, the physical design of
working refractory lining 34 may
include, but is not limited to, construction details of working refractory
lining 34, shapes of refractory
components in working refractory lining 34, sizes of refractory components in
working refractory
lining 34, and combination of refractory components in working refractory
lining 34.
[0088] Measured operational parameters may include, but are not
limited to, a preheating duration
during which the metallurgical vessel is empty and being preheated prior to
the heat, a residence time
defined by the cumulative contact duration during which the molten steel, the
slags, or a combination
thereof are in contact with working refractory lining 34 during the process to
produce the molten steel,
an amount of stirring pressure applied by a stirring of the molten steel in
the metallurgical vessel, a
flow rate of inert gas applied to the molten steel in the metallurgical vessel
during the stirring of the
molten steel in the metallurgical vessel, a stirring duration during which the
molten metal is stirred, or
any other relevant measured operational parameter identified in a specific
metal producing operation.
[0089] Using the above-referenced data, processor 12 may determine
an exposure impact that the
heat has had on working refractory lining 34 of the metallurgical vessel and
predict a future status of
working refractory lining 34 after one or more subsequent heats. The exposure
impact that the heat
has on working refractory lining 34 may be determined by comparing the
structural conditions of
working refractory lining 34 before the heat with the structural conditions of
working refractory lining
34 after the heat. The future status of working refractory lining 34 after one
or more subsequent heats
is predicted based on the determined exposure impact. In other words, the
exposure impact of the
initial heat can be used to predict the future status of working refractory
lining 34 after a second heat,
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a third heat, and so on. Processor 12 may consider data from all data sources
referenced above, but is
not limited to thereto and could conceivably include other data sources not
mentioned herein.
[0090] In one example, in order to supplement the prediction of the
future status of working
refractory lining 34, the determination of the exposure impact of working
refractory lining 34 may
also be supplemented by correlating the collected temperature data from
infrared cameras 22 with the
structural conditions of working refractory lining 34 before the handling of
the molten steel and the
structural conditions of working refractory lining 34 after the handling of
the molten steel. This may
allow the future status to be more accurately predicted.
[0091] In another example, in order to supplement the prediction of
the future status of working
refractory lining 34, the determination of the exposure impact of working
refractory lining 34 may
also be supplemented by considering, in correlation with the collected
structural condition data, an
operational impact that one or more of the aforementioned predetermined or
measured operational
parameters have on the exposure impact of the heat on working refractory
lining 34.
[0092] In one example, the historical data related to one or more
refractories applied in one or
more historical refractory linings lined over inner surfaces of outer walls of
historical metallurgical
vessels that handled molten metal or molten steel may be used to establish
historical patterns of
exposure impact. Such historical patterns may complement the comparison of the
structural conditions
of working refractory lining 34 before the handling of the molten metal or
molten steel with the
structural conditions of working refractory lining 34 after the handling of
the molten metal or molten
steel, as well as the correlation of the collected temperature data from
infrared cameras 22 therewith.
Such historical data could be amassed in storage 14 of computer complex 10
after exposure impact
determination to enable processor 12 to predict the future status of
subsequent working refractory
linings after each successive heat with more accuracy.
[0093] With respect to the use of the measured operational
parameters to assist in determination
of the exposure impact, ladle thermocouple 25 can be provided to measure a
temperature of the molten
metal or molten steel in full ladle vessel 18. In one example, ladle
thermocouple 25 may be inserted
through aperture 40 of full ladle vessel 18 and into molten steel to measure
the temperature of the
molten steel during or at the end of the secondary steelmaking process (e.g.,
the end of the refining
process). Ladle thermocouple 25 may provide the measured temperature data to
computing complex
for considering by processor 12 during the determination of the exposure
impact pursuant to the
prediction of the future status of working refractory lining 34.
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[0094] In addition, slag chemistry measurement apparatus 3 may be
provided to measure a
chemical composition of a slag generated in a metallurgical vessel during the
secondary steelmaking
process. As previously noted, for measurement of the chemical composition, a
sample of the slag
must be cooled. Slag chemistry measurement apparatus 3 may be, for example, an
XRF unit, thereby
employing an x-ray fluorescence analytical technique to determine the chemical
composition. Slag
chemistry measurement apparatus 3 may provide the measured chemical
composition of a slag to
computing complex 10 for consideration by processor 12 during the
determination of the exposure
impact pursuant to the prediction of the future status of working refractory
lining 34.
[0095] Moreover, preheater thermocouple 2 may be provided to measure
a temperature of the
metallurgical vessel when the metallurgical vessel is empty and being
preheated prior to the
metallurgical vessel being filled of the molten metal or molten steel.
Preheater thermocouple 2 may
provide the measured preheater temperature to computing complex 10 for
consideration by processor
12 during the determination of the exposure impact pursuant to the prediction
of the future status of
working refractory lining 34.
[0096] To monitor the residence time duration, a recording
mechanism, such as residence time
recording apparatus 23 featured herein, may be used to measure the cumulative
contact duration during
which the molten metal, slags, or a combination thereof are in contact with
the refractory lining during
a heat.
[0097] In addition, to monitor the duration of the preheating, a
recording mechanism, such as
preheating recording apparatus 24 featured herein, may be used to record the
duration of the preheating
performed on an empty metallurgical vessel prior to a heat. Specifically, the
duration of the preheating
could be measured by preheating recording apparatus 24 as being as little as a
few minutes and as
great as several days. Preheating recording apparatus 24 may be included in a
gas-powered preheater,
along with an automatic gas shut-off.
[0098] Further, a control mechanism, such as gas stirring control
apparatus 26, may be used to
measure various stirring parameters, including, hut not limited to, an amount
of stirring pressure
applied by a stirring of the molten steel in a full metallurgical vessel, a
flow rate of inert gas applied
to the molten steel in the full metallurgical vessel during the stirring of
the molten steel in the full
metallurgical vessel, and a stirring duration during which the molten metal is
stirred.
[0099] Orientation laser 19 can be provided to scan the empty ladle
vessel 16 to identify a physical
orientation of the empty ladle vessel 16 prior to the laser scanning of
working refractory lining 34 by
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laser scanner 20. The scanning performed by orientation laser 19 serves to
assist and increase the
accuracy of the laser scanning of working refractory lining 34 performed by
laser scanner 20. The
physical orientation of the empty ladle vessel 16 relates to the position of
empty ladle vessel 16 with
respect to the process or facility in which empty ladle vessel 16is being
used. Orientation laser 19
provides the identified physical orientation of the metallurgical vessel to
computing complex 10 for
consideration by processor 12 to determine correct positioning of empty ladle
vessel 16 for accurate
determination of the exposure impact pursuant to the prediction of the future
status of working
refractory lining 34.
[00100] More particularly, data from orientation laser 19 may allow processor
12 to determine
thickness measurements from spatial measurements of the surface of working
refractory lining 34.
Such measurements cannot be derived unless the physical location and
orientation of empty ladle
vessel 16 is assumed or precisely known. Data from orientation laser 19 may
allow processor 12 to
precisely know the physical location and orientation of empty ladle vessel 16.
[00101] While orientation laser 19 is shown in FIG. 2 to be positioned
directly under empty ladle
vessel 16, embodiments disclosed herein are not limited thereto. For example,
orientation laser 19 can
be positioned in any safe and unobstructed placed with a direct visibility of
the outer wall of empty
ladle vessel 16, so that orientation laser 19 might be positioned to scan the
bottom and the lower
portion of empty ladle vessel 16. It is also noted that physical orientation
identification by orientation
laser 19 can be supplemented through the data provided by laser scanner 20
regarding empty ladle
vessel 16.
[00102] Referring now to FIGS. 2 and 3, method 100 of predicting a future
status of working
refractory lining 34 that is lined over an inner surface of an outer wall of a
metallurgical vessel and
exposed to a heat during which the refractory lining is exposed to molten
metal or molten steel is
described.
[00103] For purposes of discussion of method 100, "metallurgical vessel" may
refer to a ladle vessel
that is exposed to molten metal or molten steel. A ladle vessel in method 100
refers generally to empty
ladle vessel 16 and full ladle vessel 18 in situations in which the emptiness
or the fullness of the ladle
vessel is not at issue. In addition, in one example, empty ladle vessel 16
receives molten steel from a
furnace when molten steel is tapped therefrom. As such, empty ladle vessel 16
transitions to full ladle
vessel 18 when molten steel is tapped from the furnace into empty ladle vessel
16.
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[00104] Moreover, while method 100 is not limited to processes in which a
metallurgical vessel is
transported, it is assumed that, during a heat in method 100, ladle vessels 16
and 18 are transported
throughout the process location or mill through transport means known to those
having ordinary skill
in the art, such as, but not limited to, cranes, conveyors, rails, and
bearings. Further, computing
complex 10, including processor 12 and any other control unit contained
therein, is enabled to control
all processes, including, but not limited to, scanning, measuring,
transporting, transferring of metals,
observing, collecting, determining, predicting, and considering.
[00105] A schematic illustration of the transportation of ladle
vessel 16 and 18 is illustrated in FIG.
2. Empty ladle vessel 16 and full ladle vessel 18 are illustrated separately.
In an example, empty ladle
vessel 16 may be initially scanned to identify a physical orientation of empty
ladle vessel 16 prior to
any scanning of working refractory lining 34. Such an initial scan may be
performed by orientation
laser 19, which was discussed above. The physical orientation of empty ladle
vessel 16 may be taken
into account by processor 12 during any further considerations,
determinations, and predictions by
processor 12 with respect to ladle vessels 16 or 18.
[00106] In addition, after physical orientation scanning and prior to
any scanning of working
refractory lining 34, while empty ladle vessel 16 is being preheated in
preparation for a heat, a
preheating temperature and a preheating duration during which empty ladle
vessel 16 is being
preheated prior to the heat may be recorded. The preheating temperature may be
measured by
preheater thermocouple 2, and the preheating duration may be recorded by
preheating recording
apparatus 24. The preheating temperature and the preheating duration may be
used by processor 12
as measured parameters in considering an operational impact that the
operational parameters related
to the steelmaking have on the structural conditions of working refractory
lining 34 after the handling
of the molten metal or molten steel.
[00107] Further measurement of operational parameters, such as, but not
limited to, a measurement
of temperature of the molten metal or molten steel in full ladle vessel 18 by
ladle thermocouple 25, a
measurement of a chemical composition of a slag in full ladle vessel 18 by
slag chemistry measurement
apparatus 3, a measurement of the cumulative contact duration during which the
molten steel, the
slags, or a combination thereof are in contact with working refractory lining
34 during the heat by
residence time recording apparatus 23, and a measurement of a variety of
stirring parameters by gas
stirring control apparatus 26, may be performed during a heat and will be
described in detail below.
Predetermined operational parameters, as described above, may be provided to
computing complex
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when convenient. However, as has previously been noted and will be described
further below, any
predetermined operational parameters provided to computing complex 10 will be
considered by
processor 12 in the determination of the exposure impact on working refractory
lining 34.
[00108]
After any additional preparative steps are completed, prior to a
heat, a laser scan of working
refractory lining 34 of empty ladle vessel 16 is conducted (S101). The
conducting of the laser scan
prior to the heat may be performed by laser scanner 20. The conducting of the
laser scan prior to the
heat may also include the collecting of data related to pre-heat structural
conditions of working
refractory lining 34.
[00109] Then, a heat is performed, during which empty ladle vessel 16 is
filled with molten metal
or molten steel, thus becoming full ladle vessel 18. This is illustrated in
the flow of FIG. 2, where
empty ladle vessel 16 is illustrated at one portion of the process and full
ladle vessel 18 is illustrated
at a later point in the process. During the heat, full ladle vessel 18 is
emptied and becomes empty
ladle vessel 16, as is illustrated by the flow in FIG. 2.
[00110] After the heat is completed, another laser scan of working refractory
lining 34 of empty
ladle vessel 16 is conducted (S102). Similar to the conducting of the laser
scan prior to the heat, the
conducting of the laser scan after the heat may be performed by laser scanner
20. Further, the
conducting of the laser scan after the heat may also include the collecting of
data related to post-heat
structural conditions of working refractory lining 34.
[00111] After the laser scanning prior to the heat and the laser scanning
after the heat, processor 12
determines (S103) an exposure impact of the heat on working refractory lining
34. Processor 12 may
determine the exposure impact by comparing the collected pre-heat structural
condition data with the
collected post-heat structural condition data. After the determination of the
exposure impact of the
heat, processor 12 predicts (S104) the future status of working refractory
lining 34 after one or more
subsequent heats based on the determination of the exposure impact of the
heat.
[00112] This prediction provides information that is crucial to detet
__________________ -nine whether the ladle vessel
can be used again with working refractory lining 34 or if working refractory
lining 34 needs replaced.
As such, accidents that result in excessive structural damage to the ladle
vessel can be avoided,
resulting in less down time, greater efficiency, and cost savings.
[00113] In one example, during the heat, one or more infrared scans of the
outer surface of the outer
wall of full ladle vessel 18 may be conducted by infrared cameras 22. The
scans enable infrared
cameras 22 to collect data related to the temperature of the outer surface
detected during the heat. This
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temperature data may be correlated with the collected structural condition
data to more accurately
determine the exposure impact and predict the future status.
[00114] In another example, the determining of the exposure impact includes
considering, in
correlation with the collected structural condition data and, optionally, in
this particular example, the
collected temperature data from the infrared scanning, an operational impact
that one or more of the
measured or predetermined operational parameters have on working refractory
lining 34 during the
heat.
[00115] The predetermined operational parameters include those predetermined
operational
parameters previously discussed herein, including, but not limited to,
historical data related to one or
more refractories applied in one or more historical refractory linings that
handled molten metal, an
initial chemical composition and origin of working refractory lining 34, an
initial design of working
refractory lining 34, a grade of steel that is desired to be produced during
the heat, physical and
chemical attributes and amounts of charging mix components added to full ladle
vessel 18 during the
heat, physical and chemical attributes and amounts of alloys added to full
ladle vessel 18 during the
heat, physical and chemical attributes and amounts of slag formers added to
full ladle vessel 18 during
the heat, physical and chemical attributes and amounts of flux additives added
to full ladle vessel 18
during the heat, and a history of ladle vessel 16 and 18 during a period in
which working refractory
lining 34 has been lined therein.
[00116] The measured operational parameters include those measured operational
parameters
previously discussed herein, including, but not limited to, a preheating
temperature during which
empty ladle vessel 16 is being preheated prior to the heat measured by
preheater thermocouple 2, a
preheating duration during which empty ladle vessel 16 is being preheated
prior to the heat measured
by preheating recording apparatus 24, a measurement of temperature of the
molten metal or molten
steel in full ladle vessel 18 by ladle thermocouple 25, a measurement of the
cumulative contact
duration during which the molten steel, the slags, or a combination thereof
are in contact with working
refractory lining 34 during the heat by residence time recording apparatus 23,
and a measurement, by
gas stirring control apparatus 26, of a variety of stirring parameters, such
as, but not limited to, an
amount of stirring pressure applied by a stirring of the molten metal in full
ladle vessel 18 during the
heat, a flow rate of inert gas applied to the molten metal in full ladle
vessel 18 during the stirring, and
a stirring duration during which the molten metal is stirred.
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[00117] Referring now to the drawings, wherein the showing is for illustrating
a preferred
embodiment of the invention only and not for limiting same, the invention with
respect to the high
temperature process for the production or refining of glass, cement, lime,
chemicals, oils and gasses,
or other materials typically called as non-metals will be described with
reference to FIGS. 4-6.
[00118] FIG. 4 is a schematic view illustrating another example of a
predictive refractory
performance measurement system. Predictive refractory performance measurement
system 404 is
used to predict the future status, or performance, of refractory linings that
are lined over inner surfaces
of outer walls of manufacturing vessels for handling glass, cement, lime,
chemicals, oils and gasses,
or other materials typically referred to as non-metals. Predictive refractory
performance measurement
system 404 may be implemented in a mill, shop, production area, or other
environments known by
those of ordinary skill in the art to be suitable for the melting, forming,
sintering, densifying,
converting and refining of non-metal. However, it is contemplated that a
substantial portion of system
404 could be implemented in any environment in which surface analysis,
temperature analysis, process
data analysis, and life expectancy calculation are desired for refractories.
[00119] Systems 4 and 404 are similar, in that both systems 4 and 404 are
designed to determine
the condition of a refractory layer applied in an industrial process after
exposure during the industrial
process to corrosive material that could serve to cause the refractory layer
to deteriorate. While much
of the hardware in systems 4 and 404 is interchangeable, certain types of
hardware are unique to system
404. In addition, some hardware used in system 4 is not needed for the
operation of system 404.
Moreover, some of the corresponding hardware of systems 4 and 404 may perform
their functions
uniquely, as the processes and many of the measured components for which
system 4 is used are
different from those for which system 404 is used.
[00120] As is the case with system 4 and FIGS. 1-3, the example apparatuses,
units, modules,
devices, and other components illustrated in FIG.4 that make up system 404 and
perform the method
and operations described herein with respect to FIGS. 5 and 6 are implemented
by hardware
components. Examples of hardware components arc not limited to the above-
described example
apparatuses, units, modules, and devices and may include controllers, sensors,
generators, drivers, and
any other electronic components known to one of ordinary skill in the art.
Such components may be
variably located according to design needs and may communicate with each other
through wired or
wireless means.
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[00121] In the non-limiting example described herein, system 404 includes
computing complex
410. Computing complex 410 may include one or more processors 412 and one or
more means of
storage 414, but is not limited thereto. Processors 412 and storage 414 of
computing complex 410
may be oriented, positioned, or connected in any way to facilitate proper
operation of computing
complex 410. This includes, but is not limited to, wired configurations,
wireless configurations, local
configurations, wide area configurations, and any combination thereof in which
communication
therebetween can be established through compatible network protocol.
[00122] Processor 412 is implemented by one or more processing elements. Such
processing
elements may be as an array of logic gates, a controller and an arithmetic
logic unit, a digital signal
processor, a microcomputer, a programmable logic controller, a field-
programmable gate array, a
programmable logic array, a microprocessor, or any other device or combination
of devices known to
one of ordinary skill in the art that is capable of responding to and
executing instructions in a defined
manner to achieve a desired result.
[00123] For simplicity, the singular term "processor" may be used in the
description of the example
processor 412 described herein, but in other examples multiple processors 412
are used, or processor
412 includes multiple processing elements, or multiple types of processing
elements, or both. In one
example, system 404 of hardware components includes multiple processors 412 in
computing complex
410, and in another example, a hardware component of system 404 includes an
independent processor
or another controller containing a processor, which then communicates data to
receive data from
processor 412 of computing complex 410. Processor 412 of computing complex 410
may be defined
as a hardware component, along with other components of system 404 discussed
below. Similar to
processor 412 and other hardware components containing processing
functionality may be defined
according to any one or more of different processing configurations, examples
of which include a
single processor, independent processors, parallel processors, single-
instruction single-data (SISD)
multiprocessing, single-instruction multiple-data (S1MD) multiprocessing,
multiple-instruction
single-data (MTSD) multiprocessing, and multiple-instruction multiple-data
(MTMD) multiprocessing.
Processor 412 may be connected via cable or wireless network to hardware
components to provide
instruction thereto or to other processors to enable multiprocessing
capabilities.
[00124] Instructions or software to control processor 412 or hardware
including processors within
system 404 to implement the hardware components and perform the methods as
described below are
written as computer programs, code segments, instructions or any combination
thereof, for
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individually or collectively instructing or configuring processor 412 or
hardware including processors
within system 404 to operate as a machine or special-purpose computer to
perform the operations
performed by the hardware components and the methods as described below. In
one example, the
instructions or software include machine code that is directly executed by
processor 412 or hardware
including processors within system 404, such as machine code produced by a
compiler. In another
example, the instructions or software include higher-level code that is
executed by processor 412 or
hardware including processors within system 404 using an interpreter.
[00125] Programmers of ordinary skill in the art can readily write the
instructions or software based
on the flow chart illustrated in FIG. 6 and the corresponding descriptions
herein with respect to the
high temperature process for the production or refining of glass, cement,
lime, chemicals, oils and
gasses, or other materials typically called as non-metals, which disclose
algorithms for performing the
operations performed by the hardware components and the methods as described
above.
[00126] Hardware components implemented in system 404, such as processor 412
or components
linked to processor 412, execute instructions or software, such as an
operating system (OS) and one
or more software applications that run on the OS, to perform the operations
described here below with
respect to FIGS. 5 and 6.
[00127] The instructions or software to control processor 412 or hardware
including processors
within system 404 to implement the hardware components and perform the methods
as described
below, and any associated data, data files, and data structures, are recorded,
stored, or fixed in storage
414. Storage 414 of computing complex 410 generically refers to one or more
memories storing
instructions or software that are executed by processor 412. However, the
hardware components
implemented in system 404, such as processor 412 or components linked to
processor 412, may
include local storage or access, manipulate, process, create, and store data
in storage 414 in response
to execution of the instructions or software.
[00128] Storage 414 may be represented by on one or more non-transitory
computer-readable
storage media. Storage 414 may be representative of multiple non-transitory
computer-readable
storage media linked together via a network of computing complex 410. For
example, non-transitory
computer-readable storage media may be located in one or more storage
facilities or one or more data
centers positioned remotely from system 404 within computing complex 410. Such
a media may be
connected to system 404 through a network of computing complex 410. The
network of computing
complex 410 allows the non-transitory computer-readable storage media remotely
located at the data
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center or the storage facility to transfer data over the network to non-
transitory computer-readable
storage medium within storage 414 of computing complex 410. In addition,
storage 414 may be
representative of both remotely and locally positioned non-transitory computer-
readable storage
media.
[00129] Examples of a non-transitory computer-readable storage medium include
read-only
memory (ROM), random-access memory (RAM), flash memory, solid state memory, CD-
ROMs, CD-
Rs, CD+Rs, CD-RWs, CD+RWs, DVD-ROMs, DVD-Rs, DVD+Rs, DVD-RWs, DVD+RWs, DVD-
RAMs, BD-ROMs, BD-Rs, BD-R LTHs, BD-REs, magnetic tapes, floppy disks, magneto-
optical data
storage devices, optical data storage devices, hard disks, solid-state disks,
and any device known to
one of ordinary skill in the art that is capable of storing the instructions
or software and any associated
data, data files, and data structures in a non-transitory manner and providing
the instructions or
software and any associated data, data files, and data structures to processor
412 of computing complex
410 or hardware including processors within system 404 so that processor 412
or processors can
execute the instructions. In one example, the instructions or software and any
associated data, data
files, and data structures are distributed over network-coupled computer
systems so that the
instructions and software and any associated data, data files, and data
structures are stored, accessed,
and executed in a distributed fashion by processor 412.
[00130] Examples of hardware components in system 404 other than processor 412
and storage 414
of computing complex 410 may include terminal 406. Terminal 406 may include a
user input, a
display, or a combination thereof, but is not limited thereto. In FIG. 4,
terminal 406 is illustrated as
being connected to computing complex 410. However, embodiments disclosed
herein are not limited
thereto. For example, terminal 406 may be connected directly to processor 412,
directly to storage
414, to both storage 414 and processor 412, or to any other hardware component
of system 404.
[00131] Terminal 406 may be configured to display information contained in
storage 414 that has
been processed by processor 412 or inputted by a user. Processor 412 oversees
determining what
should be displayed on terminal 406. Storage 414 may be configured to store
data generated by
processor 412 and inputted through terminal 406. Applications, user input, and
processor calculations
may be stored in storage 414 for access by processor 412 in order to predict
refractory performance.
[00132] Further examples of the above-referenced hardware in system 404
connected to storage
414 are illustrated in at least one of FIGS. 4 or 5 and may include, at least
one laser scanner 420,
auxiliary thermocouple 402, one or more outer view infrared cameras 422, one
or more inner view
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infrared cameras 403, cycle time recording apparatus 423, auxiliary recording
apparatus 424,
environment measuring thermocouple 425, non-metal measuring thermocouple 428,
orientation laser
419, one or more pressure sensors 407, one or more gas sensors 409, and one or
more tomography
sensors 411 for radar/tomography scanning.
[00133] Some of this hardware may only be utilized in certain applications.
For example,
functional use of tomography sensors 411 for radar/tomography scanning may be
limited to
applications for radar wave differential measurements in which system 404 is
being used to measure
refractory layers in glass melters.
[00134] Further, functional use of pressure sensors 407 and gas sensors 409
may be limited to
petrochemical applications in which system 404 is being employed to measure
refractory lining 434
when manufacturing vessel 416 includes burner systems, uses variable fuel
feeds, or is under pressure
and exposed to the presence of gases. Specifically, pressure measurements
taken by pressure sensors
407 and gas-type measurements taken by gas sensors 409 may be communicated to
processor 412 for
consideration as to how exposure to the pressure and gas makeup within
manufacturing vessel 416
impacts a life span of refractory lining 434.
[00135] Moreover, functional use of glass pull rate calculator via processor
412 may be further
configured to calculate a glass pull rate, which represents the speed at which
glass is melted in
manufacturing vessel 416 and is usually expressed in the number of tons of
glass melted per day. Such
calculations may be considered as to how the speed at which the glass is
processed in manufacturing
vessel 416, i.e., the amount of material passing through the manufacturing
vessel 416 a day, impacts
a life span of refractory lining 434.
[00136] Storage 414 may receive data from these hardware components in any
wired or wireless
manner known to those having ordinary skill in the art and communicate the
received and stored data
to processor 412 in any wired or wireless manner known to those having
ordinary skill in the art for
further processing. These operational components will be more particularly
described in the
discussion below.
[00137] FIG. 5 is a schematic view illustrating an example refractory lining
434 being lined over
an inner surface of an outer wall of manufacturing vessel 416 for which a
future status of refractory
lining 434 is to be predicted by predictive refractory performance measurement
system 404. In the
examples illustrated in FIG. 5, refractory lining 434 is lined over an inner
surface of an outer wall of
manufacturing vessel 416.
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[00138] Depending on the severity of the manufacturing processes employed
during the operational
cycles, refractory lining 434 may only last for a few months. It is assumed
that, during the operational
cycles, refractory lining 434 of manufacturing vessel 416 will be affected by
molten liquids, or hot,
abrasive, and erosive solids, or hot and corrosive gases. Therefore, the
structural conditions of
refractory lining 434 of manufacturing vessel 416 after each operational cycle
may be significantly
different from the structural conditions of refractory lining 434 in
manufacturing vessel 416 prior to
each operational cycle conducted.
[00139] As previously noted, system 404 includes at least one laser scanner
420. Laser scanner
420 may be stationary or mobile. Laser scanner 420 is configured to scan
refractory lining 434 before
and after the operational cycle of handling non-metals. Laser scanner 420 may
have a class 1 eye safe
laser with the capability to scan with a frequency of 1,000,000 points in a
second. Laser scanner 420
may also have a scanning speed of 20 seconds and a 1 to 2 =a accuracy.
[00140] Laser scanner 420 is supported by laser support apparatus 421. Laser
support apparatus
421 may be a stationary support if laser scanner 420 is stationary or a mobile
support if laser scanner
420 is mobile. If laser scanner 420 is mobile, laser support apparatus 421 may
be any means of support
known by those of ordinary skill in the art to be suitable for moving mobile
laser scanner 420. If laser
scanner 420 is stationary, laser support apparatus 421 may be any means of
fixable support known by
those of ordinary skill in the art to be suitable for fixing stationary laser
scanner 420.
[00141] The functions of scanning performed by laser scanner 420 include, but
are not limited to,
collecting structural data related to observations of pre- and post-
operational cycle structural
conditions of refractory lining 434. This data is provided to computing
complex 410 for safekeeping
in storage 414 and/or consideration by processor 412 regarding the structural
conditions of refractory
lining 434.
[00142] System 404 also may include one or more outer view infrared cameras
422 that may
conduct one or more infrared scans of an outer surface of the outer wall of
manufacturing vessel 416
during the operational cycle to collect data related to a temperature of the
outer surface of the outer
wall of manufacturing vessel 416 during the operational cycle. System 404 may
further include inner
view infrared cameras 403 to conduct one or more infrared scans of an inner
surface of the outer wall
of manufacturing vessel 416 during the operational cycle to collect data
related to a temperature of the
inner surface of the outer wall of manufacturing vessel 416 during the
operational cycle.
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[00143] In one example, outer view infrared cameras 422 may be placed in
several locations around
the outside wall of manufacturing vessel 416 to strategically measure the
temperature of the outer
surface of the outer wall of manufacturing vessel 416. The thermal reading
during the operational
cycle and between the operational cycles can he recorded by outer view
infrared cameras 422 and
analyzed for thermal discrepancies. The temperature data collected from outer
view infrared cameras
422 can be then mapped to identify deteriorating portions of refractory lining
434 by processor 412.
[00144] In another example, inner view infrared cameras 403 may be placed in
locations which
would allow for measurement of temperatures of the inner surface of the outer
wall of manufacturing
vessel 416. Such locations may include, but are not limited to, entry opening
440 of manufacturing
vessel 416, exit opening 418 of manufacturing vessel 416, or any other opening
in the structure of the
manufacturing vessel 416 that would be known by one having ordinary skill in
the art to enable inner
view infrared cameras 403 to measure the temperatures of the inner surface of
the outer wall of
manufacturing vessel 416.
[00145] Outer view infrared cameras 422 may be any infrared camera known to
those having
ordinary skill in the art to he appropriate to image an outer surface of an
outer wall of manufacturing
vessel 416 when a temperature of manufacturing vessel 416 is elevated during
the operational cycle.
Inner view infrared cameras 403 may be any infrared camera known to those
having ordinary skill in
the art to be appropriate to image an inner surface of an outer wall of
manufacturing vessel 416 when
a temperature of manufacturing vessel 416 is elevated during the operational
cycle.
[00146] The temperature data from outer view infrared cameras 422 and inner
view infrared
cameras 403 can be provided to computing complex 410 for safekeeping in
storage 414 and/or
consideration by processor 412 regarding the structural conditions of
refractory lining 434. While an
analysis utilizing ASTM 680-14 or heat transfer calculation software developed
for refractory design
may be used to calculate the temperature data obtained by outer view infrared
cameras 422 in view of
thermal resistivity and heat fluxes, embodiments disclosed herein are not
limited thereto. For example,
any software or method of analysis known to one having ordinary skill in the
art to be able to calculate
such temperature data can be utilized.
[00147] The temperature readings from inner view infrared cameras 403 during
the operational
cycle may serve to complement the temperature readings from environment
measuring thermocouple
425 or non-metal measuring thermocouple 428.
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[00148] As previously noted, when manufacturing vessel 416 is a glass melter
or a similar vessel
used for processing glass, radar/tomography scanning via tomography sensors
411 may be used for
measuring thickness of refractory lining 434, detecting incidence of glass
impregnation into refractory
lining 434 during the operational cycle, or a combination thereof. The
radar/tomography measurement
via tomography sensors 411 is taken from the outer surface of the outer wall
of manufacturing vessel
416. Tomography sensors 411 use radar wave technology to identify the
difference in density between
the glass being processed during the operational cycle and refractory lining
434.
[00149] Further, whether described above or below, the laser scanned data, the
temperature data,
the radar data, the pressure data, the gas data, the glass pull rate data, or
a combination thereof, which
is communicated to computing complex 410 for consideration by processor 412,
can be additionally
considered alongside of other measured and predetermined operational
parameters stored in storage
414 that are awaiting communication to and consideration by processor 412. The
measured
operational parameters may be supplied to computer complex 410 for reference
by processor 412
through previously discussed hardware means, including, but not limited to
pressure sensors 407, gas
sensors 409, auxiliary thermocouple 402, cycle time recording apparatus 423,
tomography sensors
411, laser scanner 420, inner view infrared cameras 403, outer view infrared
cameras 422, auxiliary
recording apparatus 424, environment measuring thermocouple 425, and non-metal
measuring
thermocouple 428. The predetermined operational parameters may be supplied to
computer complex
410 through terminal 406 via user input or historical data previously
processed by processor 412 and
stored in storage 414 for future reference regarding the future status
prediction for refractory lining
434.
[00150] Predetermined operational parameters may include, but are not limited
to, historical data
related to one or more refractories applied in one or more historical
refractory linings lined over inner
surfaces of outer walls of historical manufacturing vessels that handled non-
metals, an initial chemical
composition and origin of refractory lining 434, an initial physical design of
refractory lining 434, a
grade of the non-metal that is desired to he produced during the operational
cycle in manufacturing
vessel 416, physical and chemical attributes and amounts of charging or
continuously fed mix
components added to manufacturing vessel 416 during the operational cycle to
produce the desired
non-metal grade and chemical attributes and amounts of additives, colorants or
combustion gases
added to manufacturing vessel 416.
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[00151] For purposes of this application, the physical design of refractory
lining 434 may include,
but is not limited to, construction details of refractory lining 434, shapes
of refractory components in
refractory lining 434, sizes of refractory components in refractory lining
434, and combination of
refractory components in refractory lining 434.
[00152] Additional measured operational parameters may include, but are not
limited to, a
preheating, heat up, or cool down temperature and duration schedule according
which manufacturing
vessel 416 is being preheated or heated up prior to the operational cycle or
cooled down after the
operational cycle. Further measured operational parameters may include a cycle
time defined by the
cumulative duration of the operational cycle, or any other relevant measured
operational parameter
identified in a specific non-metal producing operation.
[00153] Using the above-referenced data, processor 412 may determine an
exposure impact that the
operational cycle has had on refractory lining 434 of manufacturing vessel 416
and predict a future
status of refractory lining 434 after one or more subsequent operational
cycles. The exposure impact
that the operational cycle has on refractory lining 434 may be determined by
comparing the structural
conditions of refractory lining 434 before the operational cycle with the
structural conditions of
refractory lining 434 after the operational cycle. The future status of
refractory lining 434 after one or
more subsequent operational cycles is predicted based on the determined
exposure impact. In other
words, the exposure impact of the initial cycle can be used to predict the
future status of refractory
lining 434 after a second cycle, a third cycle, and so on. Processor 412 may
consider data from all
data sources referenced above, but is not limited to thereto and could
conceivably include other data
sources not mentioned herein.
[00154] In one example, in order to supplement the prediction of the future
status of refractory
lining 434, the determination of the exposure impact of refractory lining 434
may also be supplemented
by correlating the collected temperature data from outer view infrared cameras
422 and inner view
infrared cameras 403 with the structural conditions of refractory lining 434
before, during, and after
each operational cycle. This may allow the future status to be more accurately
predicted.
[00155] In another example, in order to supplement the prediction of the
future status of refractory
lining 434, the determination of the exposure impact of refractory lining 434
may also be supplemented
by considering, in correlation with the collected structural condition data,
an operational impact that
one or more of the aforementioned predetermined or measured operational
parameters have on the
exposure impact of the operation cycle on refractory lining 434.
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[00156] In one example, the historical data related to one or more
refractories applied in one or
more historical refractory linings lined over inner surfaces of outer walls of
historical manufacturing
vessels that produced non-metal may be used to establish historical patterns
of exposure impact. Such
historical patterns may complement the comparison of the structural conditions
of refractory lining
434 before and after the operational cycle of producing non-metal, as well as
the correlation of the
collected temperature data from outer view infrared cameras 422 and inner view
infrared cameras 403
therewith. Such historical data could be amassed in storage 414 of computer
complex 410 after
exposure impact determination to enable processor 412 to predict the future
status of subsequent
refractory linings after each successive operational cycle with more accuracy.
[00157] With respect to the use of the measured operational parameters to
assist in determination
of the exposure impact, environment measuring thermocouple 425 can be provided
to measure a
temperature of the environment within manufacturing vessel 416. Non-metal
measuring thermocouple
428 can be provided to measure a temperature of the non-metal being processed
within manufacturing
vessel 416.
[00158] Moreover, auxiliary thermocouple 402 may be provided to measure a
temperature of
manufacturing vessel 416 when manufacturing vessel 416 is empty and being
preheated or heated up
prior to manufacturing vessel 416 being filled of the non-metal, or during
cooling down of
manufacturing vessel 416 at the end of the operational cycle. Auxiliary
thermocouple 402,
environment measuring thermocouple 425, and non-metal measuring thermocouple
428 may provide
the measured temperature to computing complex 410 for consideration by
processor 412 during the
determination of the exposure impact pursuant to the prediction of the future
status of refractory lining
434.
[00159] To monitor the cycle time duration, a recording mechanism, such as
cycle time recording
apparatus 423 featured herein, may be used to measure the cumulative contact
duration during which
the non-metal, the coatings, or a combination thereof are in contact with
refractory lining 434 during
an operational cycle.
[00160] In addition, to monitor the duration of the preheating, or heat up, or
cool down, a recording
mechanism, such as auxiliary recording apparatus 424 featured herein, may be
used to control and
record the duration and temperature of the heating performed on manufacturing
vessel 416 prior to an
operational cycle, or cooling pedal_ __ ned on manufacturing vessel 416 at the
end of the operational
cycle. Specifically, the duration of the heating or cooling could be measured
by auxiliary recording
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apparatus 424 as being as little as a few hours and as great as several days.
Auxiliary recording
apparatus 424 may be included in a gas-powered prehcater, along with an
automatic gas shut-off.
[00161] Orientation laser 419 can be provided to scan manufacturing vessel 416
to identify a
physical orientation of manufacturing vessel 416 prior to the laser scanning
of refractory lining 434
by laser scanner 420. The scanning performed by orientation laser 419 serves
to assist and increase
the accuracy of the laser scanning of refractory lining 434 performed by laser
scanner 420. The
physical orientation of manufacturing vessel 416 relates to the position of
manufacturing vessel 416
with respect to the process or facility in which manufacturing vessel 416 is
being used. Orientation
laser 419 provides the identified physical orientation of manufacturing vessel
416 to computing
complex 410 for consideration by processor 412 to determine correct
positioning of manufacturing
vessel 416 for accurate determination of the exposure impact pursuant to the
prediction of the future
status of refractory lining 434.
[00162] More particularly, data from orientation laser 419 may allow processor
412 to determine
thickness measurements from spatial measurements of the surface of refractory
lining 434. Such
measurements cannot be derived unless the physical location and orientation of
manufacturing vessel
416 is assumed or precisely known. Data from orientation laser 419 may allow
processor 412 to
precisely know the physical location and orientation of manufacturing vessel
416.
[00163] The orientation laser 419 can be positioned in any safe and
unobstructed place with a direct
visibility of the outer wall of manufacturing vessel 416, so that orientation
laser 419 might be
positioned to scan the relevant refractory lined portions of manufacturing
vessel 416. It is also noted
that physical orientation identification by orientation laser 419 can be
supplemented through the data
provided by laser scanner 420 regarding manufacturing vessel 416.
[00164] Referring now to FIGS. 5 and 6, method 600 of predicting a future
status of refractory
lining 434 that is lined over an inner surface of an outer wall of
manufacturing vessel 416 and exposed
to an operational cycle during which refractory lining 434 is exposed to non-
metal is described.
[00165] For purposes of discussion of method 600, "manufacturing vessel" may
refer to a vessel,
such as manufacturing vessel 416 that is exposed to non-metal and an
environment for processing or
producing non-metal. Further, computing complex 410, including processor 412
and any other control
unit contained therein, is enabled to control all processes, including, but
not limited to, scanning,
measuring, transferring materials to and from manufacturing vessel 416,
observing, collecting,
determining, predicting, and considering.
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[00166] In an example, manufacturing vessel 416 may be initially scanned by
orientation laser 419
to identify a physical orientation of manufacturing vessel 416 prior to any
scanning of refractory lining
434 by laser scanners 420. The physical orientation of manufacturing vessel
416 may be taken into
account by processor 412 during any further considerations, determinations,
and predictions by
processor 412 with respect to manufacturing vessel 416.
[00167] In addition, after physical orientation scanning and prior to any
scanning of refractory
lining 434, while manufacturing vessel 416 is being preheated or heated up in
preparation for an
operation cycle, or cooled down after an operation cycle, a preheating
temperature, a heat up
temperature, or a cool down temperature, and a duration during which
manufacturing vessel 416 is
being preheated or heated up prior to the operation cycle or cooled down after
the operation cycle may
be measured by auxiliary thermocouple 402, and recorded by auxiliary apparatus
424. The
temperature data and the preheating duration respectively collected by
auxiliary thermocouple 402 and
auxiliary apparatus 424 may be used by processor 412 as measured parameters in
considering an
operational impact that the operational parameters related to the high-
temperature environment for
producing a non-metal have on the structural conditions of refractory lining
434 after exposure thereto.
[00168] Further measurement of operational parameters, such as, but not
limited to, a measurement
of temperature of the non-metal in manufacturing vessel 416 by non-metal
thermocouple 428, a
measurement of temperature of the environment in manufacturing vessel 416 by
environment
measuring thermocouple 425, and a measurement of the cumulative contact
duration during which the
non-metal and the environment are in contact with refractory lining 434 during
the heat by cycle time
recording apparatus 423, may be performed during an operational cycle and will
be described in detail
below. Predetermined operational parameters, as described above, may be
provided to computing
complex 410 when convenient. However, as has previously been noted and will be
described further
below, any predetermined operational parameters provided to computing complex
410 will be
considered by processor 412 in the determination of the exposure impact on
refractory lining 434.
[001691 After any additional preparative steps arc completed, prior
to an operational cycle, a laser
scan of refractory lining 434 of manufacturing vessel 416 is conducted (S601).
The conducting of the
laser scan prior to the operational cycle may he performed by laser scanner
420. The conducting of
the laser scan prior to the operational cycle may also include the collecting
of data related to pre-
operational cycle structural condition of refractory lining 434.
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[00170] Then, an operational cycle is performed, during which manufacturing
vessel 416 is filled
with a high-temperature environment for producing a non-metal and,
subsequently, a non-metal
produced within the high-temperature environment. After the operational cycle
is completed, another
laser scan of refractory lining 434 of manufacturing vessel 416 is conducted
(S602). Similar to the
conducting of the laser scan prior to the operational cycle, the conducting of
the laser scan after the
operational cycle may be performed by laser scanner 420. Further, the
conducting of the laser scan
after the operational cycle may also include the collecting of data related to
post-operational cycle
structural conditions of refractory lining 434.
[00171] After the laser scanning prior to the operational cycle and the laser
scanning after the
operational cycle, processor 412 determines (S603) an exposure impact of the
operational cycle on
refractory lining 434. Processor 412 may determine the exposure impact by
comparing the collected
pre-operational cycle structural condition data with the collected post-
operational cycle structural
condition data. After the determination of the exposure impact of the
operational cycle, processor 412
predicts (S604) the future status of refractory lining 434 after one or more
subsequent operational
cycles based on the determination of the exposure impact of the operational
cycle.
[00172] This prediction provides information that is crucial to determine
whether manufacturing
vessel 416 can be used again with refractory lining 434 or if refractory
lining 434 needs replaced. As
such, accidents that result in excessive structural damage to the
manufacturing vessel 416 can be
avoided, resulting in less down time, greater efficiency, and cost savings.
[00173] In one example, during the operational cycle, one or more infrared
scans of the outer
surface of the outer wall of manufacturing vessel 416 may be conducted by
outer view infrared
cameras 422. The scans enable outer view infrared cameras 422 to respectively
collect data related to
the temperature of the outer surface detected during the operational cycle.
This temperature data may
be correlated with the collected structural condition data to more accurately
determine the exposure
impact and predict the future status, while also identifying deteriorating
portions of refractory lining
434 based on the determined exposure impact.
[00174] In another example, the determining of the exposure impact includes
considering, in
correlation with the collected structural condition data and, optionally, in
this particular example, the
collected temperature data from the infrared scanning, an operational impact
that one or more of the
measured or predetermined operational parameters have on refractory lining 434
during the
operational cycle.
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[00175] The predetermined operational parameters include those predetermined
operational
parameters previously discussed herein, including, but not limited to,
historical data related to one or
more refractories applied in one or more historical refractory linings exposed
to the high-temperature
environment and the non-metal, an initial chemical composition and origin of
refractory lining 434,
an initial design of refractory lining 434, physical and chemical attributes
and amounts of charging or
continuously fed mix components added to manufacturing vessel 416 during the
operational cycle,
and a history of manufacturing vessel 416 during a period in which refractory
lining 434 has been
lined therein.
[00176] The measured operational parameters include those measured operational
parameters
previously discussed herein, including, but not limited to, a preheating,
heating or cooling temperature
and temperature changes measured by auxiliary thermocouple 402, a duration,
during which changes
in manufacturing vessel 416 measured by auxiliary thermocouple occurs,
measured by auxiliary
apparatus 424, a measurement of temperature of the non-metal in manufacturing
vessel 416 by non-
metal measuring thermocouple 428, a measurement of temperature of the
environment in
manufacturing vessel 416 by environment measuring thermocouple 425, a
measurement of the
temperature of the inner surface of refractory lining 434 by inner view
infrared cameras 403, a
measurement of the cumulative contact duration during which the non-metal and
the environment are
in contact with refractory lining 434 during the operational cycle by cycle
time recording apparatus
423, pressure and gas-type measurements within manufacturing vessel 416
respectively measured by
pressure sensors 407 and gas sensors 409, measuring thickness of refractory
lining 434 via
radar/tomography scanning by tomography sensors 411, and glass pull rate
measurements calculated
by processor 412.
[00177] The foregoing description is a specific embodiment of the present
invention. It should be
appreciated that this embodiment is described for purposes of illustration
only, and that numerous
alterations and modifications may be practiced by those skilled in the art
without departing from the
spirit and scope of the invention. It is intended that all such modifications
and alterations be included
insofar as they come within the scope of the invention as claimed or the
equivalents thereof.
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