Gas Injection Lance Swirl Vane Cooling via Segmented Water Passages
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Solution Overview
Problem
Existing gas injection lances for high-temperature metallurgical processes, such as the HIsmelt process, face challenges in effectively cooling both the swirl vanes and the forward nose portion, leading to potential overheating and reduced efficiency due to inadequate cooling mechanisms.
Innovation Solution
The apparatus includes a gas flow duct with an elongate central tubular structure and flow directing vanes, featuring internal water cooling passages that divert cooling water through the vanes and nose portion, ensuring effective cooling and heat management by distributing water flow evenly across the swirl vanes and nose, preventing hot spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cooling water passages are provided only in the gas flow duct wall, then the structure is simpler, but the cooling effectiveness is insufficient leading to overheating of swirl vanes and nose portion
Solution Approach 1:
The cooling system is segmented into multiple independent cooling zones: cooling passages in the gas flow duct wall, separate cooling passages in the swirl vanes, and cooling passages in the nose portion. This segmentation allows each component to be cooled independently and effectively, preventing overheating while maintaining a manageable structural complexity through modular design.
Solution Approach 2:
Different parts of the lance are provided with cooling water passages according to their specific thermal requirements. The swirl vanes and nose portion, which are most exposed to high temperatures, are equipped with dedicated internal cooling passages, while other sections use wall passages. This local differentiation optimizes cooling effectiveness without unnecessarily complicating the entire structure.
2Reliability
If cooling water is not distributed to swirl vanes and nose portion, then the structure is simpler, but hot spots develop reducing operational stability
Solution Approach 1:
Cooling water passages are pre-configured within the swirl vanes and nose portion structure, with water inlets positioned to deliver cooling water before the hot gas reaches these components. This preliminary cooling action prevents hot spot formation and maintains operational stability, while the integrated passage design keeps the water distribution system relatively simple.
3Reliability
If the lance is exposed to extreme high temperatures without adequate cooling, then the structure is simpler, but the lance overheats leading to reduced efficiency and potential failure
Solution Approach 1:
The cooling passages are nested within the walls and structures of the gas flow duct, swirl vanes, and nose portion. The cooling water channels are integrated into the existing structural components, allowing the cooling system to be embedded within the thermal exposure zones without adding significant external complexity. This nested arrangement provides effective thermal protection while maintaining structural integrity.
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 the cooling efficiency of the swirl vanes and nose portion, allowing for reliable operation in extreme high-temperature conditions, thereby improving the stability and performance of gas injection in metallurgical vessels.
Implementation Method 1
The central structure is provided with water flow passages which provide for the flow of cooling water to the front part of the central structure which is located generally within the tip of the gas flow duct
Implementation Method 2
The flow guide vanes are provided with internal vane passages for internal water cooling of those vanes
Implementation Method 3
The vanes are in the form of a spiral and are mounted on a central body at the forward end of a gas flow duct
Implementation Method 4
spiral vanes mounted on a central body at the forward end of a gas flow duct
Implementation Method 5
post-combusting reaction gases, such as CO and H2 released from the bath in the space above the bath with oxygen-containing gas and transferring the heat generated by the post-combustion to the bath
Data Source
AI summary
An apparatus for injecting gas into a metallurgical vessel is disclosed. The apparatus comprises a gas flow duct, an elongate central tubular structure extending within the gas flow duct, a plurality of flow directing swirl vanes, inflow and outflow cooling water passages within the central structure, and a nose portion provided with one or more water cooling passages. The flow directing vanes are provided with internal water cooling vane passages. In use, water flow is communicated through the vane passages from the water inflow passage in the central structure to the water flow passage in the nose portion of the central structure such that at least some of the inflowing water will pass successively through the vane passages and the nose passage or passages and thence to the outflow passage.