Hearth Cooler Elements for Direct Smelting Vessel Refractory Protection
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Solution Overview
Problem
The HIsmelt process experiences significant refractory erosion in the upper part of the hearth due to chemical and physical attacks from hot metal and slag, leading to increased maintenance and operational challenges in direct smelting vessels.
Innovation Solution
A direct smelting vessel with a refractory lined hearth and a cooling system comprising a series of cooler elements with integrated coolant flow passages, where each cooler element is a hollow open-backed cast shell structure with a sloping top wall and convergent side walls, providing effective cooling and support for refractory bricks while minimizing the risk of hot metal accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If refractory material is used to line the hearth, then the vessel can withstand high temperatures and chemical attacks, but the refractory material suffers erosion from hot metal and slag washing
Solution Approach 1:
A water-cooled copper panel is introduced as an intermediary layer between the hot metal/slag environment and the refractory lining. The panel absorbs heat through its water cooling system, preventing direct thermal and mechanical erosion of the refractory material while maintaining structural integrity at high temperatures.
Solution Approach 2:
The invention changes the thermal parameter distribution by actively cooling the copper panel through water circulation. This creates a temperature gradient where the outer surface facing the hot metal remains hot enough for process operation, while the inner surface in contact with refractory stays cool, preventing refractory erosion.
2Temperature
If cooling panels are installed on side walls, then heat is dissipated effectively, but the structure becomes more complex
Solution Approach 1:
The copper panel serves multiple functions simultaneously: it acts as a thermal barrier protecting the refractory, a heat dissipation device through water cooling, and a structural support element for the hearth lining. This multi-functionality reduces the need for separate cooling system components.
Solution Approach 2:
The invention uses a composite structure combining copper (for thermal conduction and cooling), water (for heat removal), and refractory material (for structural integrity). This composite approach achieves effective heat dissipation while maintaining structural simplicity.
3Productivity
If the hearth is designed to contain turbulent molten metal and slag, then direct smelting can be performed, but erosion increases due to washing and splashing
Solution Approach 1:
The water-cooled copper panel acts as a protective intermediary that absorbs the mechanical impact and washing action of turbulent molten metal and slag. By positioning this erosion-resistant panel between the turbulent flow and the refractory lining, physical erosion is significantly reduced while maintaining direct smelting operations.
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 cooling system significantly reduces refractory erosion and maintains the integrity of the hearth by efficiently dissipating heat, preventing slag and molten metal from washing behind or underneath the cooling panels, thus extending the vessel's operational lifespan.
Implementation Method 1
a cooling system comprising a series of cooler elements with integrated coolant flow passages
Implementation Method 2
providing effective cooling and support for refractory bricks while minimizing the risk of hot metal accumulation
Data Source
AI summary
A direct smelting vessel and a hearth cooler element are disclosed. The vessel includes a refractory lined hearth. An inner surface of an upper part of the hearth extends upwardly and outwardly to side walls of the vessel. The upper part of the hearth incorporates a hearth cooler disposed outwardly behind the refractory lining of that part of the hearth and below the cooling panels on the side walls of the vessel. The hearth cooler comprises a plurality of cooler elements. Each cooler element has a hollow open-backed shell structure having base, top and side walls formed integrally in a cast structure and incorporating coolant flow passages.