Fireproof Ceramic Ladle Bottom With Segmented Lining
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Solution Overview
Problem
The existing designs for metallurgic ladles face challenges in efficiently removing high-temperature metal melts while preventing slag from contaminating the steel, leading to material losses and increased costs due to complex and expensive fireproof lining designs that require frequent repairs and replacements.
Innovation Solution
A fireproof ceramic base with a permanent lining and a wear lining, where the permanent lining provides a consistent sloped surface geometry that remains unchanged, allowing the wear lining to be easily replaced or repaired without altering the base's shape, ensuring consistent melt flow and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the base is designed with a sloped surface to transport melt to the discharge opening, then the efficiency of melt removal is improved, but the complexity and cost of the fireproof lining increases
Solution Approach 1:
The fireproof lining is divided into two functional segments: a permanent lining that provides the structural sloped geometry, and a replaceable wear lining that protects the surface during operation. This segmentation allows the sloped design to be maintained without requiring the entire lining to be complex and replaceable.
Solution Approach 2:
The permanent lining is installed first to establish the desired sloped geometry of the base. This preliminary action creates the foundation upon which the wear lining is subsequently placed, ensuring the slope is correctly formed before the operational lining is applied.
2Ease of repair
If the fireproof lining is designed to be replaceable for maintenance, then the ease of repair is improved, but the consistency of the base geometry changes after repair
Solution Approach 1:
The lining system is segmented into a permanent structural layer and a temporary protective layer. The permanent lining maintains the base geometry indefinitely, while the wear lining is replaced as needed without affecting the underlying geometric template.
Solution Approach 2:
The permanent lining acts as an intermediary between the base structure and the replaceable wear lining. It serves as a stable intermediate layer that preserves the geometric design while allowing the outer wear layer to be maintained or replaced.
3Reliability
If the wear lining is frequently replaced to maintain performance, then the reliability of the process is improved, but the loss of time for repair operations increases
Solution Approach 1:
The permanent lining is installed in advance to create a ready-made geometric template. This preliminary preparation ensures that when the wear lining needs replacement, the underlying structure is already in place, significantly reducing repair time.
Solution Approach 2:
The wear lining is designed as a consumable, relatively inexpensive component that can be quickly replaced. By making this outer layer replaceable and relatively simple in construction, frequent replacements do not significantly impact overall system time or cost.
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 solution enables efficient and cost-effective removal of high-quality metal melts by maintaining a consistent base geometry, reducing material losses, and extending the service life of the permanent lining while simplifying repairs and reducing fireproof material consumption.
Implementation Method 1
the permanent lining features a surface bordering to the wear lining, which is, at least in segments, sloped compared to the horizontal by more than 1°
Implementation Method 2
an upper layer made of a fireproof ceramic wear lining
Implementation Method 3
a fireproof ceramic base in the connection area to at least one wall of a vessel for the treatment of a high temperature melt
Data Source
AI summary
An exemplary embodiment relates to a fireproof ceramic bottom in the connection region to at least one wall of a vessel for handling high-temperature melts.