CN107110605B

CN107110605B - System and method for collecting and analyzing data relating to operating conditions of a top-submerged lancing injector reactor system

Info

Publication number: CN107110605B
Application number: CN201580070556.0A
Authority: CN
Inventors: R·W·玛祖塞韦奇
Original assignee: Outotec Finland Oy
Current assignee: Meizhuo Metal Co ltd
Priority date: 2014-12-24
Filing date: 2015-12-23
Publication date: 2020-03-27
Anticipated expiration: 2035-12-23
Also published as: PE20171301A1; EP3237823A1; AU2015370483B2; PL3237823T3; AU2015370483A1; KR20170096138A; CN107110605A; KR102034940B1; EA201791302A1; JP6503069B2; JP2018508731A; WO2016103196A1; EP3237823B1; ES2769200T3; EA033240B1

Abstract

A system is provided for collecting and analyzing data relating to operating conditions in a top-submerged lancing injector reactor system having a lance, the lower end of which is to be submerged in a molten bath during operation of the top-submerged lancing injector reactor system. The system comprises: (a) at least two sensors configured to sense an indicator of an operating condition and generate a sensed data signal, each sensor being a different sensor type and at least one sensor of the at least two sensors being a lance-based sensor; and (b) a central processing unit for receiving the plurality of sensed data signals and analyzing the sensed data signals in relation to at least two indicators of the operating condition to determine a current state of the operating condition.

Description

System and method for collecting and analyzing data relating to operating conditions of a top-submerged lancing injector reactor system

Background

Melt-bath smelting (Molten bath smelting) or other pyrometallurgical (pyrometallurgical) operations, which require interaction between a Molten bath (bath) and a source of oxygen-containing gas, utilize several different arrangements for supplying gas. Typically, these operations involve direct injection into molten matte (matte)/metal. This may be by means of bottom blowing tuyeres as in a bessel (Bessemer) type furnace or side blowing tuyeres as in a Peirce-Smith type converter. Alternatively, the injection of gas may be provided by a lance, either top-blown or submerged injection. Examples of top-blown lance injection are the KALDO and BOP steel works, where pure oxygen is blown from above the bath to produce steel from the molten iron. Another example of top-blown lance injection is the Mitsubishi copper process, in which lances cause bursts of oxygen-containing gas (e.g., oxygen-enriched air) to impinge upon and pass through the top surface of the molten bath to produce and convert, respectively, copper matte. In the case of submerged lance injection, the lower end of the lance is submerged such that injection occurs within the molten bath rather than from above the slag layer of the molten bath to provide top submerged injection (TSL) injection.

For top blowing and TSL injection, the lance is subjected to a strong prevailing bath temperature. Top blowing in the mitsubishi copper process uses a number of relatively small steel lances with an inner tube of about 50mm diameter and an outer tube of about 100mm diameter. The inner tube ends at about the level of the furnace ceiling, well above the reaction zone. The outer tube of the water cooled collar, which is rotatable to prevent its attachment at the top of the furnace, extends down into the gas space of the furnace to position its lower end about 500-800mm above the upper surface of the molten pool. Particulate feed entrained in air is blown through the inner tube, while oxygen-enriched air is blown through the annular space between the tubes. Despite the spacing of the lower end of the outer tube above the bath surface and any cooling of the lance by the gas passing through it, the outer tube burns back to about 400mm per day. Thus, the outer pipe is slowly lowered and when needed, a new part is attached to the top of the outer consumable pipe.

The lance used for TSL injection is much larger than the lance used for top blowing, such as the lance in the mitsubishi process described above. TSL lances typically have at least an inner tube and an outer tube, as described below, but may have at least one other tube concentric with the inner and outer tubes. Typical large TSL lances have an outer tube diameter of 200 to 500mm or more. Further, the lance is longer and extends downwardly through the top of the TSL reactor, which may be about 10 to 15 metres high, so that the lower end of the outer tube is immersed to a depth of about 300mm or more into the slag phase of the molten bath, but is protected by a coating of solidified slag formed and maintained on the outer surface of the outer tube by the cooling action of the injected gas stream passing therethrough. The inner tube may terminate at about the same level as the outer tube, or at a higher level up to about 1000mm above the lower end of the outer tube. Thus, it may be the case that only the lower end of the outer tube is submerged.

The inner tube of the TSL lance may be used to supply feed materials such as concentrate, flux and reductant which are injected into the slag layer of the molten bath, or it may be used for fuel. An oxygen-containing gas, such as air or oxygen-enriched air, is supplied through the annular space between the pipes. When submerged injection is initiated within the slag layer of the molten bath, oxygen-containing gas and fuel (such as fuel oil, clean coal or hydrocarbon gas) are supplied to the lance, and the resulting oxygen/fuel mixture is combusted to generate a flame burst that impinges into the slag. This causes the slag to tilt within the bath, resulting in significant bath movement. This molten bath movement, along with the injection of gas or other material through the lance, causes movement of the lance due to the induced forces. The range of motion experienced by the top-submerged lance has the potential to provide important information about the process operations taking place in the molten bath.

Since the contents of the top-submerged lancing injector reactor are not visible, it may be difficult for an operator to have any real knowledge of the operating conditions within the reactor. Data regarding the operation of the reactor is collected using a standard range of equipment, including equipment that typically resides in or on the reactor shell or liner, such as thermocouples, flow meters, and the like. Due to the very harsh environment within the reactor, any instrumentation used to monitor operating conditions is always costly and requires frequent maintenance and/or replacement.

Conventional methods of monitoring operating conditions using standard equipment often use data collected in an isolated and/or linear fashion. For example, the temperature of the slag bath may be measured using a thermocouple, and the temperature measurement used as an isolated reading to attempt to infer what is happening within the reactor. This approach ignores the inherent interactions between factors that affect and/or indicate various operating conditions and makes it difficult to provide a plant operator with an accurate diagnosis of the operating conditions within the reactor.

Discussion of the aspects of the invention included herein, including documents, acts, materials, devices, articles and the like, is intended to explain the context of the invention. This is not to be taken as an acknowledgement or suggestion that any of the material referred to was published, known or part of the common general knowledge in the patent field as at the priority date of the claims.

It is desirable to provide one or more sensors for monitoring operating conditions in the slag bath.

Disclosure of Invention

According to an aspect of the present invention there is provided a system for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system, the system having a lance, the lower end of which is to be submerged in a molten bath during operation of the top-submerged lancing injector reactor system, the system comprising:

(a) at least two sensors configured to sense an indicator of an operating condition and generate a sensed data signal, each sensor being a different sensor type and at least one of the two sensors being a lance-based sensor; and

(b) a central processing unit for receiving the plurality of sensed data signals and analyzing the sensed data signals in relation to at least two indicators of the operating condition to determine a current state of the operating condition.

The present invention may be implemented using various combinations of sensors including various low cost sensors. For example, temperature sensors, pressure sensors, motion sensors, position sensors, sound and/or image sensors may be employed. In the context of the present invention, it is necessary that at least two sensors are of different types, so that they can be used to sense different but possibly complementary indicators of operating conditions. Further, at least one of the sensors is a lance-based sensor. For example, if a first sensor is used to sense the movement of the lance and the sensor signal indicates that the lance is not moving, then it is helpful to collect data from a second sensor type, e.g., sensing the position of the lance inside the reactor to confirm the diagnosis. For example, if the position sensor indicates that the lance is not submerged in the molten bath, then the two independently detected signals may be combined and analyzed to provide an accurate diagnosis of the current operating conditions, depending on the data collected using a single sensor type, which is not possible.

In the example provided, both the lance motion sensor and the lance position sensor constitute lance-based sensors in that the lance motion sensor is mounted on the lance to sense movement of the lance, and the lance position sensor is configured to sense mechanical interaction of the lance with the top-submerged lancing injector reactor system. However, it should be understood that the status of the operating condition may be determined so long as one of the at least two sensors is a lance-based sensor.

The lance-based sensor may be configured to sense a mechanical interaction of the lance with the top-submerged lancing injector reactor system in the form of an indicator related to lance position, lance submergence, or lance wear. Further, the lance-based sensor may be configured to sense the mechanical interaction by sensing a direct measurement of the mechanical interaction.

In certain embodiments, the central processing unit compares the current state of the operating condition to an optimal operating condition to determine whether one or more process controls require adjustment to transition the current operating condition to the optimal operating condition.

Feedback regarding the current state of the operating conditions may be provided to an operator of the top-submerged lancing injector reactor system. That is, an operator may be provided with one or more instructions for manually adjusting process control to transition the current operating conditions to optimal operating conditions.

Alternatively, feedback regarding the current state of the operating condition may be provided directly to a process control unit associated with the submerged lancing injector reactor system. In this embodiment, the process control unit is provided with instructions for autonomously adjusting the process control to shift the current operating conditions to the optimal operating conditions. For example, if the combination of sensors determines that the slag condition in the molten bath is not desirable, i.e., too thick and viscous due to too low a temperature of the molten bath, then the instruction to the operator or process control unit may be to increase the temperature of the molten bath in an attempt to shift the current operating conditions to more flowing slag.

In a particular embodiment, at least three different types of sensors are provided to enable detection of various operating conditions.

The sensor may be selected from a variety of sensor types, including pressure, motion, sound, temperature, and image sensors. For example, the motion sensors may generally include orientation sensors, and more specifically include accelerometers, gyroscopes, magnetometers, inertial measurement units, and the like. Such lance-based sensors sense the orientation of the lance, for example, by detecting the magnitude and direction of movement of the lance, the acceleration of the lance in various directions, and/or the G-force (G-force) experienced by the lance. The position sensor may take the form of a position encoder that measures the position of the lance relative to the hearth and may or may not be mounted on the lance. Sound and image sensors (e.g., in the form of still or video cameras) may provide useful data about slag viscosity, such as sound due to generated melt-splash patterns. Similarly, there are certain characteristic sound frequencies that can be attributed to optimal operating conditions. For example, if no bubbling frequency is recorded, this is an indication that the lance tip is not submerged in the molten bath, which may be supported by data signals generated by one or more other types of sensors.

While some of the above-described sensor types (such as image and sound sensors) are only indicative of a particular operating condition, other sensor types can provide a direct measurement of the operating condition. Such sensor types include sensors for measuring bath temperature, lance movement, lance position or lance submergence. At least one of these sensor types is preferably included in a system for collecting data relating to operating conditions.

The operating condition indicated by the sensed signal may relate to one or more of: bath temperature, slag condition, lance position, lance submergence, or lance wear.

According to another aspect of the present invention, there is provided a method for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system having a lance, the lower end of which is to be submerged in a molten bath during operation of the top-submerged lancing injector reactor system, the method comprising the steps of:

(a) providing at least two sensors configured to sense an indicator of an operating condition during operation of the top-submerged lancing injector reactor system and generate a sensed data signal, each sensor being a different sensor type and at least one of the at least two sensors being a lance-based sensor;

(b) transmitting the sensed data signals generated by the at least two sensors to a central processing unit; and

(c) the sensed data signals associated with at least two indicators of the operating condition are analyzed to determine a current state of the operating condition.

The lance-based sensor may be mounted on the lance and/or configured to sense mechanical interaction of the lance with the top-submerged lancing injector reactor system. The lance-based sensor may also be configured to sense a mechanical interaction of the lance with the top-submerged lancing injector reactor system in the form of an indicator related to lance position, lance submergence, or lance wear. The mechanical interaction of the lance with the top-submerged lancing injector reactor system may sense an indicator related to lance position, lance submergence, or lance wear.

The method may further comprise the step of comparing the current state of the operating condition with an optimal operating condition; and determining whether one or more process controls require adjustment to transition the current operating conditions to the optimal operating conditions.

In another embodiment, the method further comprises the step of providing feedback to an operator of the top-submerged lancing injector reactor system regarding the current status of the operating condition.

Alternatively, the method further comprises the step of providing feedback regarding the current state of the operating condition to a process control unit associated with the submerged lancing injector reactor system.

In one form of the invention, the at least two sensors are selected from the following sensor types: pressure, motion, sound, temperature, and image.

Optionally, the step of providing at least two sensors in the top-submerged lancing injector reactor system comprises providing at least three sensors.

Preferably, at least one of the at least two sensors is configured to provide a direct measurement of at least one of the following indicators of the operating condition: bath temperature, lance movement, lance position, or lance submergence.

The operating condition indicated by the method may relate to one or more of: bath temperature, slag condition, lance position, lance submergence, or lance wear.

Drawings

The invention will now be described in more detail with reference to the accompanying drawings. It should be understood that the illustrated embodiments are examples only, and should not be taken as limiting the scope of the invention as defined in the following claims.

Fig. 1 is a partially cut-away schematic view of a molten pool smelting furnace including a top submerged lance according to the prior art.

FIG. 2 is a schematic diagram illustrating a system for collecting and processing data related to operating conditions in a top-submerged lancing injector reactor according to an embodiment of the present invention.

FIG. 3 is a table illustrating the interrelationship between various sensor types as indicators of various operating conditions, according to an embodiment of the present invention.

Fig. 4 is a flow diagram illustrating a method for collecting and processing data related to operating conditions in a top-submerged lancing injector reactor system according to an embodiment of the present invention.

Detailed Description

Referring initially to fig. 1, an exemplary top-submerged lancing injector reactor system 100 is shown. The reactor 102 has a cylindrical housing 104 closed at its top end by a top cover 106, with an off-take flow 108 projecting upwardly from the top cover 106 to an exhaust gas boiler/heat exchanger 110. In fig. 1, a portion of the shell 104 has been removed to enable viewing of the interior of the reactor 102, but the shell 104 is circumferentially continuous at all levels of its height except for the tap hole. The roof 106 has an inlet 112 through which a top submerged injection lance 114 extends downwardly so that the lower end portion of the lance 115 is submerged in a molten pool 116. The reactor 102 also has a feed port 118 opened through the top cover 106 to enable raw materials for the desired pyrometallurgical operation to be charged into the basin 116; and a burner port 120 for enabling insertion of a burner 122 if needed when heating the reactor. The lance 114 has connectors 124 that enable the lance 114 to be connected to separate sources of fuel/reductant and oxygen-containing gas so that these materials can pass down through the lance 114 and mix at the lower outlet of the lance to feed the combustion mixture, respectively. The combustion of the fuel and oxygen mixture creates a combustion zone in the molten pool 116 at the lower outlet end of the lance 115, as well as strong turbulence in the molten pool 116, which causes the raw materials charged through the port 118 to disperse in the molten pool to cause the desired pyrometallurgical reaction therein.

The top submerged lancing injector reactor system 100 shown in fig. 1 is typically operated by an operator who controls the position of the lance 114 within the reactor 102 by raising or lowering the lance relative to the molten bath by means of a lifting device 126 attached to the lance. The operator makes various manual observations of the position of the lance and the movement of the lance, which allows the operator to intuitively understand the range of motion of the lance indicating optimal operating conditions in the reactor and the range of movement of the lance indicating suboptimal operating conditions within the reactor over time.

Referring now to fig. 2, the system of the present invention provides a method for improved guidance of the operator as to how specific observations relate to operating conditions within the reactor and how the operator should respond appropriately to those operating conditions that are suboptimal. A system 200 for collecting, processing and analyzing data relating to operating conditions in a top-submerged lancing injector reactor system 100 is provided. As shown in fig. 1, a top submerged lancing (hereinafter also referred to as "TSL") injector reactor system 100 has a lance 114, the lower end 115 of which will be submerged in a molten pool 116 during operation of the TSL injector reactor system. Referring back to fig. 2, the system 200 includes at least two sensors 210, each of the at least two sensors being a different sensor type, and at least one of the at least two sensors being a lance-based sensor. Each sensor 210 is configured to sense an indicator of an operating condition and generate a sensed data signal. The central processing unit 220 receives the sensing data signal. The central processing unit 220 then processes and analyzes the sensed data signals to determine the current state of the operating condition.

Alternatively, as shown in FIG. 2, the central processing unit 220 is coupled directly to the process control unit 230. In this case, feedback regarding the current state of the operating condition is transmitted directly from the central processing unit 220 to the process control unit 230. The direct feedback may be converted into instructions for the process control unit 230 to adjust the process control of the reactor in an effort to adjust the current operating conditions to the optimal operating conditions.

Alternatively, in the case where the central processing unit 220 is not directly coupled to the process control unit 230, feedback regarding the current operating conditions may be provided to the operator along with recommendations for making adjustments to the process control of the reactor in an effort to improve the operating conditions. In this case, the necessary adjustment is effected manually by the operator in the usual manner.

As shown, the system employs at least two sensors, each sensor being a different sensor type. At least one of the sensors is a lance-based sensor that is either mounted on the lance, for example in the form of a lance motion sensor, or is configured to sense the mechanical interaction of the lance with the top-submerged lancing injector reactor system, for example in the form of a lance position sensor that is not necessarily mounted on the lance itself, but rather senses the position of the lance relative to the reactor. These sensors are selected from a wide variety of low cost sensors. Examples of suitable temperature sensors (which are also lance-based sensors) are described in international PCT application PCT/IB 2014/060638. Such sensors are capable of directly measuring the bath temperature which may be indicative of a number of operating conditions occurring within the reactor, including slag conditions, i.e. flowing or viscous.

For example, a pressure sensor is used to measure any restriction or blockage of fluid injected via the spray gun. The pressure sensor or transmitter (transmitter) may be mounted in a suitable location on any fluid delivery line or may be a lance-based sensor mounted near the discharge point of the lance (i.e. the lance tip). That is, the pressure in any line supplying oxygen, air or fuel to the lance may be measured at any particular point. A change in pressure reading at that particular point will generally indicate that a restriction or occlusion has occurred. A significant restriction or blockage occurs when the lance moves from above the molten bath to a submerged position due to the static head that occurs when the discharge point is below the slag surface. This means that differences in pressure head or back pressure readings taken at the same point in the fluid flow line may be an indicator of lance submergence and other potential blockages or restrictions that may occur during lance operation. When combined with readings from at least one other sensor (such as, for example, a lance position sensor, or a lance movement sensor that is also an indicator of whether the lance tip is submerged in the slag bath), it is easier to accurately determine whether the increase in back pressure is due to lance submergence or some other restriction in the fluid flow line.

Injecting oxygen-containing gas and fuel into the molten bath causes the slag to tilt in the molten bath. Slag or bath movement and forces induced by gases or other materials injected through the lance itself result in various involuntary movements of the lance. The magnitude and direction of movement and the force and/or acceleration of a lance at least partially submerged in the molten pool are reliable indicators of the operating conditions in the molten pool. These movements and forces are sensed by one or more motion sensors, which may take the form of orientation sensors, magnetometers, gyroscopes, accelerometers or inertial measurement units, as disclosed in the co-pending application entitled "A Sensing Device for determining an Operational Condition in a Mobile Box of a Top-Submerged Lance Injector Reactor System".

Other operating conditions that may be measured relative to the lance are lance position and lance submergence. Lance position is a hypothetical measure of lance tip position relative to the hearth top surface, and lance submergence is an actual measure of lance tip position relative to the molten pool surface.

The lance position may be measured by a position sensor attached to the lance lift mechanism (for raising and lowering the lance within the reactor) or to the lance guide or cart. Such a position sensor may be provided in the form of a position encoder. It should be noted that the actual position of the lance within the reactor can only be inferred from this measurement, since it is necessary to calibrate each new lance and infer the lance tip position relative to the roof of the furnace. Thus, if the length of the lance changes, for example due to wear of the lance tip caused by use, the actual position of the lance tip relative to the hearth will also change. Knowing the depth of the molten pool is often insufficient to provide a measure of lance submergence because of the need to know the lance position. Furthermore, the depth of the molten pool may vary due to the accumulation of material on the hearth or the like.

The measurement of lance submergence may be determined by calculation, for example using lance position measurements and manual bath height measurements. An inferred measurement of submergence may be discerned using a sound sensor, where a shift in measured sound frequency is observed between above the molten bath and the submerged operating position of the lance to allow the point at which the lance becomes submerged to be determined. From this point on, the lance can be lowered by a defined distance and therefore the degree of immersion is known. Similarly, as previously described, the measurement of back pressure may be used to determine the point at which the lance is submerged.

Measuring the sound produced by TSL operation may also be an effective measurement. Due to the low injection velocity of typical TSL lances, "bubble" frequencies of about 3Hz are considered a characteristic. Simply, this means that the injected fluid forms bubbles and breaks up at the discharge end of the lance approximately three times per second. These generate characteristic bubbling sounds that can be measured. In its simplest form, if no bubbling sound is detected at all, it can be concluded that the lance is not submerged in the molten bath. The nature and frequency of the sound will vary with slag conditions. Furthermore, the splash pattern generated within the reactor can be captured on a still image or a video image. If the volume and size of the normal splash, which indicates optimal operating conditions, are known, then the change in volume and size of the splash can be used as an indicator of a change in conditions. For example, without the spatter being visible, the lance is neither within nor close to the surface of the molten bath. When the lance tip is nearly submerged, the spatter will be very good. If the slag is very viscous, the splashed slag tends to form splatters in the form of slabs, strings, or streams. These changes in the form of splatter can be easily identified by image analysis.

The system and method of the present invention will be best illustrated by way of example, in view of the various operating conditions that may be inferred and/or verified using different sensor types.

For example, in a first simple example, in which a lance motion sensor is used to indicate whether the lance is moving in a normal or abnormal manner, if lance movement is not sensed, then the lance is likely to be unsubmerged and operating outside the slag bath. The diagnosis may be verified using lance position or lance submergence measurements. However, in this simple case, the gun operator will typically identify and correct the problem based solely on the lack of gun movement. In this case, both the lance motion sensor and the lance position sensor constitute lance-based sensors.

In a second, more complex example, data signals generated by three different types of sensors may be used to determine adverse operating conditions: a lance motion sensor, a lance position sensor, and a temperature sensor. In this case, the lance motion sensor measures excessive movement indicative of an abnormal operating condition. This data itself may indicate one of many problems related to process factors or problems with mechanical interactions within the reactor. Therefore, the following analysis using data collected from all three sensor types was employed to derive a comprehensive diagnosis:

1. the lance motion sensor detecting an abnormal movement condition indicating a higher degree of movement than normal movement;

2. the position index of the spray gun displays that the spray gun is in the correct position; and

3. the bath temperature indicates a low temperature condition.

In this case, both the lance motion sensor and the lance position sensor constitute lance-based sensors. The temperature sensor may be, but is not necessarily, a lance-based sensor. The suggested course of action would be to increase the energy input to the system, for example, by increasing the rate of fuel addition via the lance.

In the second example, it appears that the bath temperature indication may provide a solution alone. However, the third example uses the same three sensors in the case where the temperature of the molten pool is also low. In this example, the following criteria occur:

1. the bath temperature is indicated as low;

2. the lance is indicated as being in the correct position relative to the furnace; and

3. the lance motion sensor indicates that the lance is not moving.

In this case, the combined sensor information indicates that the lance tip has worn back to a point where the lance is not submerged in the molten bath but is in its upper position. In this example, the course of action would be to remove the lance from service to repair the lance tip, and the approach of adding more fuel would not be able to correct the problem and restore optimal operating conditions.

In a fourth example, sensors for acoustic measurements, lance position, lance backpressure, and bath temperature are utilized. The indices of these sensors show:

1. sound indicates abnormal operation;

2. the position of the spray gun is correct;

3. the bath temperature is in the correct range;

4. gun backpressure was abnormal, indicating a high reading.

In this example, at least the lance position sensor and the lance backpressure sensor constitute lance-based sensors. The diagnosis is that the slag chemistry is not in the correct range and needs to be adjusted by slag chemistry modification.

The above examples illustrate that analyzing data signals generated by at least two different types of sensors, wherein at least one of the two sensors is a lance-based sensor, is superior to relying on an operator to make an assessment of the signals from the various sensors. This integrated approach may provide consistency of operation and faster response to process or mechanical changes that affect operational efficiency.

Referring now to FIG. 3, some examples of possible interactions between various sensor types are shown. Depending on the application, the sensors may be grouped together. Preferably, the analysis of a minimum number of low cost sensors will be combined to enable low cost operation and more stable plant operation.

Referring now to fig. 4, there is shown a flow chart illustrating a method 400 for collecting and analyzing data relating to operating conditions in a top-submerged lancing injector reactor system having a lance whose lower end is to be submerged into a molten pool during operation of the top-submerged lancing injector reactor system. At 410, the method includes the step of providing at least two sensors in the top-submerged lancing injector reactor system, each sensor being a different sensor type, and at least one of the two sensors being a lance-based sensor, each sensor configured to sense at least one operating condition indicator during operation of the top-submerged lancing injector reactor system. At step 420, the method includes the step of transmitting the sensed data signals generated by the at least two sensors to a central processing unit. At step 430, the sensed data signals associated with the at least two operating condition indicators are analyzed to determine a current state of the operating condition.

The system of the present invention provides a lower cost top submerged lance injection reactor and more consistent operation thereof using relatively low cost sensors. Transmitting the sensed signals determining the various operating factors to a central processing unit for processing and analysis enables the sensed signals to be analyzed by an expert system module using proprietary algorithms to provide improved diagnostics that can be used to guide operator actions or directly instruct the plant control unit to make appropriate adjustments. This enables more consistent and stable plant operation and more efficient reactor operation between transfers.

While the invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate that many alternatives, modifications, and variations are possible in light of the foregoing description. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which may fall within the spirit and scope of the present invention as disclosed.

Claims

1. A system for collecting and analyzing data relating to operating conditions in a top-submerged lancing injector reactor system having a lance, the lower end of which is to be submerged in a molten bath during operation of the top-submerged lancing injector reactor system, the system comprising:

(a) at least two sensors configured to sense an indicator of an operating condition and generate a sensed data signal, each sensor being a different sensor type and at least one sensor of the at least two sensors being a lance-based sensor; and

(b) a central processing unit for receiving a plurality of sensed data signals and analyzing the sensed data signals in relation to at least two indicators of the operating condition to determine a current state of the operating condition,

wherein feedback regarding the current state of the operating condition is provided to a process control unit associated with the submerged lancing injector reactor system,

wherein the central processing unit communicates directly with the process control unit to coordinate one or more process controls,

wherein the at least two sensors are selected from at least two of the following sensor types: pressure, motion, sound, temperature, and image,

wherein the central processing unit compares the current state of the operating condition with the optimal operating condition to determine whether one or more process controls require adjustment to transition the current operating condition to the optimal operating condition, and

wherein the operating condition indicated by the system relates to one or more of: bath temperature, slag condition.

2. A system for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system according to claim 1, wherein the lance-based sensor is mounted on the lance and/or is configured to sense a mechanical interaction of the lance with the top-submerged lancing injector reactor system.

3. A system for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system according to claim 2, wherein the lance-based sensor is configured to sense a mechanical interaction of the lance with the top-submerged lancing injector reactor system in the form of an indicator relating to lance position, lance submergence or lance wear.

4. A system for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system according to claim 3, wherein the lance-based sensor is configured to sense a mechanical interaction of the lance with the top-submerged lancing injector reactor system by sensing a direct measurement of the mechanical interaction.

5. A system for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system according to any one of claims 1 to 4, wherein feedback regarding the current status of the operating condition is provided to an operator of the top-submerged lancing injector reactor system.

6. A system for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system according to any one of claims 1 to 4, wherein the system comprises at least three sensors, each sensor configured to sense an operating condition indicator and generate a sensed data signal.

7. A system for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system according to any one of claims 1 to 4, wherein at least one of the at least two sensors is configured to provide a direct measurement of at least one indicator of an operating condition: bath temperature, lance movement, lance position, or lance submergence.

8. A method for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system having a lance, the lower end of which is to be submerged in a molten bath during operation of the top-submerged lancing injector reactor system, the method comprising the steps of:

(a) providing at least two sensors configured to sense an indicator of an operating condition during operation of the top-submerged lancing injector reactor system and generate a sensed data signal, each sensor being a different sensor type and at least one sensor of the at least two sensors being a lance-based sensor;

(c) analyzing the sensed data signals related to at least two indicators of the operating condition to determine a current state of the operating condition,

the method further includes providing feedback regarding a current state of the operating condition to a process control unit associated with the submerged lancing injector reactor system,

the method further comprises comparing the current state of the operating condition with an optimal operating condition; and determining whether one or more process controls need to be adjusted to shift the current operating conditions to the optimal operating conditions, an

Wherein the operating condition indicated by the method relates to one or more of: bath temperature, slag condition.

9. A method for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system according to claim 8, wherein the lance-based sensor is mounted on the lance and/or is configured to sense a mechanical interaction of the lance with the top-submerged lancing injector reactor system.

10. A method for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system according to claim 8 or 9, wherein the lance-based sensor is configured to sense a mechanical interaction of the lance with the top-submerged lancing injector reactor system in the form of an indicator relating to lance position, lance submergence or lance wear.

11. A method for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system according to any one of claims 8 to 9, wherein the lance-based sensor is configured to sense a mechanical interaction of the lance with the top-submerged lancing injector reactor system in the form of an indicator relating to lance position, lance submergence or lance wear.

12. A method for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system according to any one of claims 8 to 9, further comprising the step of providing feedback to an operator of the top-submerged lancing injector reactor system regarding a current status of the operating condition.

13. A method for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system according to any one of claims 8 to 9, wherein the step of providing at least two sensors in the top-submerged lancing injector reactor system involves providing at least three sensors.

14. A method for collecting and analysing data relating to an operating condition in a top-submerged lancing injector reactor system according to any one of claims 8 to 9, wherein at least one sensor of the at least two sensors is configured to provide a direct measurement of at least one of the following indicators of the operating condition: bath temperature, lance movement, lance position, or lance submergence.