Composite Copper-Steel Distributor for Post-Combustion Lance
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Solution Overview
Problem
Post-combustion lances experience severe bending and failure due to low yield strength of high thermal conductivity components in the distributor, leading to frequent replacement, with existing solutions like protective sleeves being impractical and internal reinforcing tubes not effectively addressing the issue.
Innovation Solution
A composite reinforced distributor assembly comprising an annular member, an inner reinforcing sleeve made of steel, and an outer sleeve made of copper, with longitudinal ribs and cooling fluid passageways to provide structural reinforcement and maintain gas flow, while allowing for thermal conductivity and oxidation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high thermal conductivity metals (such as copper) are used for the PC distributor, then heat transfer requirements are met and protection from furnace atmosphere is improved, but yield strength is reduced leading to severe bending and failure
Solution Approach 1:
The patent applies composite materials by combining copper (for thermal conductivity) and steel (for strength) in a hybrid distributor structure. The copper components provide necessary heat transfer properties while the steel components provide structural strength to resist bending and failure, resolving the contradiction between thermal performance and mechanical strength.
Solution Approach 2:
The distributor is segmented into multiple components with different materials - copper sections for thermal management and steel sections for structural support. This segmentation allows each material to be used where it provides the most benefit, with the steel reinforcing the copper components at critical stress points.
2Ease of operation
If the lance is subjected to bending stresses during loading, unloading, and deskulling operations, then operational flexibility is maintained, but permanent deflection and failure occur at the PC distributor
Solution Approach 1:
The hybrid copper-steel construction provides both the flexibility needed for operational movements and the strength to resist permanent deflection. The steel components specifically reinforce areas prone to bending stress during loading, unloading, and deskulling operations.
Solution Approach 2:
The steel reinforcement is pre-installed in the distributor structure to provide ahead-of-time protection against bending stresses that will occur during normal operations including loading, unloading, and deskulling maneuvers.
3Object-affected harmful factors
If protective sleeves are used to protect the lance during shipping, then bending protection is provided, but the sleeves must be removed before service and are often removed too early causing subsequent bending
Solution Approach 1:
The steel reinforcement is built into the distributor structure during manufacturing, providing permanent protection before the lance is ever put into service. This eliminates the need for separate protective sleeves that would need to be installed and removed.
Solution Approach 2:
The protective function is extracted from removable sleeves and integrated directly into the distributor structure itself through the steel reinforcement, eliminating the need for separate protective components that complicate the system.
4Productivity
If the PC distributor is made from high thermal conductivity metals, then cooling efficiency is improved, but the maintenance interval is reduced due to frequent bending and failure
Solution Approach 1:
The copper-steel composite maintains the high thermal conductivity of copper for efficient cooling while the steel reinforcement prevents bending and failure, thereby extending the maintenance interval. The steel components are strategically placed to reinforce the copper structure at high-stress areas.
Solution Approach 2:
Different material properties are applied locally - copper provides thermal conductivity where heat transfer is needed, while steel provides strength and bending resistance where structural support is required. This local differentiation allows the distributor to achieve both cooling efficiency and extended service life.
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 significantly enhances the structural integrity of the post-combustion lance distributor, reducing bending and failure rates, and allowing for efficient cooling and gas distribution, thus extending the maintenance interval and reducing replacement frequency.
Implementation Method 1
the PC distributor (and often, the piping associated therewith) is made of high thermal conductivity metals such as high purity copper
Implementation Method 2
A composite reinforced distributor assembly comprising an annular member, an inner reinforcing sleeve made of steel, and an outer sleeve made of copper, with longitudinal ribs
Data Source
AI summary
A distributor for a post-combustion lance, comprising: an annular member, an inner reinforcing sleeve and an outer sleeve, wherein the inner reinforcing sleeve defines a plurality of first openings and the annular member defines a plurality of second openings, wherein each of the first and second openings is in fluid communication, directly or indirectly, with a first cooling fluid passageway of the lance. Each of the first openings may be contiguous with and in direct fluid communication with one of the second openings. Additionally, the annular member may define a plurality of third openings, wherein each of the third openings is in fluid communication with a second cooling fluid passageway of the lance.