Hot-State Refractory Lining Repair Using External Thermal Imaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for repairing refractory linings of metallurgical vessels lack precision and quality, especially when dealing with molten metal, as they do not effectively visualize and evaluate temperature ranges and material distribution during the repair process.
Innovation Solution
The method involves using a thermal imaging camera to photographically record and evaluate temperature ranges of the refractory lining and gunning jet before, during, and after material supply, allowing for real-time adjustments to achieve optimal coating and adherence, with the camera positioned outside the vessel to avoid heat damage and provide immediate feedback for controlling the repair process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a television camera is attached to the line close to the nozzle to observe the inside of the vessel, then the areas to be repaired can be visualized and the operator can work from outside the hot vessel, but the camera housing requires complex cooling devices and heat-resistant transparent openings
Solution Approach 1:
The imaging function is extracted from the hot environment inside the vessel. Instead of placing the camera inside or on the lance, the patent uses a camera positioned outside the vessel to capture images through the transparent refractory lining, eliminating the need for complex cooling and heat-resistant modifications to the camera housing.
Solution Approach 2:
The transparent refractory lining serves as an intermediary medium that allows optical transmission from the hot interior to the cooler exterior where the camera is positioned. This mediator enables imaging without direct thermal contact between the camera and the hot vessel interior.
2Manufacturing precision
If refractory material is supplied to repair the lining, then the lining can be restored, but it is difficult to precisely control and evaluate the material distribution and layer thickness
Solution Approach 1:
The patent implements a feedback mechanism where the camera continuously captures images of the refractory material application process. These images are transmitted to the operator in real-time, enabling immediate assessment of material distribution and layer thickness, and allowing for instantaneous adjustments to achieve the desired repair quality.
Solution Approach 2:
The patent utilizes visual contrast and color differentiation in the captured images to evaluate the repair process. The refractory material, being at a different temperature than the vessel lining, creates visible thermal contrast that helps the operator assess material distribution and thickness in real-time.
3Measurement precision
If the camera is positioned inside the vessel to capture repair process images, then direct visualization is possible, but the camera is exposed to extreme heat and requires complex protective measures
Solution Approach 1:
The camera is extracted from the high-temperature environment inside the vessel and repositioned outside. The transparent refractory lining acts as a window that allows the camera to capture images of the repair process without being exposed to the extreme heat, eliminating the need for complex cooling systems.
4Adaptability or versatility
If manual operation of the gunning lance is used, then the operator can adjust to different repair scenarios, but the repair precision and consistency are limited by human factors
Solution Approach 1:
The real-time visual feedback from the camera enables the operator to make precise, informed adjustments during the repair process. The operator can continuously monitor material distribution and layer thickness, allowing for consistent high-quality repairs while maintaining the adaptability of manual operation.
Solution Approach 2:
The system combines the adaptability of manual lance operation with dynamic visual feedback. The operator can dynamically adjust the lance position, angle, and material flow rate based on real-time image feedback, achieving both versatility and precision.
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 approach enables precise and high-quality repairs by accurately evaluating parameters like layer thickness and material distribution, ensuring optimal coating and adherence, and allowing for immediate adjustments to the repair process based on real-time data comparison with target specifications.
Implementation Method 1
at least a partial region of the worn areas of the refractory lining of the vessel to be repaired or the gunning jet is recorded photographically with visualization of the temperature ranges
Implementation Method 2
a thermal imaging camera to photographically record and evaluate temperature ranges
Data Source
AI summary
A method for repairing a refractory lining of a metallurgical vessel in the hot state. This repair takes place using a supplying apparatus. In addition, recording of at least the worn regions and monitoring of the repair are carried out by a monitoring device. Before, during and/or after the supplying of material, at least a partial region of the areas of the refractory lining of the vessel or the gunning jet is recorded photographically with visualization of the temperature ranges. This results in an evaluation with regard to different parameters such as properties, layer thickness and/or distribution of the supplied material. It has been demonstrated that visualization of the temperature ranges of the areas to be repaired and of the refractory material during supplying of material enables different parameters to be established very accurately, and as a result, optimal coating of the wall lining can be achieved.