Solids Injection Lance Blockage Removal Tool
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Solution Overview
Problem
The existing methods for removing blockages in solids injection lances in molten bath-based smelting processes require complete production stoppage and slag draining, which is inefficient and time-consuming.
Innovation Solution
A method and apparatus that utilize a blockage-removing tool advanced through the supply line and lance under elevated gas pressure to clear blockages without stopping production, allowing for continued operation at reduced rates and faster return to normal production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing methods for removing blockages are used, then blockages can be cleared, but complete production stoppage and slag draining are required
Solution Approach 1:
The lance is designed with an internal channel providing preliminary access path for the removal tool. The gas pressure system is pre-configured to enable tool advancement through the lance without requiring production stoppage, preparing the system in advance for quick blockage removal
Solution Approach 2:
Gas pressure is applied to advance the removal tool through the supply line and lance to the blockage. The gas pressure also prevents slag from entering the lance outlet during the blockage removal operation, enabling continuous operation without production stoppage
2Ease of operation
If existing blockage removal methods are used, then blockages are cleared, but slag must be drained from the bath
Solution Approach 1:
The blockage removal function is extracted as a separate, independent operation that can be performed through the lance without affecting the molten bath. The removal tool is advanced through the supply line and lance to clear the blockage while the bath remains undisturbed and slag draining is avoided
Solution Approach 2:
Gas pressure serves as an intermediary mechanism to advance the removal tool through the lance and prevent slag entry. This intermediary approach enables blockage removal without direct manipulation of the bath or slag level, simplifying the overall operation
3Reliability
If blockage removal requires production stoppage, then safety can be maintained, but productivity is reduced
Solution Approach 1:
Gas pressure is used to control the blockage removal process, preventing slag from entering the lance outlet during the operation. This pneumatic control maintains safety by containing the molten bath while enabling continuous production without stoppage
Solution Approach 2:
The blockage removal operation is integrated into the continuous production process. The removal tool is advanced and operated without stopping the production flow, and gas pressure maintains safety conditions throughout the continuous operation
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
Enables continuous production with reduced downtime by preventing slag entry into the lance and maintaining optimal molten bath temperature, thus prolonging production continuity and reducing the time to return to normal rates.
Implementation Method 1
the gas pressure conditions are elevated such that slag is prevented from entering an outlet end of the lance
Implementation Method 2
operating the tool under elevated gas pressure conditions to remove the blockage such that solid feed material and gas are able to flow through the solids injection lance
Data Source
AI summary
An apparatus for removing a blockage in a solids injection lance extending into a direct smelting vessel The solids injection lance has a single inlet coupled to a section of supply line that conveys gas and solids to the solids injection lance and that is upstream and co-axial with the solids injection lance. The apparatus has a tool that extends through the supply line section and the solids injection lance to remove a blockage of solid material and an assembly for advancing the tool through the solids injection lance and the supply line section to the blockage from an upstream side of the blockage.