Molten Slag Energy Extraction Using Immersed Treatment Vessel
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Solution Overview
Problem
Current technologies lack a sustainable, large-scale method for recovering and reusing the high-quality thermal energy contained in molten slags from steelmaking operations, due to challenges such as extremely high temperatures, low thermal conductivity, intermittent availability, and solidification issues.
Innovation Solution
The process involves immersing a high-melting-point object or a treatment vessel containing a material to be thermally treated into the molten slag, allowing energy extraction while minimizing heat loss through insulation and strategic movement within the slag pot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If molten slag is cooled to extract thermal energy, then energy recovery is improved, but solidification occurs reducing extraction efficiency
Solution Approach 1:
The patent changes the physical-chemical parameters of slag by adding fluxes (such as calcium carbonate, silica, or alumina) to modify the liquidus temperature and viscosity characteristics. This allows the slag to remain in a molten state at lower temperatures, extending the window for heat extraction while preventing premature solidification. The flux addition transforms the thermal properties of the slag system.
2Object-generated harmful factors
If carbon consumption is decreased through energy recovery, then environmental benefits are improved, but extraction process complexity increases
Solution Approach 1:
The patent combines multiple functions into a single integrated system: the slag cooling process is merged with heat exchange to preheat incoming materials, and flux addition is combined with the tapping process. This integration allows energy recovery without requiring completely separate complex systems, as the heat extraction occurs during the existing slag handling operations.
Solution Approach 2:
The patent introduces thermal energy as an intermediary between the molten slag and the materials requiring heating. Instead of direct contact or complex heat transfer mechanisms, the slag itself serves as the heat carrier, transferring thermal energy to preheat charge materials, water, or gases that pass through or near the slag stream, simplifying the overall system architecture.
3Loss of energy
If heat loss is minimized through insulation, then energy efficiency is improved, but heat transfer to extraction medium is reduced
Solution Approach 1:
The patent applies different thermal insulation characteristics to different regions of the slag handling system. Insulation is provided on the exterior surfaces of slag containers and transfer conduits to prevent heat loss to the environment, while the interior surfaces maintaining direct contact with the extraction medium remain thermally conductive to facilitate efficient heat transfer from the molten slag to the charging materials or heat exchange fluid.
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 effectively extracts and utilizes the high-quality thermal energy from molten slags, reducing energy losses and providing significant cost, operational, and environmental benefits for the steel industry.
Implementation Method 1
The vessel is heated by the high-temperature molten medium
Implementation Method 2
minimizing heat loss through insulation
Data Source
AI summary
Methods and systems are provided for extracting and utilizing the energy contained in molten slags generated from metal producing and refining operations. The energy is extracted while the slag is contained within a containment vessel, such as a slag pot, after the slag has been discharged from a furnace. The energy is accessed by immersing into the slag a temperature-resistant treatment vessel, such as, a cylindrical vessel made of graphite, having an internal cavity. The energy from the slag is transmitted by direct contact with the surface of the treatment vessel. The treatment vessel and slag may be moved relative to each other to overcome the low thermal conductivity of the slag. Any substance placed within the cavity is thereby heated without directly contacting the molten slag. The methods and systems provide for high temperature chemical reactions, energy conversions, or transfer operations within the internal cavity.