Thermal Lance Ignition Cartridge with Induction Preheating
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Solution Overview
Problem
Existing systems for igniting thermal lances are either manually operated, pose safety risks due to the need for human intervention near hot steel, and require complex or costly external devices, or rely on hazardous pyrotechnic materials that are difficult to transport and store safely, with limited reliability and control over ignition conditions.
Innovation Solution
A device comprising a steel cartridge filled with high-calorific value material, such as carbon, and an induction heater assembly that heats the cartridge to a high temperature without oxygen, allowing remote and automatic ignition of the thermal lance when oxygen is supplied, eliminating the need for external triggering and hazardous materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If manual ignition with external devices (welding torch) is used, then ignition can be achieved, but operator safety is compromised due to exposure to liquid steel splashes and hot metal
Solution Approach 1:
The patent replaces manual mechanical ignition operations with an automated electrical ignition system. The igniter assembly with heating element automatically ignites the fuel charge through electrical resistance heating, eliminating the need for operators to manually position and operate external ignition devices near hazardous zones.
Solution Approach 2:
The patent introduces an igniter assembly as an intermediary device between the oxygen supply system and the fuel charge. This intermediary component safely contains the ignition process within the cartridge, mediating the transition from cold to hot state without exposing operators to direct contact with molten metal or high-temperature zones.
2Extent of automation
If pyrotechnic materials (iron thermite) are used for self-ignition, then automatic ignition is achieved, but transport and storage safety is compromised due to explosion risks
Solution Approach 1:
The patent changes the physical and chemical parameters of the ignition system by using a controlled electrical heating element instead of pyrotechnic compositions. The heating element operates at controlled temperatures through electrical resistance, avoiding the uncontrolled exothermic reactions and explosion hazards associated with iron thermite and similar pyrotechnic materials during transport and storage.
Solution Approach 2:
The patent employs a disposable igniter assembly that can be safely replaced between operations. This disposable component eliminates the need for complex safety protocols during transport and storage of pyrotechnic materials, as the electrical heating element and fuel charge are contained in a simple, non-hazardous cartridge that can be discarded after single use.
3Productivity
If simultaneous ignition and oxygen supply are performed, then ignition efficiency is improved, but process control is reduced due to inability to separate heating and combustion phases
Solution Approach 1:
The patent implements preliminary heating of the fuel charge through electrical resistance heating before oxygen supply is activated. The heating element pre-ignites the fuel charge within the cartridge, creating controlled combustion conditions before the oxygen jet is introduced, thereby separating the heating phase from the combustion phase for improved process control.
Solution Approach 2:
The patent ensures continuous useful action by maintaining the heating element active throughout the ignition sequence. The electrical heating continues to provide thermal energy to the fuel charge while oxygen is supplied, ensuring uninterrupted combustion initiation and maintaining high ignition efficiency while allowing independent control of heating and oxygen supply rates.
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
Enables safe, automatic, and reliable ignition of thermal lances, reducing the risk of human injury and material hazards, improving handling safety, and enhancing process control by separating the heating and ignition steps, allowing for robotic operation and reduced material costs.
Implementation Method 1
an induction heater assembly (16), adapted to heat the cartridge (10)
Implementation Method 2
an induction heater assembly (16), adapted to heat the cartridge (10)
Implementation Method 3
supplied by oxygen (17) intended to ignite the lance (11), wherein the cartridge (10) comprises high-calorific value material (15)
Implementation Method 4
an exothermic reaction, which brings the cutting end of the lance to a temperature ranging from 3500°C to above 5000°C
Data Source
Figure 1~3
AI summary
A device and process for igniting oxygen thermal lances or melting lances comprises a cartridge (10) coupled to the operating end of the thermal lance (11) and suppliable (14) by oxygen (17) intended to ignite the lance; the cartridge (10) contains high calorific value material (15) and is associated with a heater assembly (16) adapted to heat the cartridge, in a short time at a high temperature up to cause said material (15) to burn; the lance is then transferred in the operating position where it is supplied by oxygen (17) to the cartridge contacting the burnt material to start the step of igniting the lance.