Lance Tip Furnace Material Detection Reservoir
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Solution Overview
Problem
Metal making lances face premature failure due to 'hot-spots' and ingestion of furnace material, which can lead to catastrophic combustion and damage when furnace material is ingested and oxygen flow is restarted, as existing detection methods are not effective in quickly identifying ingestion and stopping gas flow.
Innovation Solution
A system with a temperature sensor adjacent to the inner wall of the lance tip, connected to a control station that automatically shuts off gas flow and activates alarms and coolant shut-off upon detecting furnace material, utilizing a reservoir to direct ingested material towards the sensor for rapid detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a temperature sensor is placed inside the lance tip to detect furnace material ingestion, then detection reliability is improved, but the lance tip becomes more susceptible to hot-spots and burn-through due to the sensor interfering with coolant water flow
Solution Approach 1:
A reservoir structure is introduced as an intermediary component between the furnace material ingestion site and the temperature sensor. The reservoir collects ingested furnace material and directs it toward the sensor, enabling reliable detection without requiring the sensor to be positioned in the direct path of coolant flow, thus avoiding hot-spot formation
2Difficulty of detecting and measuring
If the lance tip structure is modified to improve furnace material detection, then detection capability is improved, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
The reservoir is designed to pre-collect and concentrate furnace material before it reaches the temperature sensor. This preliminary action of material collection and direction simplifies the detection mechanism, as the sensor only needs to detect material that has already been funneled into the reservoir, reducing the need for complex sensor arrays or scanning mechanisms
3Object-affected harmful factors
If automatic shutdown systems are implemented to prevent combustion, then safety is improved, but the system complexity and response time requirements increase
Solution Approach 1:
The temperature sensor provides continuous feedback on furnace material presence to the control system. When the sensor detects furnace material in the reservoir, it triggers an automatic shutdown sequence that closes the oxygen supply valve and activates alarms. This feedback mechanism enables simple, reliable automatic protection against combustion without requiring complex prediction or analysis systems
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 rapid and reliable detection of furnace material ingestion, immediately terminating oxygen-containing gas flow to prevent combustion and extending lance tip life, thereby preventing damage to the lance and surrounding equipment.
Implementation Method 1
a temperature sensor disposed adjacent to an inner surface of an inner wall of a metal making lance tip
Implementation Method 2
The inner wall of the lance tip is also preferably formed with a reservoir for collecting ingested furnace material and directing it toward the temperature sensor
Implementation Method 3
water or other coolant fluid may be continuously circulated through the lance to cool the lance, especially the lance tip assembly which is exposed to the greatest temperatures during lance operation
Data Source
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AI summary
A fully automated system and method for rapidly and reliably detecting the ingestion of furnace material within the tip of a metal making lance. The system utilizes a temperature sensor disposed adjacent to the inner surface of the inner wall of a metal making lance tip. The sensor is in communication with a control station. The control station is preferably in operative communication with a valve for shutting off gas flow to the lance and, optionally, at least one alarm, a coolant fluid shut-off valve, and any other lance operation mechanisms as may be desired or necessary when furnace material is detected by the sensor. The inner wall of the lance tip is also preferably formed with a furnace material collecting reservoir for collecting ingested furnace material and directing it toward the temperature sensor for quick and reliable furnace material detection.