Swirl Vane Cooling via Segmented Internal Water Passages

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Solution Overview

Problem

Existing gas injection lances for high-temperature metallurgical processes, such as the HIsmelt process, face challenges in effectively cooling swirl vanes due to extreme temperature conditions, leading to potential damage and inefficient heat management.

Innovation Solution

The apparatus features a gas flow duct with an elongate central structure and swirl vanes having internal water flow passages for cooling, with a centralized water supply and return system, ensuring even cooling distribution and resistance equalization across all passages, and is constructed with copper vanes externally coated with hard metals for durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If spiral flow guide vanes are mounted on a central structure in a gas flow duct, then swirl is imparted to the gas flow, but the vanes are exposed to extreme temperatures and cannot be effectively cooled

Engineering Contradiction:

Improvetemperature resistance of swirl vanesVSAvoidcooling effectiveness of swirl vanes

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The swirl vanes are segmented into multiple separate vanes rather than a single continuous structure. Each vane can be independently cooled through internal water passages, allowing targeted cooling where heat exposure is most severe while maintaining the overall swirl-generating function of the assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Water is introduced as an intermediary cooling medium flowing through internal passages within each vane. This water acts as a heat transfer intermediary, absorbing thermal energy from the hot vane surfaces and carrying it away through the cooling system, thereby protecting the vanes from extreme temperatures.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If internal water cooling passages are added to the swirl vanes, then cooling effectiveness is improved, but the device complexity increases

Engineering Contradiction:

Improvecooling effectiveness of swirl vanesVSAvoidstructural complexity of cooling system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cooling function is merged with the structural function of the swirl vanes themselves. The vanes are constructed as hollow structures with internal cooling passages integrated into their walls, combining the swirl-generating structural role with the heat dissipation function in a single integrated component rather than adding separate external cooling apparatus.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The central structure serves multiple functions: it provides structural support for mounting the vanes, acts as a water distribution manifold to deliver cooling water to each vane, and serves as a return passage for collecting cooled water. This multi-functionality reduces the need for separate dedicated components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Stability of the object's composition

If multiple water flow passages are provided in each vane, then cooling uniformity is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecooling uniformity across vanesVSAvoidmanufacturing complexity of vanes

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

Each vane is divided into multiple separate water flow passages rather than a single large passage. This segmentation of the cooling system into multiple smaller channels improves cooling uniformity across the vane surface by distributing water flow more evenly across different regions, preventing localized hot spots while maintaining manufacturability through standardized passage patterns.

Inventive Principle:

Principle #1Segmentation

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 design provides effective cooling of swirl vanes, preventing hot spots and ensuring efficient heat management, even at extreme temperatures, thereby enhancing the longevity and performance of the gas injection lance.

Implementation Method 1

the flow directing vanes are formed with internal water flow passages for flow of cooling water internally along each vane

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

cooling water which flows through supply and return passages within the wall of the duct

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS8017068B2Inducing swirl in a gas flow

Publication Date: 2011.09.13 SHANDONG MOLONG PETROLEUM MACHINERY CO LTD

AI summary

An apparatus for injecting gas into a metallurgical vessel supporting a metallurgical process is disclosed. The apparatus includes a gas flow duct, an elongate central structure extending within the gas flow duct, and a plurality of flow directing swirl vanes disposed about the central tubular structure adjacent the forward end of the duct. The flow directing vanes are formed with internal water flow passages for flow of cooling water internally along each vane. The elongate central structure is formed with a cooling water supply passage for supply of cooling water to the internal water flow passages in the vanes and a water return passage for outflow of cooling water which has passed through the internal water flow passages in the vanes.