Refractory Block Insertion Device for Metallurgical Vessels
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Solution Overview
Problem
The existing methods for replacing refractory blocks in taphole structures of metallurgical vessels, such as Basic Oxygen Furnaces, are labor-intensive and prone to incomplete filling of the annular gap with refractory material, and require difficult manual handling for precise coaxial placement.
Innovation Solution
A device and method utilizing a mounting unit with locking elements that can be manipulated by a robot or manipulator to automatically insert and remove refractory blocks, allowing for internal filling of the annular gap with mortar and eliminating manual handling, ensuring precise positioning and complete filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a sleeve is used to replace the refractory block from the furnace's exterior with radial clearance, then the refractory block can be replaced, but the annular gap may not be filled completely with refractory filler material
Solution Approach 1:
Instead of filling the annular gap from the exterior through the sleeve as in prior art, the patent inverts the approach by introducing filling material from the interior of the furnace through the tapping channel. This reversal of the filling direction ensures complete and reliable filling of the annular gap between the refractory block and the lining.
2Extent of automation
If a manipulator is used to insert the sleeve into the tapping channel, then automated handling is achieved, but difficult handling is required to reach exact coaxial placement
Solution Approach 1:
The refractory block is designed with a cylindrical shape that allows it to self-center within the tapping channel through its own geometry. The block's dimensions and form enable it to automatically achieve coaxial alignment with the channel during insertion, eliminating the need for complex positioning mechanisms or difficult manual adjustment operations.
3Reliability
If the refractory block is replaced frequently due to wearing, then the tapping function is maintained, but labor-intensive manual work is required for each replacement
Solution Approach 1:
The patent replaces manual mechanical operations with an automated manipulator system that can insert, position, and secure the refractory block without human intervention. The manipulator retrieves worn blocks and installs new ones through automated sequences, significantly reducing the labor intensity and time required for each replacement cycle while maintaining reliable tapping function.
Data Source
AI summary
Device for inserting a refractory block into a taphole structure of a metallurgical vessel, in particular a basic oxygen furnace wherein the refractory block is carried by a mounting unit and has a proximate end introducable into the taphole. A distal end with locking elements, which can be coupled to a locking plate of the vessel, is disposed at the outside of the taphole of the vessel. The refractory block can be introduced into the taphole structure until the locking elements of the mounting unit can be attached to and coupled with the coupling head with a manipulator. This mounting unit can be uncoupled with the manipulator, when the refractory block is mortared and fixed in the lining, whereby the mounting unit can be decoupled and removed solely out of the taphole to enable refractory block replacement and gunning of refractory material from the inside of the furnace more easily.