Tundish Dry Vibratable Form Mold Gap Design
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Solution Overview
Problem
Existing methods for forming and curing a thin, slag-resistant refractory layer in a steel tundish are inefficient, requiring multiple steps and materials, and do not effectively address the need for quick replacement and improved slag resistance.
Innovation Solution
A device and method involving a mold positioned within the tundish to form a gap between the mold and the refractory lining, allowing for the insertion of dry refractory material, which is then heated to cure and form a thicker, replaceable hot-face refractory layer, particularly thicker at the upper end where slag is most likely to form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thin layer of dry refractory material is applied over the castable layer, then the refractory lining becomes more slag-resistant, but the curing process becomes time-consuming and complex
Solution Approach 1:
The patent applies radiant heat at controlled intensities (e.g., 50-150 kW/m²) to accelerate the curing of dry refractory material. By changing the thermal parameters (temperature, heat flux, exposure time) and using multiple heat sources simultaneously, the curing time is reduced from hours to minutes while ensuring complete curing of the refractory layer
Solution Approach 2:
The patent pre-heats the tundish and refractory layers before applying the dry refractory material. This preliminary heating action prepares the substrate by removing moisture and creating optimal conditions for rapid curing, thereby reducing the overall curing time required for the final refractory layer
2Ease of manufacture
If a uniform thickness refractory layer is applied throughout the tundish, then the manufacturing process is simplified, but material is wasted in areas where it is not needed
Solution Approach 1:
The patent applies dry refractory material selectively to specific zones within the tundish where slag accumulation is most problematic (e.g., upper portions, areas near slag lines). The refractory is applied to a thickness that varies by location - thicker where needed for slag resistance, thinner or not applied where not needed - optimizing material usage while maintaining protection where required
3Reliability
If multiple layers of refractory material are applied sequentially, then the slag resistance is improved, but the processing time and complexity increase
Solution Approach 1:
The patent combines multiple refractory application steps into a single operation by applying the dry refractory material directly over the existing castable layer in one continuous process. The simultaneous heating and curing process merges what would traditionally be separate application and curing operations, significantly improving productivity while maintaining the protective refractory layer
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 approach allows for quick and efficient formation of a thicker, slag-resistant refractory layer, reducing material usage and extending the life of the refractory lining by concentrating thickness in high-wear areas, thereby improving operational efficiency and reducing maintenance needs.
Implementation Method 1
A heating means extends through the upper wall of the mold for heating the interior chamber of the mold
Data Source
AI summary
A mold dimensioned to be positioned within a refractory-lined tundish. The mold has an upper wall and a side wall extending downwardly from the upper wall, the side wall having a shape generally conforming to the shape of the internal cavity of the tundish and having a lower end formed to rest on the refractory lining on the bottom wall of the refractory-lined tundish. The upper wall and side wall define an interior chamber. The side wall of the mold and the refractory lining on the sloping wall of the tundish form a gap therebetween. The gap extends around the mold, the mold being dimensioned such that the gap between the side wall of the mold and the refractory lining on the side wall of the tundish is wider at an upper portion of the internal cavity than at a lower portion of the cavity. A heating means extends through the upper wall of the mold for heating the interior chamber of the mold.