Wedge-Shaped Refractory Sill and Jamb Assembly for Electric Arc Furnace
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing structure of electric arc furnaces, with a refractory-lined slag discharge opening, is prone to damage and dislodgement of bricks during slag removal, leading to costly and time-consuming repairs due to the lack of stability and confinement of bricks around the sill area.
Innovation Solution
A sill and jamb assembly formed by refractory blocks, which are wedge-shaped and bonded together by metal elements that fuse during furnace heat, providing a stable and integral unit less susceptible to damage during slag removal processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional refractory bricks are used to form the slag discharge opening, then the structure allows easy construction and maintenance, but the bricks are prone to dislodgement and damage during slag removal
Solution Approach 1:
The patent combines multiple refractory bricks into a single integrated refractory block that forms the sill and jamb assembly. This merging of separate brick elements into one unified component eliminates the dislodgement issues of individual bricks while maintaining construction feasibility through modular installation of the integrated block.
Solution Approach 2:
The refractory block is constructed as a composite structure containing a refractory material-filled cavity within a structural framework. This composite design provides enhanced structural integrity and resistance to impact forces during slag removal, while the refractory material maintains the thermal and chemical resistance properties needed for furnace operation.
2Ease of manufacture
If bricks are used to form the sill and jamb assembly, then the structure can be constructed with standard materials, but the bricks dislodge and require expensive repairs
Solution Approach 1:
By merging multiple bricks into a single integrated refractory block, the patent reduces the number of individual components that can fail or dislodge. This integration means that instead of repairing or replacing individual displaced bricks, the entire block functions as one unit, significantly reducing repair frequency and associated costs.
Solution Approach 2:
While the refractory block itself is integrated, it is designed as a modular component that can be installed and replaced as a single unit. This segmentation at the component level (rather than brick level) maintains ease of installation while eliminating the need for frequent repairs of individual bricks.
3Ease of operation
If the slag discharge opening is formed with a gap in the brick ring, then the opening can be created for slag removal, but the bricks above the sill are not constrained and are vulnerable to impact forces
Solution Approach 1:
The integrated refractory block combines the functions of both the sill and jamb structures into one piece. This merging creates a continuous, unbroken structure that maintains the integrity of the brick ring while still providing the necessary slag discharge opening, thereby constraining the bricks above the sill and preventing their dislodgement.
Solution Approach 2:
The refractory block extends vertically to form both the sill (lower portion) and jamb (upper portion) structures. This dimensional extension provides confinement and support to the bricks above the sill opening, preventing their dislodgement while maintaining the operational slag discharge pathway.
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
The refractory sill and jamb assembly enhances the stability of the slag opening, reducing the risk of brick dislodgement and damage during slag removal, thus minimizing the need for frequent repairs and maintaining furnace operation efficiency.
Implementation Method 1
refractory blocks, which are wedge-shaped and bonded together by metal elements that fuse during furnace heat
Data Source
AI summary
A sill and door jamb assembly providing an opening in an electric arc furnace, the sill and door jamb assembly having a sill block assembly and two jamb block assemblies. The sill block assembly having side-by-side sill blocks, each of the sill blocks being positioned side-by-side to form the sill block assembly and having an upper end and a lower end. The lower end of the sill block assembly is confined within a plurality of courses of the refractory bricks. Each jamb block assembly having a plurality of jamb blocks positioned side-by-side. Each of the jamb block assemblies having a lower end and an inner surface abutting the distal ends of the sill block assembly. The inner surfaces of the jamb block assemblies and the upper surface of the sill block assembly form the slag opening in the furnace.