Refractory Impact Pad Barriers for Ladle Shroud Misalignment

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Solution Overview

Problem

Existing refractory impact pads face turbulence issues due to misalignment of ladle shrouds, particularly those with reduced cross-section upper inlet/outlet openings, leading to splash and unfavorable flow patterns during casting.

Innovation Solution

The impact pad features a design with barriers projecting from the inner surface, shaped as inverted V or W, to distribute and focus the metal stream, reducing velocity and turbulence, and maintaining a large inflow/outflow cross-section to minimize splashing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the upper inlet/outlet opening cross-section is reduced, then the impact pad can be more compact, but turbulence and splashing increase due to misalignment of ladle shroud

Engineering Contradiction:

Improveimpact pad volumeVSAvoidturbulence and splashing

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The inner wall surface is segmented into multiple zones with different barrier configurations. The first barrier zone has barriers spaced to distribute the metal stream, while the second barrier zone has barriers spaced to focus the stream. This segmentation allows the impact pad to maintain a reduced cross-section while managing turbulence through localized flow control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the impact pad have different barrier densities and configurations. The first barrier zone is positioned to receive the metal stream from the ladle shroud, while the second barrier zone is positioned to receive the stream from the bottom. This local differentiation allows optimal flow control in each region without increasing the overall cross-sectional area.

Inventive Principle:

Principle #3Local quality

2Speed

If barriers are added to the inner wall surface, then metal stream velocity and turbulence are reduced, but device complexity increases

Engineering Contradiction:

Improvemetal stream velocityVSAvoidinner wall structure complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The inner wall is divided into two functional zones with different barrier configurations. The first barrier zone uses barriers spaced to distribute the incoming metal stream, while the second barrier zone uses barriers spaced to focus the stream before it reaches the bottom. This segmentation achieves velocity control with a relatively simple two-zone structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using a single uniform barrier configuration throughout, the invention uses different barrier spacing patterns in different zones. The first zone has closer spacing to distribute flow, while the second zone has wider spacing to focus flow. This inverted approach to uniformity achieves better flow control with less overall complexity.

Inventive Principle:

Principle #13The other way round (Inversion)

3Stability of the object's composition

If barriers are positioned closer to the upper end, then flow distribution is improved, but the inflow cross-section is reduced

Engineering Contradiction:

Improveflow pattern stabilityVSAvoidinflow cross-section area

Core Design Contradiction:

Stability of the object's compositionVSArea of stationary object

Solution Approach 1:

The first barrier zone is positioned in the upper region to receive and distribute the metal stream from the ladle shroud. The second barrier zone is positioned in the lower region to receive and focus the stream before it reaches the bottom. This vertical segmentation allows flow stabilization without significantly reducing the inflow cross-section area.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The barrier density and spacing are optimized locally in each zone. The first zone has higher barrier density to distribute flow, while the second zone has lower density to focus flow. This local optimization maintains adequate inflow cross-section while achieving stable flow patterns through targeted intervention.

Inventive Principle:

Principle #3Local quality

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 effectively reduces metal stream velocity and turbulence, prevents splashing, and enhances energy dissipation, improving flow properties and manufacturing efficiency.

Implementation Method 1

With respect to the inflowing metal stream they act like a diffuser, distributing the metal stream into opposite directions both towards the bottom (impact surface) of the impact pad

Methodology Applied

Scientific EffectFluid flow distribution:

Implementation Method 2

With respect to any metal melt, which has been redirected from the bottom and adjacent wall portions of the impact pad the said barriers have the effect of focusing of the metal stream along the opposed inclined or curved legs of the barriers up to the transition area between the legs of the respective barrier

Methodology Applied

Scientific EffectFluid flow focusing: Focusing