Submerged Lance Calcium Wire Injection Depth Control
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Solution Overview
Problem
Current methods for adding calcium to molten steel in steelmaking are inefficient due to its low density, volatility, and reactivity, leading to short residence time and excessive exposure to atmospheric oxygen, resulting in inadequate utilization.
Innovation Solution
A system and method involving a lance with a wire feeding apparatus that positions the outlet below the surface of the molten metal, using a distance measuring device to determine the correct depth and maintain the lance at a predetermined depth between the slag layer and molten metal, ensuring efficient calcium wire dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If calcium-containing particulate materials are added in bulk to the molten material, then the addition process is simple, but the materials rapidly rise to the surface without sufficient residence time
Solution Approach 1:
The patent uses a water-cooled copper nozzle as an intermediary device to deliver calcium wire directly to the molten material. The nozzle serves as a mediator that enables precise placement of calcium at the optimal depth, resolving the contradiction between simple addition and sufficient residence time by providing a controlled delivery mechanism.
Solution Approach 2:
The patent changes the physical state and delivery parameters of calcium from bulk particulate form to continuous wire form. This parameter change allows the calcium to be fed continuously through the nozzle and deposited at controlled depths, achieving both operational simplicity and extended residence time in the melt.
2Duration of action of moving object
If calcium-containing materials are poured directly into the tapping stream from the furnace, then residence time is increased, but excessive reaction with atmospheric oxygen occurs
Solution Approach 1:
The water-cooled copper nozzle acts as a protective intermediary that delivers calcium wire into the molten material while minimizing exposure to atmospheric oxygen. The nozzle system provides a controlled delivery path that reduces harmful oxidation reactions while maintaining adequate residence time.
Solution Approach 2:
The patent creates a localized inert environment around the calcium delivery point by submerging the nozzle tip below the molten material surface. This inert environment protection prevents excessive oxidation of calcium while it is being delivered and initially mixed into the melt.
3Device complexity
If calcium is added by surface wire feeding, then large gas flows are not needed, but high volatility of calcium hinders efficient utilization
Solution Approach 1:
The water-cooled copper nozzle serves as a critical intermediary that enables efficient delivery of calcium wire into the molten material without requiring large gas flows. The nozzle system overcomes calcium's high volatility by providing direct, controlled placement into the melt, thereby maintaining both low device complexity and high productivity.
Solution Approach 2:
The patent replaces the mechanical gas-propulsion system used in powder injection with a water-cooled copper nozzle system that delivers calcium wire through direct contact and thermal conduction. This mechanical substitution eliminates the need for large gas flows while maintaining efficient calcium utilization.
4Ease of operation
If inert gas injection through a refractory lance is used to inject calcium powder, then calcium can be delivered into the melt, but high level of turbulence is generated causing excessive exposure to oxygen and nitrogen
Solution Approach 1:
The water-cooled copper nozzle replaces the inert gas injection system as the intermediary for calcium delivery. This new intermediary delivers calcium wire directly to the molten material without generating high turbulence, thereby eliminating excessive exposure to atmospheric oxygen and nitrogen while maintaining effective calcium delivery capability.
Solution Approach 2:
The patent uses water cooling (hydraulic principle) in the copper nozzle to prevent premature melting of the calcium wire and to control the delivery process. This hydraulic approach replaces the pneumatic gas injection method, reducing turbulence and harmful atmospheric exposure while maintaining delivery effectiveness.
Data Source
AI summary
A method and system for dispensing an additive wire involves use of a lance for delivering the additive wire and determination of location data with respect to a surface of a metallurgical melt into which the lance is placed.