Blowback Ignitor Cap for Thermal Lance Delayed Ignition
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Solution Overview
Problem
Existing thermal lance ignition systems face challenges with reliable ignition, premature ignition, lack of automation, and safety concerns due to the need for precise oxygen flow and human operator intervention.
Innovation Solution
The development of a blowback ignitor cap that directs heat energy along the exterior surface of the thermal lance, providing delayed ignition and integrating the ignitor cap directly into the thermal lance system, which includes internal primary and secondary fuels and a sealed distal end to enhance heat transfer and combustion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard ignition method (submerging thermal lance into molten metal with low flow oxygen) is used, then ignition can be achieved, but the process is physically dangerous, difficult to control, and requires precise operator intervention
Solution Approach 1:
The patent introduces an auxiliary ignitor system with primary and secondary fuels as an intermediary device between the operator and the thermal lance ignition process. This ignitor cap contains composition A (primary fuel with low auto-ignition temperature) and composition B (secondary fuel with intermediate ignition energy requirements), which together provide a controlled ignition sequence that eliminates the need for operators to manually submerge the thermal lance into molten metal
Solution Approach 2:
The ignitor cap is pre-assembled with both primary and secondary fuels in specific configurations (such as the primary fuel surrounding the secondary fuel or arranged in sequential chambers). This preliminary preparation allows the ignition sequence to occur automatically when activated, removing the need for real-time operator intervention during the critical ignition phase
2Reliability
If auxiliary ignitor with two-stage fuel is used, then combustion reliability is increased, but the device complexity and lack of automation increase
Solution Approach 1:
The patent combines both primary fuel (composition A) and secondary fuel (composition B) into a single integrated ignitor cap assembly. This merged design allows the two-stage combustion process to occur within one compact device rather than requiring separate ignitor components, thereby maintaining combustion reliability while reducing overall system complexity
Solution Approach 2:
The ignitor cap serves multiple functions simultaneously: it contains and sequences both primary and secondary fuels, provides structural support for the ignition process, and acts as the interface between the oxygen supply system and the thermal lance. This multi-functionality reduces the number of separate components needed in the system
3Use of energy by moving object
If primary fuel with low auto-ignition temperature is used, then ignition energy requirement is reduced, but the combustion duration is short and energy output is insufficient
Solution Approach 1:
The patent implements a sequential two-stage combustion process where composition A (primary fuel) ignites first and burns quickly to provide initial ignition, followed by composition B (secondary fuel) which ignites subsequently and burns for a longer duration. This periodic action ensures that the low energy requirement for starting combustion is met by the first stage, while the second stage extends the combustion duration and provides sustained energy output
Solution Approach 2:
The patent changes the chemical composition parameters between the two fuel stages: composition A has a very low auto-ignition temperature for easy ignition, while composition B has an intermediate ignition energy requirement and longer burn time. By adjusting these chemical parameters, the system achieves both easy ignition and sustained combustion
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the reliability and efficiency of thermal lance ignition by ensuring consistent heat transfer and combustion, reducing the need for precise oxygen control and human intervention, and improving safety and ergonomics.
Implementation Method 1
The primary fuel is the easiest to ignite and is a material with a very low auto-ignition temperature, such that it takes a relatively small amount of thermal energy for this material to begin combustion and start the ignition/combustion chain
Implementation Method 2
The secondary fuel combusts for a longer period of time and provides a more exothermic combustion reaction, thereby generating more thermal energy than the primary fuel
Implementation Method 3
gas flows from the thermal lance into the proximal end of the blowback ignitor cap, axially through the internal primary fuel and the secondary fuel, and is then redirected by the sealed distal end of the housing back through the internal primary fuel and the secondary fuel and out through the at least one opening and along an exterior surface of the thermal lance
Implementation Method 4
Increasing the thermal energy from ambient conditions to levels required for combustion is difficult
Implementation Method 5
direct the heat energy from the ignitor cap along the exterior surface of the thermal lance
Data Source
AI summary
An ignitor cap for a thermal lance including a proximal end adapted to receive the thermal lance, a distal end, a housing having a sidewall extending from the proximal end to the distal end and defining a passageway, and primary fuel and secondary fuel disposed within the passageway. At least a portion of the primary fuel is in contact with the secondary fuel and/or the distal end is substantially sealed and the proximal end includes at least one opening such that, when the thermal lance is received in the proximal end of the ignitor cap, gas flows axially through the primary fuel and the secondary fuel, and is then redirected by the sealed distal end back through the primary fuel and the secondary fuel and out through the at least one opening and along an exterior surface of the thermal lance. Also, thermal lances including such an ignitor cap.