Refractory Tap-Hole Insert for Furnace Repair
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Solution Overview
Problem
The existing methods for refurbishing tap-holes in arc, blast, or smelter furnaces are slow, hazardous, and result in non-uniform performance due to manual placement of preformed bricks, leading to frequent replacements and increased downtime.
Innovation Solution
A method involving the use of a prefabricated, hollow refractory tap-hole insert with lateral through holes, detachably connected to a clay gun, which is inserted into the tap-hole channel and filled with grouting material through these holes to securely fix it in place, allowing for quick and safe refurbishment without direct exposure to hazardous conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If manual refurbishment with preformed bricks is used, then the tap-hole can be repaired, but the repair process is slow and requires furnace shutdown
Solution Approach 1:
The refractory insert is pre-formed off-site with the exact geometry and dimensions needed, eliminating the time-consuming manual bricklaying process during furnace shutdown. The insert is ready for immediate installation, reducing repair time and furnace downtime.
Solution Approach 2:
The repair function is extracted from the manual bricklaying process and embodied in a pre-formed refractory insert that can be quickly installed. This separates the complex manual assembly operation from the simple installation operation, enabling faster repairs.
2Ease of repair
If manual brick placement is used, then the tap-hole can be refurbished, but the positioning is non-uniform leading to frequent replacements
Solution Approach 1:
The refractory insert is pre-formed with precise geometry and uniform material distribution in a controlled manufacturing environment. This ensures consistent positioning and uniform performance, eliminating the variability introduced by manual brick placement.
Solution Approach 2:
The repair approach changes from discrete manual brick placement to a continuous pre-formed insert with controlled material parameters. This ensures uniform density, composition, and geometric dimensions, leading to consistent tap-hole performance and reduced replacements.
3Ease of repair
If craftsmen work in hot conditions to position bricks, then the tap-hole can be repaired, but the work is dangerous and requires specialized labor
Solution Approach 1:
The dangerous manual brick placement operation in the hot furnace environment is replaced by a simple mechanical installation of a pre-formed insert. This extracts the hazardous manual labor from the repair process, eliminating the need for specialized craftsmen to work in thermal hazard zones.
Solution Approach 2:
The refractory insert is designed to be self-positioning and self-supporting during installation, requiring minimal manual intervention in the hot zone. The insert's geometry and the installation mechanism work together to automatically ensure proper positioning without requiring skilled manual adjustment in hazardous conditions.
4Ease of repair
If preformed bricks are used for refurbishment, then the tap-hole can be repaired, but the bricks are dislodged by discharged metal or slag requiring frequent replacement
Solution Approach 1:
The refractory insert is made from advanced composite refractory materials with enhanced mechanical strength, thermal shock resistance, and erosion resistance. These composite materials provide superior durability compared to traditional individual bricks, resisting dislodgment by discharged metal and slag, and extending tap-hole service life.
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 method enables faster, safer, and more reliable refurbishment of tap-holes, extending their lifespan by ensuring optimal positioning and sealing, reducing the need for specialized labor and minimizing production losses.
Implementation Method 1
filled with grouting material through these holes to securely fix it in place
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention relates to a method for refurbishing a tap-hole. The method comprises the following steps: A making a tap-hole channel trough a tap-hole block in a lower section of an arc, blast or smelter furnace, and B restoring said tap-hole channel to form a refurbished tap-hole; characterized by the following steps: 1. detachably connecting a prefabricated, hollow, refractory tap-hole insert comprising a shell to a clay gun, wherein said tap-hole insert comprises a. a first end and a second end in axial direction, wherein said second end is blocked. b. an opening arranged on said first end, c. a hollow passage in axial direction, wherein said hollow passage is accessible through said opening, d. at least one lateral through hole, arranged in said shell, 2. inserting said tap-hole insert into said tap-hole channel, wherein said clay gun is fluidly coupled with said tap-hole insert and said tap-hole channel, 3. injecting a grouting material from said clay gun into said tap-hole insert and through said through hole into said tap-hole channel and, 4. disconnecting said tap-hole insert from said clay gun.