Refractory Ceramic Gas Flushing Device Segmentation
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Solution Overview
Problem
Existing gas flushing devices for metallurgical vessels face issues with safety and maintenance, as they are prone to molten metal infiltration and require frequent replacement due to wear and ferrostatic pressure, leading to inefficiencies and increased maintenance costs.
Innovation Solution
A gas flushing device comprising a refractory ceramic base part for gas supply and a functional, gas-permeable part for gas distribution, with a detachable coupling for easy assembly and replacement, where the base part remains in the vessel and is designed to be long-lasting, while the functional part can be regularly renewed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a permanent refractory lining with a hollow chamber and gas-permeable plate is used, then gas can be introduced into the molten metal, but molten metal infiltration through the plate and plate breakage under ferrostatic pressure occur
Solution Approach 1:
The gas flushing device is divided into a base part (gas-tight, refractory ceramic) and a functional part (gas-permeable, wears easily). The base part remains permanently in the vessel while the functional part can be regularly replaced. This segmentation prevents molten metal infiltration by isolating the gas distribution function from direct contact with molten metal, while allowing easy replacement of wear-prone components.
2Reliability
If refractory gas flushing elements are installed in the base of a tundish, then gas distribution is achieved, but all parts must be replaced in the event of wear
Solution Approach 1:
The device is segmented into a permanent base part and a replaceable functional part. The base part with gas line remains in the tundish base, while the functional part with gas-permeable sections can be detached and replaced. This allows maintenance of only the wear-prone functional part rather than replacing the entire device.
Solution Approach 2:
The coupling between base part and functional part is designed to be detachable, allowing the functional part to be dynamically replaced when worn. This dynamic maintenance approach improves ease of manufacture and reduces downtime compared to permanent installation requiring full replacement.
3Reliability
If a gas flushing device with steel jacket and multiple components is used, then gas distribution is achieved, but device complexity increases and replacement is required for wear
Solution Approach 1:
The device is simplified into two main segments: a base part for gas supply and a functional part for gas distribution. This reduces the number of components compared to multi-part designs with separate steel jackets, anti-bump blocks, and purge plugs, while maintaining gas distribution functionality.
Solution Approach 2:
The base part and functional part are merged into a integrated assembly where the functional part rests directly on the base part with a coupling connection. This merging reduces complexity by eliminating separate mounting structures and simplifying the overall device architecture.
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 design enhances safety by minimizing contact with molten metal and reduces maintenance frequency, allowing for continuous operation with reduced wear and tear on the gas line, thereby improving operational efficiency and extending the lifespan of the device.
Implementation Method 1
The functional part is at least partially gas-permeable, that is to say it has gas-permeable sections. The gas that flows in via the gas line in the base part is to be guided through the gas-permeable sections into the molten metal.
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a gas flushing device for installing into a metallurgical vessel, having the following features when assembled in the base of the metallurgical vessel: - a largely gas-tight lower base part is provided, - a gas line runs in the base part from a first end in the region of a first outer surface of the base part to a second end in the region of a second outer surface of the base part, - the second end of the gas line is designed as the first section of a coupling, - the second section of the coupling is located in the region of an outer connection surface of the functional part which lies against the base part by means of the connection surface, - in the functional position, a gas distributing device runs from the second section of the coupling to the at least one free functional part surface designed as a gas discharge surface through the functional part, and - the base part and the functional part each consists of a refractory ceramic material.