Systems and methods for steam condensation in aluminum direct chill casting pit

Abstract

A direct chill (DC) casting system may be used to cast a metal ingot from a molten metal such as aluminum or aluminum alloys. The DC casting system includes a steam condensation system that condenses steam generated during a DC casting process as recycled water. The recycled water may be used for subsequent cooling of the metal ingot during the DC casting process.

1 . A direct chill (DC) casting system for casting a metal ingot, the DC casting system comprising a steam condensation system for condensing steam generated during a DC casting process as recycled water. 
     
     
         2 . The DC casting system of  claim 1 , wherein the steam condensation system comprises a plurality of sprayers configured to spray water inside a casting pit of the DC casting system. 
     
     
         3 . The DC casting system of  claim 2 , wherein the plurality of sprayers comprise a plurality of nozzles. 
     
     
         4 . The DC casting system of  claim 2 , wherein the plurality of sprayers are configured to control a direction of steam flow and/or air flow by spraying the water inside the casting pit. 
     
     
         5 . The DC casting system of  claim 4 , wherein the plurality of sprayers are adjustable such that the direction of steam flow and/or air flow is adjustable by spraying the water inside the casting pit. 
     
     
         6 . The DC casting system of  claim 1 , wherein the steam condensation system comprises:
 a conduit comprising at least one inlet and at least one outlet and configured to receive the steam;   a suction device configured to generate a suction force for pulling the steam through the at least one inlet into the conduit; and   at least one sprayer within the conduit for spraying water within the conduit.   
     
     
         7 . The DC casting system of  claim 6 , wherein the conduit comprises a first end, a second end, and a side wall extending from the first end to the second end, wherein the suction device is provided at the first end, and wherein the at least one inlet and the at least one outlet are provided on the side wall of the conduit. 
     
     
         8 . The DC casting system of  claim 1 , wherein the steam condensation system comprises a conduit for receiving the steam and a cooling device on an external surface of the conduit for cooling the conduit. 
     
     
         9 . The DC casting system of  claim 8 , wherein the cooling device comprises at least one of a processing gas line for the DC casting process or a plurality of heat exchanger fins. 
     
     
         10 . The DC casting system of  claim 1 , further comprising means for directing the recycled water back to the DC casting process and/or to other processing steps for the metal ingot. 
     
     
         11 . A method of direct chill (DC) casting a metal ingot, the method comprising:
 cooling the metal ingot emerging from a mold by directing water from a coolant supply onto the metal ingot;   condensing steam generated by the cooling of the metal ingot as recycled water; and   providing the recycled water to the coolant supply.   
     
     
         12 . The method of  claim 11 , wherein condensing the steam comprises spraying water into the steam. 
     
     
         13 . The method of  claim 11 , wherein condensing the steam comprises directing the steam into a conduit and condensing the steam within the conduit using a cooling device. 
     
     
         14 . The method of  claim 13 , wherein the cooling device comprises at least one of:
 a sprayer within the conduit, and wherein condensing the steam comprises spraying water into the steam within the conduit; or   a cooling device is on an external surface of the conduit, and wherein condensing the steam comprises cooling the conduit using the cooling device.   
     
     
         15 . A metal processing system for processing a metal substrate, the metal processing system comprising a steam condensation system for directing a flow of steam generated during metal processing of the metal substrate by spraying water relative to a direction of the flow of the steam. 
     
     
         16 . The metal processing system of  claim 15 , wherein the metal processing system is a direct chill (DC) casting system for producing a metal ingot from a molten metal. 
     
     
         17 . The metal processing system of  claim 15 , wherein the steam condensation system is configured to spray water parallel to the direction of the flow of the steam or in a cross-direction relative to the direction of the flow of the steam. 
     
     
         18 . The metal processing system of  claim 15 , wherein the steam condensation system is adjustable such that the direction of water sprayed by the steam condensation system is adjustable relative to the direction of the flow of the steam. 
     
     
         19 . The metal processing system of  claim 15 , wherein the steam condensation system is further configured to condense steam generated during metal processing of the metal substrate. 
     
     
         20 . The metal processing system of  claim 15 , wherein the steam condensation system comprises a plurality of sprayers configured to spray water in a steam-generating area of the metal processing system.