FIGS. 2 and 3 show an apparatus 10 for heating steel products 100 of the casting semi-products type, typically steel billets.

Hereafter, for simplicity, we will refer to billets 100, or blooms, as products treated in the apparatus 10, but this reference is made only by way of example

The apparatus 10 comprises a furnace 11, preferably of the direct combustion irradiation type and with continuous feed. The furnace 11 has an entry end 110 and an exit end 111 opposite the entry end 110, in correspondence of which there are located respectively a loading station 12, or charging station, and an unloading station 13, or discharging station, configured respectively to load the billets 100 into the furnace 11 in correspondence with the entry end 110 and to unload the heated billets 100 from the furnace 11 in correspondence with the exit end 111.

Inside the furnace 11 there is defined a straight path for feeding the billets 100, extending between the entry end 110 and the exit end 111, through which the billets respectively enter and exit the furnace 11.

The entry 110 and exit 111 ends are defined by respective end walls 112, 113 of the furnace 11, which also has two lateral walls 114, 115 each connected to the two end walls 112, 113, as well as an upper wall 116, also called vault, and a lower wall 117, also called bottom. These walls 112-117 contribute to delimit an internal volume of the furnace in which the heating of the billets 100 is operated, and in which the path for feeding the billets 100 is located.

The feed path is defined on a horizontal plane P, located at an intermediate height inside the furnace 11 (FIG. 2) between the upper wall 116 and the lower wall 117, preferably at about half the height of the furnace 11.

The billets 100 are disposed in special receivers 200, commonly referred to as seatings, which are displaced in an advantageously continuous manner between the entry end 110 and the exit end 111.

Advantageously, the furnace 11 comprises an entry aperture disposed in correspondence with the entry end 110, more preferably in correspondence with a lateral wall 114, 115 of the furnace 11.

The furnace 11 is divided internally into a first part 20 and a second part 30, which are disposed in this order along the feed path. The first part 20 starts from the entry end 110 and is set at a first temperature T1 for the pre-heating of the billets 100, in order to raise their temperature gradually. For this reason, the first part 20 of the furnace 11 is also called the pre-heating zone. For example, the temperature T1 in the first part 20 ranges between approximately 700 and 1000-1100° C., depending on the steel to be heated.

The second part 30 is located between the first part 20 and the exit end 111, and is set at a second temperature T2 higher than the first temperature T1 (FIG. 1). The temperatures T2, typically higher than 1000° C., are such as to heat the billets 100 to the point of making them plastically deformable.

As can be seen from FIG. 2, the first part 20 delimits an entry zone 21, or charging zone, adjacent to the entry end 110 of the furnace 10. The entry zone 21 is followed by a pre-heating zone 22, also included in the first part 20 of the furnace 11.

Preferably, the second part 30 is also separated into two zones, a heating zone 31, which directly follows the pre-heating zone 22, and an equalization zone 32 located between the heating zone 31 and the exit end 13 of the furnace 11.

In the example shown in FIGS. 2 and 4, the heating zone 31 is divided into an upper heating half-zone 31A and a lower heating half-zone 31B, located below the upper heating half-zone 31A.

Similarly, the equalization zone 32 is divided approximately in half into an upper equalization half-zone 32A and a lower equalization half-zone 32B.

This division of the heating zone 31 and of the equalization zone 32 is preferably materialized by the plane P for feeding the billets 100. It follows that the pre-heating zone 22 is also divided into an upper pre-heating half-zone 22A and a lower pre-heating half-zone 22B (FIGS. 2 and 3).

The heating zone 31 is set at a temperature T2 higher than the maximum temperature T1 of the pre-heating zone 22, and has the purpose of heating the billet 100 until it is deformable, for the subsequent rolling. The equalization zone 32, with a temperature T2 even higher than the heating zone 31, has the purpose of levelling out the temperature of the steel between the inside of the billet and its surface.

The temperature inside the furnace 11 is gradually and continuously increased along the rectilinear feed path, starting for example from 700° C. in correspondence with the entry end 110 to reach temperatures of the order of 1000° C. at the end of the first part 20. In the second part 30, the temperature T2 is substantially maintained at the same high value, or slightly higher than the temperature obtained at the end of the pre-heating zone 22, so as to increase the temperature of the billet, both on its surface and also in its interior. For example, the temperature T2 in the second part can be of the order of 1100° C.

It should be noted that the temperatures inside the furnace 11 are regulated so as not to overheat the surface of the billets, to the detriment of skin-heart homogeneity.

The zones 21, 22, 31, 32 defined above advantageously have well-known sizes and volumes, which allows to effectively control their physical parameters during the functioning of the thermal heating apparatus 10, in particular the temperature and the concentrations of fuel and of comburent present inside them.

In the example shown, the first part 20 and the second part 30 have substantially equal lengths. The entry zone 21 has a height preferably lower than the height of the other zones 22, 31, 32, all three of which have the same height.

Advantageously, the limit between the first part 20 and the second part 30 is materialized by an internal edge 23 which protrudes from the upper wall of the furnace 11. This upper internal edge 23 can have a height such that its lower end is at the same height of the upper wall in the entry zone 21.

The apparatus 10 also comprises, inside it, combustion members 40, or burners, distributed between the different zones 21, 22, 31, 32 previously defined. The burners 40 are connected to a source of fuel, for example methane, and a source of comburent which preferably contains oxygen, in particular air, by means of suitable means for feeding fuel and means for feeding comburent, for example pipes.

In the example shown in FIG. 2, the apparatus comprises several burners 40, referred to as lateral, disposed in the lateral walls 114, 115 of the furnace 11, and at least one burner 41, referred to as frontal, disposed in correspondence with the exit end 111. More advantageously, the furnace 11 comprises a plurality of front burners 41, for example eight, regularly distributed between the lateral walls 114, 115 so as to uniformly heat the upper equalization half-zone 32A.

It should be noted that the burners 40 are disposed in the pre-heating zone 22, in the heating zone 31 and in the equalization zone 32. By way of example only, it can be provided that on each of the lateral walls 114, 115 of the furnace there are four burners 40 in the pre-heating zone 22 and in the heating zone 31, and only two burners 40 in the equalization zone 32.

In the latter zone 32, the lateral burners 40 are preferably disposed only in the lower equalization half-zone 32B, due to the presence of the front burners 41 in the upper equalization half-zone 32A.

The burners 40, 41 used in the furnace 11 are advantageously able to operate in any condition whatsoever of comburent quantity with respect to fuel quantity.

In particular, there is defined a ratio LAMBDA=A_real/A_theoretical, in which A_realis the quantity of comburent actually delivered, and A_theoreticalis the quantity of comburent to which there corresponds the precise quantity of oxygen necessary and sufficient to complete the combustion reactions involved, which are:

C+O₂=CO₂+33910 kj/kg

2H₂+O₂=2H₂O+143000 kj/kg

S+O₂=SO₂+8800 kj/kg

If LAMBDA is equal to 1, the combustion is carried out with the precise theoretical quantity of oxygen. The burners 40 are able to operate both with LAMBDA less than 1, and also with LAMBDA greater than 1.

The apparatus 10 also comprises means for feeding fuel, to feed the fuel from the corresponding source to the burners 40, 41, and means for feeding comburent, to feed the comburent from the corresponding source to the burners 40, 41.

Preferably, the means for feeding comburent and the means for feeding fuel are configured to feed the fuel in excess with respect to the comburent in correspondence with the second part 30. In this way, a complete consumption of the comburent, and therefore of the oxygen, is promoted during combustion which allows to heat and maintain the temperature of the billets, preventing the formation of scale on the steel products (“scale free” products).

In the present invention, the scale is reduced by at least 50% with respect to known solutions, even down to negligible values.

For example, it can be provided that the means for feeding comburent and the means for feeding fuel are configured to feed the excess fuel so as to have a sub-stoichiometric proportion of oxygen in the equalization zone 32, and to have a sub-stoichiometric or stoichiometric presence of oxygen in the heating zone 31.

By stoichiometric proportion we mean, in the context of this description, that the quantity of oxygen introduced is exactly equal to that suitable for burning the exact quantity of fuel introduced (this corresponds to LAMBDA=1).

Similarly, by sub-stoichiometric proportion we mean that the quantity of oxygen introduced is smaller than the quantity necessary to burn the quantity of fuel introduced (this corresponds to LAMBDA<1). In other words, when the air is fed in a sub-stoichiometric proportion, the combustion reaction theoretically leads to the complete consumption of oxygen while the fuel is not totally consumed.

On the contrary, the means for feeding fuel and comburent are preferably configured so as to feed the excess comburent (LAMBDA>1) into the first part 20 of the furnace 11.

It is also advantageous to provide that the apparatus 10 is equipped with an additional comburent injection circuit, also called post-combustion system, configured to complete the combustion of the fuel transferred (without being combusted) from the second part 30 of the furnace 11 (where the comburent is fed in sub-stoichiometric proportion) to the first part 20 (where the comburent is fed in excess). In this way, the excess fuel in the second part 30 is burned in the first part 20 and the combustion reaction is used to transfer heat to the steel semi-products.

This provision allows to optimize fuel consumption. The post-combustion circuit comprises nozzles 50 located in the first part 20 of the furnace 11, obviously inside the latter. According to some embodiments, the circuit also comprises a control device configured to check that the fuel has been consumed.

Advantageously, it can be provided to dispose the nozzles 50 on the upper internal edge 23, more advantageously on the surface of the upper internal edge 23 facing toward the first part 20 of the furnace 11, so as to directly inject the comburent into it, while avoiding injecting it into the second part 30 of the furnace (FIG. 2).

In the example shown, the post-combustion circuit is capable of operating the consumption of excess fuel in the upper half-zone 22A of the pre-heating zone 22. In order to further optimize fuel consumption, other nozzles 50 can be provided (not shown) disposed in the lower zone of the first part 20 of the furnace, preferably in the lower half-zone 22B of the pre-heating zone 22.

For example, a second internal edge can be provided, which can be similar to the internal edge 23 of the upper wall, but disposed on the lower wall. The nozzles of the lower half-zone 22B can be advantageously disposed on this lower internal edge, and facing toward the pre-heating zone 22. The presence of the lower internal edge also allows to further determine the separation between the first part 20 of the furnace 11 and the second part 30.

Preferably, the control device is configured to measure the presence of oxygen, and possibly also of carbon monoxide CO in the entry zone 21. For this purpose, the control device can comprise a laser spectrometer 51, one or more oxygen probes 52 to detect free oxygen and one or more CO sampling probes. The spectrometer 51 and the free oxygen probe 52 are preferably disposed in the entry zone 21.

The furnace 10 also preferably comprises oxygen sensors able to monitor the presence and concentration of oxygen inside the furnace 11. Preferably, the furnace comprises at least one sensor in each of the entry 21, pre-heating 22, heating 31 and equalization 32 zones.

Advantageously, the sensors are configured to monitor the presence of oxygen continuously. More advantageously, they are of the optical type, for example of the laser type.

Preferably, the furnace 11 also comprises a fumes extraction system, configured to extract the combustion fumes from the inside of the furnace 11 toward the outside. More preferably, the fumes extraction system, which is known and therefore not described further in the present application, is located in the first part 20 of the furnace 11.

According to some embodiments, the apparatus 10 can also comprise a plurality of probes 70 connected to the furnace 11 to detect the presence and/or concentration inside it of other chemical compounds such as, for example, carbon monoxide CO, carbon dioxide CO₂, hydrogen H₂and/or methane CH₄.

In the example shown, the apparatus 10 comprises four probes 70 in each of the pre-heating 22, heating 31 and equalization 32 zones of the furnace 11. Preferably, the probes 70 are disposed in the lateral walls 114, 115 of the furnace 11 (FIGS. 2 and 4). More preferably, they are disposed in pairs, the two components of one same pair each being placed in one respective lateral wall 114, 115 and facing each other.

Even more preferably, the two pairs of each of the pre-heating 21, heating 31 and equalization 32 zones are disposed one above the other, that is, vertically aligned. For example, in the heating 31 and equalization 32 zones, it can be provided to have one pair of probes 70 in the upper half-zone 31A, 32A, and the other in the lower half-zone 31B, 32B.

The furnace 10 also preferentially comprises thermometers disposed in the different zones of the furnace so as to detect the temperature in correspondence therewith.

According to some embodiments, the furnace 11 also provides laser sensors disposed so as to be able to check the straightness of the billets 100 and their state of advance inside the furnace.

It should be noted that all the sensors as above are advantageously connected to the furnace without providing holes in its walls, or providing an appropriate sealing thereof, in order to limit the risks of air entering inside it as much as possible.

Advantageously, the apparatus 10 also comprises a series of measures aimed at improving the gas seal, in order to prevent the loss of fuel and/or comburent, but also and above all the entry of unwanted air into the furnace. In this way, it is possible to regulate the composition of the atmosphere inside the different zones 21, 22, 31, 32 of the furnace 11 with greater precision. These measures are substantially present in all the zones of the furnace 11 that separate the internal volume of the furnace 11 from the outside, with particular regard to the hottest part of the furnace, that is, the second part 30. For example, the furnace 11 can comprise doors with improved seal.

In the example shown in FIGS. 2 and 3, the loading station 12 is located outside the entry end wall 112. The loading station 12 in turn comprises a plurality of conveyor devices 120 each comprising a roller 121 located inside the furnace 11, and a corresponding motor member 122 located outside the furnace. The roller 121 and the motor member 122 are coupled by means of a shaft 123 which passes through a corresponding through aperture 124 made in the end wall 112 of the furnace 11 (FIG. 2a).

Similarly, the unloading station 13 is located outside the exit end wall 113 and comprises conveyor devices 130, provided to convey the billets 100 out of the furnace 11, and transfer devices 140 to transfer the billets 100 from the feed plane P to the conveyor devices 130.

The conveyor devices 130 (FIGS. 5 and 6) are similar to the conveyor devices 120 of the loading station 12, and comprise a roller 131 placed during use inside the furnace 11, and a motor member 132 to drive it, the roller 131 and the motor member 132 being reciprocally coupled by means of a shaft 133 rotatably inserted inside a fixed sleeve 133a. The sleeve 133a is made to pass through a through aperture made in the exit end wall 113, so that the motor member 132 remains outside the furnace 11.

Each conveyor device 130 of the unloading station 13 is provided with a sealing device 134 disposed around the sleeve 133a and placed during use outside the furnace. The sealing device 134 comprises an attachment collar 135 attached around the sleeve 133a and configured to be attached in the through aperture of the exit end wall 113 of the furnace 11 so as to close it hermetically. The attachment collar 135 provides an internal chamber 136 in which water is present as an insulating substance. It should be noted that the internal chamber 136 has a diameter smaller than the diameter of the attachment collar 135, and is configured to be inserted inside the through aperture of the exit end wall 113.

The conveyor device 130 also comprises a support ring 137 placed between the attachment ring 135 and the motor member 132, and provided with a pair of packings 137a, for example of the type made of rubber or suchlike. Between the attachment ring 135 and the support ring 137 there is provided a bellows sleeve 138 around the sleeve 133a and distanced from it so as to form a cylindrical chamber 138a. The cylindrical chamber 138a, hermetically closed both on the side of the attachment ring 135 and also on the side of the support ring 137, is connected to a feed aperture 139 through which an inert gas is fed, for example nitrogen or argon. The cylindrical chamber 138a, which extends up to the attachment ring 135, allows to improve the air tightness in correspondence with the attachment ring 135, making up for any losses of seal at the joint between the attachment ring 135 and the sleeve 133a.

In the example shown, the conveyor devices 120 of the loading zone are not provided with the same sealing device described above, but it is obviously possible that they can be, to the advantage of an optimized control of the quantity of air also inside the first part 20 of the furnace 11.

The unloading station 13 also comprises a pair of transfer devices 140 (FIG. 7) which each comprise two transfer members 141 configured to be inserted inside the furnace 11 and displace the billets 100. The transfer members 141 are configured as arms provided with a corresponding seating 141a for a section of billet 100 (FIGS. 7 and 8), and integral with respective supports 141b perpendicular thereto (FIGS. 8 and 9). In particular, in an inactive position (FIG. 8), the arm 141 is oriented horizontally while the support 141b is oriented vertically downward.

Each transfer member 141 is enclosed in a respective hermetically closed containing box 142, comprising an end aperture 142a to allow the passage of the arm 141, and a lower aperture 142b to allow the passage of the support 141b. The end aperture 142a is intended to be attached to the exit end wall 113 of the furnace 11, which determines its hermetic closure. The lower aperture 142b, on the other hand, is left open, and has an elongated shape in the longitudinal direction with respect to the containing box 142 so as to allow the forward and backward displacement of the support 141b, and is delimited by four walls 142c which extend vertically inside the containing box 142 (FIGS. 8 and 9).

The transfer member 141 also comprises a clamping crankcase 143 attached to the support 141b, of rectangular parallelepiped shape and enclosed in the containing box 142. In particular, the clamping crankcase 143 is totally open on its lower side and is disposed around the four walls 142c that delimit the lower aperture 142b of the containing box 142.

The containing box 142 is partly filled with liquid water, at a level in any case lower than the height of the walls 142c that delimit the lower aperture 142b but high enough so that the lower edge of the clamping crankcase 143 is always immersed, regardless of its position, for example the inactive position (FIG. 8) in which the arm 141 is not raised, or a lifting position (FIG. 9) in which the arm is made to advance so that its end is inside the furnace 11 and raised. The rest of the inside of the containing box 142 is filled with an inert gas, such as nitrogen or argon.

The combination of walls 142c, clamping crankcase 143 and water level inside the containing box 142 allows to block the air that passes through the lower aperture 142b in the clamping crankcase 143. Furthermore, if some air were to pass between the lower edge of the crankcase 143 and the body of water, it would be blocked by the inert gas that fills the rest of the containing box 142.

FIGS. 10 and 11 show a discharge aperture 150 of the furnace 11, through which the heated billets 100 are discharged. The discharge aperture 150 is advantageously provided at the end of the lateral wall 114 of the furnace 11, in the proximity of the exit end 113.

The discharge aperture 150 is provided with a closing door 151 which can be driven between a closing position, in which it is in contact with the discharge aperture 150 so as to close it hermetically (FIG. 11), and an opening position in which it is distanced from the discharge aperture 150 (FIG. 10). The discharge aperture 150 is suitably surrounded by a sealing device 152 which comprises a packing 153 in correspondence with the external surface of the discharge aperture 150, so as to come into contact with the closing door 151 when it is in the closing position. In this way, a first seal is operated in order to prevent the passage of air.

The sealing device 152 also comprises a first internal chamber 154 located behind the packing and extending outside it with respect to the discharge aperture 150. The first internal chamber 154 is filled with water as a sealing liquid. There is also provided a pair of lateral chambers 155, located directly on the sides of the discharge aperture 150, between the latter and the first internal chamber 154 (FIG. 11). These lateral chambers 155 are provided to be filled with an inert gas, such as nitrogen or argon, and each comprise a respective vertical linear aperture 156 oriented toward the discharge aperture 150 so as to blow the inert gas toward the discharge aperture 150, thus creating an inert gas barrier to prevent the entry of air when the closing door 151 is in the opening position. The chambers 155 therefore act as barrier means.

In a preferred solution, another element that improves the hermeticism of the furnace 11 is made in the upper wall 116, which consists of a plurality of modules 116a oriented transversely with respect to the furnace 11 and assembled in succession by means of tie-rods 160 connected to each other by means of connection plates 161. FIG. 12 shows a detail of the assembly of a module 116a to a lateral and longitudinal beam 118 of the upper wall 116. The plate used is bent into an I, shape so as to be attached both to the beam 118, in correspondence with a lateral surface thereof, and also to a module 116a, by means of a tie-rod 160, in correspondence with its upper surface.

In order to hermetically close this zone, in which apertures are created between the edge of the module and the plate 161, for example, it is provided to insert an internal closing member 162 provided with a lip 163 that protrudes perpendicularly and is configured to be housed in a sealed manner in the space between the edge of the module 116a and the plate 161. In addition to the internal closing member 162, there is also provided a packing 164 with a flat shape, advantageously made of fiber.

Similarly, in correspondence with the transverse joints between two consecutive modules 116a (FIG. 13), it is provided to insert, between the two modules, a T-shaped internal closing member 162, that is, provided with two lateral lips 163, and two packings 164a made of fiber, one attached to the lower surfaces of the two consecutive modules 116a, the other clamped between the internal closing member 162 and the plate 161 located above the space between the two modules 116a. This plate 160 is centered with respect to the space so as to partly cover both modules 116a, so that it can be attached to both of them by means of respective tie-rods 160 (FIG. 13).

It should be noted that the upper wall 116 is provided with two lateral packings 164 and as many internal closing members 162 which each extend along a respective lateral beam 118, and with a plurality of transverse packings 164 and as many lateral closing members 162 located in correspondence with the joints between two consecutive modules 116a. In this way, all the apertures between the modules and the lateral beams are closed.

Finally, in order to improve the seal in correspondence with the lower wall 117, sealing members have been inserted in hoppers 170 that collect the scale, which constitute the main access point for air in this zone of the furnace 11.

Such hoppers 170 comprise a lower duct 171 with a substantially cylindrical shape that can be selectively closed by a closing element