Tundish Impact Pad with Inclined Facets for Misaligned Flow

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Solution Overview

Problem

Existing impact pads in tundishes face challenges in maintaining symmetric flow distribution and minimizing turbulence when the incoming stream of molten steel is misaligned, leading to uneven residence time and thermal distribution, which can cause operational issues and defects in steel products.

Innovation Solution

A refractory impact pad with a base having an upwardly facing impact surface and a wall extending around its periphery, featuring multiple facets with inclined or declinated surfaces to accommodate misalignment, ensuring symmetric flow distribution and minimizing erosion, even when the incoming stream is not perfectly centered.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a conventional impact pad with a single apex is used, then the structure is simple, but it cannot accommodate misalignment of the incoming molten steel stream, causing uneven flow distribution and turbulence

Engineering Contradiction:

Improveaccommodation of misalignmentVSAvoidimpact pad structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The impact pad surface is segmented into multiple facets instead of a single apex. Each facet is inclined at different angles to redirect molten steel flow from various misalignment positions, transforming the single-point impact structure into a multi-zone flow control structure that handles off-center streams effectively

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the impact pad surface are given different local properties through varied facet inclinations. The facets are designed with specific angles tailored to receive and redirect flow from particular misalignment positions, creating localized flow control zones that collectively handle a wide range of stream orientations

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If the ladle shroud is not vertical or not centered, then the setup is more flexible, but it causes uneven residence time and thermal distribution to various strands

Engineering Contradiction:

Improveladle shroud orientation flexibilityVSAvoidresidence time uniformity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The impact pad employs asymmetric facet configurations where facets on different sides of the pad have different inclinations and orientations. This asymmetric design compensates for asymmetric misalignment conditions, ensuring that even when the ladle shroud is off-center or non-vertical, the flow distribution to multiple strands remains relatively uniform in terms of residence time and thermal exposure

Inventive Principle:

Principle #4Asymmetry

3Object-affected harmful factors

If the impact pad has a vertical sidewall, then the flow redirection is effective, but it causes excessive erosion at the impact zone

Engineering Contradiction:

Improveflow redirection effectivenessVSAvoidresistance to erosion

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The impact pad incorporates curved or rounded features at the impact zone rather than sharp vertical corners. The facets are designed with curved transition zones that distribute the impact load over a larger area, reducing stress concentration and erosion at the impact point while maintaining effective flow redirection capability

Inventive Principle:

Principle #14Spheroidality (Curvature)

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

The impact pad achieves symmetric flow distribution and reduced turbulence, minimizing defects and operational issues by effectively redirecting and stabilizing the molten steel flow, even with non-vertical or off-centered ladle shroud orientations.

Implementation Method 1

the impact pad achieves symmetric flow distribution and reduced turbulence, minimizing defects and operational issues by effectively redirecting and stabilizing the molten steel flow

Methodology Applied

Scientific EffectFlow redirection:

Implementation Method 2

The stream of molten steel from the ladle generally enters the tundish with considerable force, and this can generate considerable turbulence within the tundish itself. Impact pads disclosed in the prior art have generally been designed with particular attention to the upwardly directed component of the resulting flow.

Methodology Applied

Scientific EffectTurbulence reduction: Turbulence

Data Source

PatentEP3496882B1Impact pad

Publication Date: 2021.11.17 VESUVIUS USA CORP

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AI summary

An impact pad (30) for metallurgical processes is formed from refractory material, and contains a base (31) having an impact surface (32) facing upwardly against a stream of molten metal entering a vessel containing the impact pad. A wall (34) having a plurality of adjacent wall portions (36, 38) extends upwardly from the base (31). The impact surface (32) contains at least one nonhorizontal facet extending inwardly from a wall portion (36, 38); all lines in the facet extending perpendicularly to the wall portion have an inclination or declination with respect to the horizontal plane.