Slag Notch Segmented Insert Cooling Metallurgical Vessels
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Solution Overview
Problem
The existing slag notch structures in metallurgical vessels, particularly in HIsmelt and HIsarna processes, face challenges with structural integrity due to high operating temperatures and the risk of solidified metal interfering with the drainage process, leading to potential process interruptions and damage to the vessel's internal structure.
Innovation Solution
A slag notch with a steel member that defines a passageway for molten slag, incorporating a cooling system, such as water cooling, to maintain structural integrity and prevent damage from high temperatures, and a design that minimizes metal intrusion and facilitates easy plugging and unplugging during slag tapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a slag notch structure is used to drain molten slag at high operating temperatures, then slag drainage function is achieved, but structural integrity deteriorates due to thermal damage
Solution Approach 1:
The slag notch structure is divided into multiple segments: a replaceable insert portion that can be removed and replaced, and a permanent holder portion that remains in the vessel wall. This segmentation allows the vulnerable insert to be replaced without damaging the entire structure, resolving the contradiction between maintaining structural integrity at high temperatures and enabling slag drainage.
Solution Approach 2:
The insert portion is designed with specific material properties and geometric parameters (such as tapered shape with included angle of 60-120 degrees) that change how it interacts with thermal conditions. The tapered geometry and material selection allow the insert to withstand thermal stress better, maintaining structural integrity while functioning at operating temperatures.
2Productivity
If a slag notch structure is used to drain molten slag, then slag drainage is enabled, but the structure is damaged by solidified metal interference
Solution Approach 1:
The vulnerable insert portion is extracted as a separate, removable component from the permanent holder. When solidified metal interferes with drainage or damages the insert, the insert can be removed and replaced without affecting the holder or requiring vessel shutdown, thus maintaining continuous operation capability while enabling effective slag drainage.
Solution Approach 2:
The insert is designed with a tapered shape that preliminarily prevents solidified metal from blocking the drainage path. The geometry facilitates smooth slag flow and reduces the likelihood of solidification interference before it occurs, maintaining both drainage efficiency and continuous operation.
3Ease of operation
If a complex plugging system is used to close the slag notch during operation, then slag drainage control is improved, but device complexity increases
Solution Approach 1:
The insert is designed as a simple, replaceable component that can be easily plugged or replaced using basic materials like refractory cement or sand. Instead of complex mechanical plugging systems, the solution uses simple disposable-like inserts that can be quickly sealed by filling with basic materials, reducing device complexity while maintaining ease of operation for slag tapping control.
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 solution ensures the slag notch retains structural integrity at operating temperatures, prevents interruptions, and reduces the risk of damage to the vessel's internal structure by effectively managing the flow of molten slag and solidified metal, ensuring continuous and safe operation of the smelting process.
Implementation Method 1
incorporating a cooling system, such as water cooling, to maintain structural integrity and prevent damage from high temperatures
Data Source
AI summary
A slag notch for a metallurgical vessel includes a steel member that defines a passageway for molten slag and a system for cooling the steel member.