Powder-Bottom Converter Hot Replacement for Extended Service Life
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Solution Overview
Problem
The service life of powder-bottom-injecting converters is significantly shorter than conventional converters due to the formation of an inverted cone-shaped pit around the bottom purging/powder injection brick, leading to premature reconstruction and increased costs.
Innovation Solution
A long-life service method involving collaborative hot replacement of the furnace bottom and bottom purging bricks, where multiple groups of independently removable bricks are used, with automatic erosion detection and sequential replacement, allowing for continued operation even after brick erosion, and maintaining the converter body's integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If powder-bottom-injecting converter is used to improve metallurgical reaction kinetics and steel purity, then steel quality is improved, but furnace bottom erosion accelerates and service life shortens
Solution Approach 1:
The converter furnace bottom is divided into multiple independently replaceable bottom plates (first bottom plate, second bottom plate, third bottom plate, etc.), each equipped with its own bottom purging bricks. When one bottom plate erodes, it can be replaced independently without replacing the entire furnace bottom or stopping production, thus extending overall converter service life while maintaining steel purity benefits
Solution Approach 2:
The patent implements a rotating replacement system where worn bottom plates are discarded and replaced with new ones from a reserve pool. The removed bottom plates can be recovered, refurbished, and reused after regenerating the refractory lining, creating a sustainable cycle that reduces waste and maintains continuous operation
2Productivity
If bottom purging brick is used for powder injection to enhance mixing and reaction, then metallurgical efficiency is improved, but inverted cone-shaped pit forms and brick erosion accelerates
Solution Approach 1:
Bottom purging bricks are segmented into multiple groups (first group, second group, third group, etc.) distributed across different bottom plates. Each group can be independently replaced when eroded, allowing continuous operation with other groups still functional. This segmentation prevents single-point failure and extends the operational life of the powder injection system
Solution Approach 2:
Reserve bottom plates with fresh bottom purging bricks are prepared in advance before they are needed. When erosion is detected on current bottom plates, pre-prepared replacement plates are immediately installed, eliminating downtime and ensuring continuous metallurgical efficiency without waiting for refurbishment cycles
3Reliability
If frequent converter reconstruction is performed to prevent steel leakage, then safety is maintained, but production downtime increases and costs rise
Solution Approach 1:
The furnace bottom is segmented into multiple independently replaceable bottom plates rather than a single monolithic structure. When erosion reaches critical levels on one plate, only that specific plate needs replacement, not the entire furnace bottom. This segmentation enables localized maintenance that maintains safety while minimizing production downtime and reconstruction costs
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
This method extends the service life of powder-bottom-injecting converters from 1000-3000 heats to 6000-10000 heats, making them suitable for large-scale production by preventing steel leakage and reducing maintenance costs.
Implementation Method 1
the inner tube is a powder transport pipe configured to transport a high-pressure and high-speed powder flow
Implementation Method 2
the lance is wrapped with a refractory material to make a bottom purging/powder injection brick
Implementation Method 3
Cooling protective gas is purged inside the annular gap pipe
Implementation Method 4
the bottom blowing of oxidizing gas and powder will bring about the technical defects of high temperature, high oxidation and severe erosion of the powder-bottom-injecting converter furnace bottom
Data Source
AI summary
A long-life service method for powder-bottom-injecting converter based on collaborative hot replacement of furnace bottom and bottom purging brick belongs to the field of steelmaking technologies using powder-bottom-injecting converters. According to equipment characteristics, process characteristics, and erosion characteristics of the powder-bottom-injecting converter, the design, arrangement, installation, use, maintenance, and replacement of the bottom purging/powder injection bricks are systematically optimized and improved, a technology of automatically detecting the erosion height of bottom purging bricks is adopted, and hot replacement of bottom purging/powder injection bricks and hot replacement of the converter furnace bottom are used collaboratively, which not only can prolong the service life of a single bottom purging/powder injection brick, but also can greatly prolong the overall life of the powder-bottom-injecting converter from 1000-3000 heats in the prior art to 6000-10000 heats. Hence, the life of the powder-bottom-injecting converter is as long as that of a conventional converter.