Smelting Lance Mounting Part Segmentation for Slag Bond Removal
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Solution Overview
Problem
The existing metallurgical lances used in the Hismelt process face difficulties in withdrawal due to slag accretion, which forms a bond with the vessel wall, making it challenging to remove the lances after a smelting operation without cooling the vessel.
Innovation Solution
A modified solids injection lance with an annular lance mounting part of increased cross-sectional size and a lance mounting tube system that allows for inward movement to break slag accretions, facilitated by a hydraulic power device, enabling easier withdrawal by creating an enlarged opening for the lance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the lance is inserted into the vessel for injecting solid particulate material, then the smelting operation can be performed effectively, but slag accretion forms a bond between the lance and the vessel wall making withdrawal difficult
Solution Approach 1:
The lance is divided into a removable lance shaft and a stationary mounting part. The mounting part remains in the vessel wall while the shaft can be withdrawn independently, separating the injection function from the withdrawal problem.
Solution Approach 2:
The problematic slag accretion zone is extracted from the lance shaft and transferred to the stationary mounting part. The mounting part is designed to be replaced rather than withdrawn, isolating the withdrawal difficulty from the operational lance.
2Ease of operation
If the vessel is cooled to enable slag breaking equipment to be brought into the vessel, then the lances can be removed, but significant downtime is required
Solution Approach 1:
The mounting part is designed in advance with replaceability in mind. The connection between mounting part and lance shaft allows for quick detachment without requiring vessel cooling, preparing the system for rapid maintenance.
Solution Approach 2:
The mounting part is designed as a disposable or easily replaceable component. Instead of attempting to remove the entire lance including the mounted portion, the mounting part can be left in place or quickly replaced, eliminating the need for lengthy cooling periods.
3Ease of operation
If the lance mounting part is of increased cross-sectional size, then the opening in the vessel shell must be larger, but this facilitates lance withdrawal by creating an enlarged opening
Solution Approach 1:
The lance system is segmented into the mounting part (stationary or easily replaceable) and the lance shaft (withdrawable). The mounting part can have a larger cross-section that simplifies withdrawal, while the shaft maintains its functional dimensions.
Solution Approach 2:
The mounting part extends in a dimension perpendicular to the lance shaft axis, creating an annular mounting part that protrudes radially. This dimensional change allows the mounting part to have increased cross-sectional area without significantly increasing the length of the lance shaft that must pass through the vessel wall.
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 solution allows for the efficient removal of lances without the need for significant vessel cooling, reducing downtime and operational complexity by breaking slag bonds during the withdrawal process.
Implementation Method 1
an annular cooling jacket surrounding the central core tube throughout a substantial part of its length and provided with internal water flow passages for flow of cooling water therethrough
Implementation Method 2
a hydraulic power device, enabling easier withdrawal by creating an enlarged opening for the lance
Data Source
AI summary
A smelting apparatus includes a vessel and a solids injection lance extending through an opening in the wall of a vessel barrel into the interior space of the vessel. The lance includes a central core tube through which to pass solid particulate material into the vessel and an annular cooling jacket surrounding the central core tube throughout a substantial part of its length. The lance has a mounting structure including a tubular part extended about the cooling jacket and about twice the diameter of the cooling jacket. The tubular part fits within a tubular lance mounting bracket welded to the shell of the vessel barrel to extend outwardly from the vessel. The lance is held within the mounting bracket by clamping bolts acting between flanges on the tubular part and the tubular bracket.