Cyclone Smelt Reduction Vessel With Independent Temperature Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing metallurgical vessels with cyclone and smelt reduction parts in open connection face challenges in independent temperature control, leading to imbalanced temperatures and inefficient energy management, particularly due to the reliance on carbon-containing materials and oxygen injection.

Innovation Solution

Introducing a mixture of oxygen gas and combustible gas, such as natural gas, into the cyclone part to enhance temperature control independently of the smelt reduction part, utilizing the energy release from combustible gas combustion for precise heat management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If oxygen gas is injected into the cyclone part to control temperature, then temperature control in the cyclone part is improved, but temperature control in the smelt reduction part becomes difficult to maintain independently

Engineering Contradiction:

Improvetemperature control in cyclone partVSAvoidindependent temperature control

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The invention divides the temperature control function into two independent systems: one for the cyclone part using oxygen gas injection, and another for the smelt reduction part using carbon-containing material addition. This segmentation allows each part to be controlled independently despite their open connection, resolving the contradiction between temperature control effectiveness and operational independence.

Inventive Principle:

Principle #1Segmentation

2Temperature

If carbon containing material is added to the smelt reduction part to control temperature, then temperature control in smelt reduction part is improved, but insufficient heat is generated for complete carbon monoxide conversion

Engineering Contradiction:

Improvetemperature control in smelt reduction partVSAvoidheat generation for carbon conversion

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The invention uses oxygen gas as an intermediary substance injected into the cyclone part to provide additional heat for carbon monoxide conversion. This mediator supplies the necessary energy without directly adding carbon-containing materials to the smelt reduction part, enabling complete carbon conversion while maintaining temperature control.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention extracts the heat generation function from the smelt reduction part by injecting oxygen gas into the cyclone part. This separates the temperature control function (handled by carbon-containing material in smelt reduction part) from the heat generation function (handled by oxygen injection in cyclone part), allowing both functions to operate optimally independently.

Inventive Principle:

Principle #2Taking out (Extraction)

3Temperature

If more oxygen gas is injected into the smelt reduction part to increase temperature, then temperature in smelt reduction part is improved, but temperature becomes too high and disrupts the balance with cyclone part

Engineering Contradiction:

Improvetemperature in smelt reduction partVSAvoidtemperature balance between parts

Core Design Contradiction:

TemperatureVSStability of the object's composition

Solution Approach 1:

The invention segments the temperature control function so that the cyclone part uses oxygen gas injection for heat generation while the smelt reduction part uses carbon-containing material addition for temperature control. This segmentation prevents the need to over-inject oxygen into the smelt reduction part, maintaining temperature balance and stability between the two connected parts.

Inventive Principle:

Principle #1Segmentation

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

Achieves improved temperature control in the cyclone part, reduces CO2 emissions, and optimizes energy use by allowing for better process balance and reduced coal consumption.

Implementation Method 1

introducing the combustible gas together with the oxygen gas releases a lot of energy during the combustion process

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 2

the injection of oxygen gas in this part does generate enough energy, and therefore heat, as it converts the carbon monoxide to carbon dioxide

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentUS12595520B2Apparatus for the production of molten iron

Publication Date: 2026.04.07 TATA STEEL IJMUIDEN BV

AI summary

Apparatus for the production of molten iron including a metallurgical vessel, having a surrounding wall, a cyclone part provided on top of a smelt reduction part, the cyclone part being in open connection with the smelt reduction part and having at least one supply apparatus around the circumference of the surrounding wall adjusted to introduce oxygen gas into the cyclone part, wherein the at least one supply apparatus is further adjusted to introduce a mixture of oxygen gas and a combustible gas.