Solids Injection Lance Puncture Detection System
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Solution Overview
Problem
Existing solids injection lances in molten bath-based smelting processes face safety concerns due to abrasive wear, which can lead to punctures and potential explosions, limiting the operational duration of the lances and increasing the risk of accidents.
Innovation Solution
A solids injection lance equipped with a puncture detection system that includes an annular chamber with inert gas under pressure, which detects changes in pressure or gas flow to alert for punctures, allowing for timely replacement and minimizing further wear, thereby enhancing safety and extending the operational life of the lance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If solids injection lances are used for extended operational periods, then productivity is improved, but the risk of puncture due to abrasive wear increases
Solution Approach 1:
The puncture detection system performs preliminary detection of wear-induced punctures before they lead to catastrophic failure. The system continuously monitors the lance integrity and triggers an alarm or automatic shutdown when a puncture is detected, allowing for planned replacement during scheduled maintenance periods rather than forced interruption due to safety incidents.
Solution Approach 2:
The detection system provides continuous feedback on the lance condition by monitoring for punctures caused by abrasive wear. This feedback loop enables real-time assessment of lance integrity, allowing operators to adjust operational parameters or schedule replacements based on actual wear conditions rather than fixed time intervals.
2Reliability
If lance replacement frequency is increased to maintain safety, then reliability is improved, but productivity deteriorates due to frequent interruptions
Solution Approach 1:
By detecting punctures early through the monitoring system, the invention enables planned replacements during scheduled maintenance windows rather than urgent replacements following safety incidents. This preliminary detection allows operators to prepare replacement lances in advance and perform swaps during planned downtime, minimizing disruption to production.
Solution Approach 2:
The detection system automatically monitors lance condition and can trigger automatic shutdown procedures when punctures are detected, eliminating the need for continuous manual monitoring. The system serves itself by providing continuous safety assessment and autonomously initiating protective actions, reducing the burden on operators while maintaining high safety standards.
3Strength
If water-cooled panels are used to maintain lance integrity, then strength is improved, but the risk of steam explosion upon puncture increases
Solution Approach 1:
The puncture detection system provides preliminary warning before a water-cooled lance can fail catastrophically. By detecting punctures early in the wall thickness, the system allows operators to shut down the system and replace the lance before the cooling water can escape and contact molten metal, preventing steam explosion while maintaining the thermal protection benefits of water-cooled design.
Solution Approach 2:
The detection system acts as a protective buffer by identifying puncture conditions before they can lead to catastrophic failure. This preliminary detection creates a safety buffer that allows for controlled shutdown and replacement, cushioning against the potential harm of steam explosions while preserving the thermal management advantages of water-cooled lances.
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 puncture detection system provides a safety mechanism to detect and address lance punctures before they become catastrophic, allowing for longer operational runs and reducing the frequency of lance replacements, thus improving safety and efficiency in smelting processes.
Implementation Method 1
The puncture detection system may be adapted to detect a change of pressure in the solids injection tube or a flow of a gas into or from the tube as a result of a puncture in the tube
Data Source
AI summary
A solids injection lance includes (a) a tube that defines a passageway for solid feed material to be injected through the tube and has an inlet for solid material at a rear end and an outlet for discharging solid material at a forward end of the tube and (b) a puncture detection system for detecting a puncture in the solids injection tube.