Solids Injection Lance Buffer Zone Wear Reduction
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Solution Overview
Problem
The existing molten bath-based smelting processes face challenges in effectively minimizing abrasive wear and thermal shock in solids injection lances due to the high abrasiveness and temperature differences of metalliferous and carbonaceous materials, leading to potential damage and reduced operational reliability.
Innovation Solution
Creating a buffer zone within the solids injection lance by selecting appropriate solid feed materials, such as carbonaceous material, to reduce abrasive wear and thermal shock, where the buffer zone material can be at ambient temperature and the central section material can be hot, ensuring a mixture that shields the lance from high wear and shock regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If metalliferous material and carbonaceous material are injected through the solids injection lance, then the smelting process can proceed effectively, but abrasive wear and thermal shock damage the lance
Solution Approach 1:
The patent introduces a buffer zone material (such as coal or carbonaceous material) as an intermediary substance between the lance wall and the abrasive metalliferous material. This buffer material protects the lance wall from direct contact with hot, abrasive ore particles, thereby reducing wear and thermal shock while maintaining effective smelting operations.
Solution Approach 2:
The patent pre-establishes a buffer zone by injecting less abrasive carbonaceous material ahead of or alongside the metalliferous material. This cushioning layer is created in advance to absorb the impact and reduce the harmful effects of thermal shock and abrasion before the harsher materials reach the lance wall.
2Temperature
If hot metalliferous material is injected to maintain smelting temperature, then thermal shock increases the lance damage risk
Solution Approach 1:
The buffer zone material serves as a thermal intermediary, absorbing and distributing the thermal shock from hot metalliferous material before it reaches the lance wall. This mediator layer reduces the temperature differential impact on the lance structure while maintaining the necessary smelting temperatures in the bath.
3Reliability
If expensive wear-resistant materials are used for the lance, then reliability improves, but manufacturing cost increases
Solution Approach 1:
The patent employs a strategy of using a sacrificial buffer zone material (such as coal or carbonaceous material) that is less expensive than wear-resistant lance materials. This buffer material consumes itself through gradual wear, protecting the more expensive lance structure and extending its service life without requiring the lance to be made entirely of expensive wear-resistant materials.
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 buffer zone effectively reduces abrasive wear and thermal shock, enhancing the operational reliability and longevity of the solids injection lance by using less abrasive materials and temperature management, thereby reducing the need for expensive wear-resistant materials.
Implementation Method 1
The buffer zone effectively reduces abrasive wear and thermal shock, enhancing the operational reliability and longevity of the solids injection lance
Implementation Method 2
The buffer zone effectively reduces abrasive wear and thermal shock, enhancing the operational reliability and longevity of the solids injection lance
Data Source
AI summary
A method for injecting a solid feed material through a solids injection lance includes creating flow conditions in an injection passageway of the lance so that at least a part of the feed material flowing along the passageway forms a buffer zone between a wall of a tube that defines the passageway and feed material flowing along a central section of the passageway.