Segmented Refractory Blast Lance for High-Temperature Metallurgy

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Solution Overview

Problem

Blast lances used in metallurgical processes face significant thermal, chemical, and mechanical stresses due to exposure to high temperatures, corrosive slag, and viscous molten metals, which existing refractory materials struggle to withstand effectively.

Innovation Solution

A blast lance design comprising a cylindrical lance core surrounded by a refractory casing with n+1 refractory tubular sections separated by n refractory annular structures, allowing for varying material properties and improved structural stability through horizontal casting, using refractory concrete for tubular sections and annular structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a monolithic refractory coating is cast using partition plates, then different types of refractory coatings can be cast in different sections, but the partition plates need to be withdrawn adding a process step and potentially leaving gaps between adjacent sections

Engineering Contradiction:

Improveability to use different refractory coatings in different sectionsVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The blast lance is divided into multiple sections (head section, bath section, slag section, cold section) each with specific refractory coating requirements. The monolithic refractory coating is segmented into distinct sections separated by reinforcement rings, allowing each section to be optimized for its specific functional requirements while being cast as a single integrated piece.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Reinforcement rings are introduced as intermediary elements between adjacent refractory coating sections. These reinforcement rings serve as both structural connectors and form definition elements, eliminating the need for removable partition plates while ensuring proper separation and alignment of different refractory coating sections.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If partition plates are used to separate refractory coating sections, then different refractory materials can be cast in different sections, but gaps may form between adjacent sections after partition plate removal

Engineering Contradiction:

Improvedifferent refractory materials in different sectionsVSAvoidgap-free connection between sections

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

Reinforcement rings act as permanent intermediary elements that maintain precise spacing and alignment between adjacent refractory coating sections. These rings are integrated into the monolithic casting, ensuring that the separation between sections is consistent and gap-free, while still allowing different refractory materials to be used in each section.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The reinforcement rings are merged with the monolithic refractory coating casting, combining the structural reinforcement function with the section separation function. This integration ensures that the rings remain in place during casting and provide permanent, gap-free separation between different refractory coating sections without requiring subsequent assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If refractory concrete is used for the blast lance, then good high temperature resistance and temperature change resistance are achieved, but the material needs to meet multiple contradictory requirements for different sections

Engineering Contradiction:

Improvehigh temperature resistanceVSAvoidmeeting multiple contradictory requirements

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

Different sections of the blast lance are assigned different refractory coating materials tailored to their specific functional requirements. The head section uses materials optimized for thermal shock resistance, the bath section for chemical stability, the slag section for corrosion resistance, and the cold section for mechanical strength, while all sections use refractory concrete base material for high temperature resistance.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The blast lance is segmented into distinct functional zones (head, bath, slag, cold sections) each with specialized refractory coating requirements. This segmentation allows each section to be optimized for its specific purpose while maintaining overall structural integrity through the monolithic casting approach.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12529521B2Blast lance for gas blowing, its use and method of production

Publication Date: 2026.01.20 IMERTECH SAS

AI summary

The present invention relates to blast lances for gas blowing in metallurgical processes, the blast lance comprising a cylindrical lance core and a refractory casing, wherein the said refractory casing comprises n+1 refractory tubular sections and n or more refractory annular structures, wherein each set of two neighbouring refractory tubular sections is connected via a refractory annular structure, and wherein n is an integer of 1 or higher. The invention further relates to the use and method of production of such blast lances.