Smelting Lance Extraction Track and Carriage System
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Solution Overview
Problem
The HIsmelt smelting process requires the frequent removal and replacement of long, heavy solids injection lances and associated delivery lines from a metallurgical vessel, which is challenging due to their slender and heavy nature, necessitating efficient extraction methods to facilitate quick refurbishment and maintenance.
Innovation Solution
A smelting apparatus and method utilizing an elongate track and carriage system to support and move the lances and delivery lines from an inclined position to an upright position, allowing for safe removal and installation using an overhead crane or hoist, with a lance connector and hoist actuable to lower the lances to a vertical position for lifting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If lances are made long and slender to reach the bottom region of the vessel, then delivery precision is improved, but handling and extraction difficulty increases
Solution Approach 1:
The extraction system is segmented into multiple functional components: an overhead crane for vertical lifting, a hoist for controlled lowering, and a carriage system with rails for horizontal movement. This segmentation allows each component to handle specific aspects of the lance extraction, making the overall process manageable despite the lance's length and weight.
Solution Approach 2:
The carriage system acts as an intermediary between the heavy lance and the overhead crane. The carriage supports the lance during extraction and provides a stable platform for the hoist to operate, mediating the transfer of the lance from the vessel to the crane for final removal.
2Reliability
If lances are made heavy to withstand high temperatures and pressures, then reliability is improved, but extraction and removal difficulty increases
Solution Approach 1:
The overhead crane and hoist system provides counterbalancing force to support the heavy lance weight during extraction. The crane's lifting capacity is designed to counteract the lance's weight, enabling controlled removal despite the heavy mass required for withstanding operational conditions.
Solution Approach 2:
The extraction system uses dynamic control through the hoist mechanism to manage the lance's weight. The hoist can be actuated to lower the lance controllably, transforming the static heavy weight into a dynamically managed load that can be precisely controlled during the extraction process.
3Ease of repair
If frequent removal and replacement of lances is performed, then maintenance quality is improved, but operational downtime increases
Solution Approach 1:
The overhead crane and carriage system are positioned and ready in advance to immediately extract lances when removal is required. This preliminary positioning of the extraction equipment allows for rapid response, minimizing the time needed to begin the extraction process and reducing overall downtime.
Solution Approach 2:
The extraction system is designed to rapidly move the lance from the vessel to the removal point in a single continuous motion. The carriage travels along the rails and the crane lifts in one coordinated action, skipping intermediate steps and rushing through the extraction process to minimize time loss.
4Ease of operation
If a complex extraction system with multiple components is used, then extraction capability is improved, but device complexity increases
Solution Approach 1:
The overhead crane serves multiple functions: it supports the heavy lance during extraction, provides vertical lifting capability, and can position lances for replacement. This multi-functionality reduces the need for separate specialized equipment, simplifying the overall system despite its capabilities.
Solution Approach 2:
The carriage system combines horizontal movement along rails with vertical hoisting capability in a single integrated unit. This merging of functions into one component reduces the total number of separate parts and simplifies the control system compared to having independent mechanisms for each motion.
Data Source
AI summary
A metallurgical vessel (11) has circumferentially spaced tubular mountings (25) through which to extend solids injection lances (31) into the vessel. Lance extraction apparatus (33) comprises an elongate track support structure (41) supporting a twin rail track (40) inclined upwardly and outwardly from the vessel above the direction of inclination of a respective lance (31). Interconnected upper and lower carriages (42, 44) are moveable along track (40) by operation of a hoist (47). Extraction apparatus (33) is operable sequentially to remove solids delivery line sections (36) and (37) and the lance (31) by connection to the carriages (42, 44) and upward movement of those carriages along track (40). Upper carriage (42) carries a pivot arm (51) for connection to upper parts of components to be removed such that those components can be pivoted downwardly to positions in which they can be hung from an overhead crane for removal to a remote location.