JP2023014120A - stave protection system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a novel stave protection system for a metallurgical furnace.

SOLUTION: A stave protection system for a metallurgical furnace comprises: a stave having an X direction and a Y direction and provided with a front face provided with a row of grooves stretching in the X direction; and inserts slidably stored in the grooves, and mutually separated along the grooves. The center of each insert is deviated from the center of the insert stored in the adjacent groove in each of the X direction and the Y direction, and each insert projects from the front face of the stave, and has a flow guide face tilted with respect to each of the X direction and the Y direction in an X-Y plane. Upon the use, owing to the deviation of each insert in each of the X direction and the Y direction and the tilted flow guide face, a furnace load substance flows in a direction having components in each of the X direction and the Y direction under gravity, thereby, the load substance is dispersed between the inserts over the whole front face of the stave, and/or the load substance is captured between the inserts.

SELECTED DRAWING: Figure 6b

COPYRIGHT: (C)2023,JPO&INPIT

Description

The present invention relates to stave protection systems for metallurgical furnaces, such as blast furnaces.

A conventional blast furnace comprises several parts and components including a furnace chest, a furnace belly, a bosh section, a tuyere section, a hearth section, and a taphole. The inner shell of a blast furnace is sometimes protected by water-cooled cold plates called staves, which protect the shell from overheating during the reduction processes that occur within the furnace. Modern staves are generally constructed of copper or copper alloys. However, other materials may be used, for example steel or cast iron.

The stave may be subject to wear from the solid feedstock as it is charged into the furnace and descends through the furnace. In some situations, the wear has been so severe that it has become necessary to replace the staves before the completion of their planned useful life. This is costly due to furnace downtime. Therefore, it is important to design staves to resist wear so as to prolong their useful life.

It has been found that stave wear is reduced by forming a freeze-adhered layer on the front face of the stave during operation. For this purpose, the stave has a machined front face, or hot face, with ribs and grooves that retain the deposits on the stave. A portion of a typical copper stave of this type is shown in FIG.

An improvement on this concept is the addition of a front protective material or cladding, which is harder than the copper base material, but still allows freezing on the surface to form a protective adhesion layer. . This has been accomplished using a copper stave and a combination of silicon carbide and graphite bricks as shown in FIG. 2 which shows a cross section thereof.

US Pat. No. 5,300,000 describes a stave having a front face with ribs and grooves forming a fastening means for bonding a refractory brick lining, refractory gunite, or process-generated deposition layer to a surface. A metal insert is provided in the groove as shown schematically in FIG. Metal inserts cover the sides of the ribs to protect the ribs from corrosion. However, a potential problem with this solution is that the metal insert may be prone to distortion and/or buckling, and the use of a material that is less conductive than the stave body material (when it is copper). may reduce the thermal performance of the stave and affect freezing of the protective adhesion layer.

Referring now to Figure 4, it is proposed to place a plurality of protruding rectangular blocks in each groove in the face of the stave and to space the blocks from each other along the length of the groove. The block may comprise silicon carbide or some other hard material, which provides a protective cladding on the face of the stave. The blocks are separated from each other by shorter spacer inserts. The insert may protect the faces of the staves in the area between each block. As shown in FIG. 4, each block is preferably alternated between each groove to form a checkerboard pattern on the face of the stave.

Therefore, existing solutions for reducing stave wear rates are:
i) installing a refractory/ceramic wear lining in or in front of the stave;
ii) placing a ledge on the front face of the stave to promote thicker deposits; and iii) placing a cladding within the machined shape on the front face.

Although these solutions have provided some improvements, there is still a need for new techniques that can reduce stave wear rates, extend service life, and reduce furnace outage times.

US Pat. No. 6,300,000 relates to a cooling element for furnace linings.

WO 2009/147192 pamphlet German Utility Model No. 7331936

According to one aspect of the invention, a stave protection system for a metallurgical furnace, the stave comprising a front face having an X direction and a Y direction perpendicular to the X direction to define an XY plane, comprising: a stave whose front surface comprises an array of grooves extending in the X direction and an insert slidably received by the groove, the inserts so received by the respective grooves being spaced apart from each other along the groove; the center of the insert received by one of the grooves is offset in each of the X and Y directions from the center of the insert received by the adjacent groove, each of the inserts projecting from the front face of the stave, and XY inserts with flow guide surfaces inclined with respect to each of the X and Y directions in the plane, whereby in use the offset and inclined flow guide surfaces of each insert in each of the X and Y directions allow the furnace to The flow of the load material flows under gravity in a direction having components in each of the X and Y directions, thereby distributing the load material between the inserts across the front surface of the stave and/or distributing the load material between each insert. A stave protection system is provided that captures the

As described in more detail herein, the insert constitutes a cladding for the front face (or hot face) of the stave, thereby providing a protective layer of load material when the stave is used in a furnace. is formed on the anterior surface. By offsetting each insert and providing slanted flow guide surfaces, the load material is advantageously distributed simultaneously in the X and Y directions over the face of the stave.

Depending on the configuration and placement of the inserts (eg, the offset and shape of each insert), the load material is trapped by or between the inserts as it flows under gravity. Capturing of the load material may occur as the load material passes over the inclined flow guide surfaces in each of the X and Y directions.

The load material may be first distributed across the front face of the stave as described above and then captured by or between the inserts. Thus, in use, the offset and slanted flow guide surfaces of each insert in each of the X and Y directions cause the flow of furnace load material to flow under gravity in a direction having a component in each of the X and Y directions, which The load material is distributed between each insert across the front face of the stave and trapped between each insert.

The load material may be trapped by or between the inserts without first being distributed across the front surface of the stave. For example, the load substance may be trapped in localized regions of the front surface without first being diffused over all or even most of the front surface. Thus, in use, the offset and slanted flow guide surfaces of each insert in each of the X and Y directions cause the flow of furnace load material to flow under gravity in a direction having a component in each of the X and Y directions, which traps the load material between each insert at the front face of the stave.

Thus, the inserts either serve to distribute the load material across the front surface of the stave and then trap the load material between each insert, or simply distribute the load material between each insert without prior distribution of the load material across the front surface. act as a trap. Whether the load material tends to be distributed across the front surface may depend on flow conditions including, for example, the volume and weight of the load material and the flow rate, temperature, and viscosity of the load material.

Additionally, the load material can directly enter the space between each insert from a flow direction substantially perpendicular to the XY plane. Such load material can be captured by or between the inserts without necessarily first passing over the inclined flow guide surfaces in each of the X and Y directions.

As used herein, "loading materials" are defined as (i) iron-bearing materials in the blast furnace, such as iron ore or iron ore pallets, and (ii) blast furnace slag, i.e. iron ore or iron pellets, coke and fluxes (e.g. , limestone or dolomite) are melted together in a blast furnace and then solidified.

Misalignment in the X direction is such that an imaginary line extending in the Y direction intersects the flow guiding surface of an insert received by one of the grooves and the flow guiding surface of an insert received by an adjacent groove. may

Misalignment in the Y direction is such that an imaginary line extending in the X direction intersects the flow guiding surface of an insert received by one of the grooves and the flow guiding surface of an insert received by an adjacent groove. may

Misalignment in the X direction is such that an imaginary line extending in the Y direction intersects the flow guiding surface of an insert received by one of the grooves and the flow guiding surface of an insert received by an adjacent groove. The offset in the Y direction is such that an imaginary line extending in the X direction intersects the flow guiding surface of an insert received by one of the grooves and the flow guiding surface of an insert received by an adjacent groove. It may be nazure.

The offset in the X direction is D, the distance in the X direction between the center of each insert received by one of the grooves, and the distance between the center of each insert received by an adjacent groove and the center of each insert received by one of the grooves. The offset may be such that the distance in the X direction from the center of the received insert is D/2.

Each of the flow guide surfaces may be perpendicular to the front face of the stave.

Each insert may comprise a protrusion containing a flow guiding surface and a mounting portion received by a respective groove. The insert may have a unitary construction such that the projection and mounting portion are integrated. Alternatively, the insert may have a non-unitary construction such that the projection and mounting portion are separate elements.

The protrusion may be polyhedral and the sides of the protrusion may be provided with flow guiding surfaces. The protrusion may be hexagonal and each of four of the six sides of the protrusion may be provided with a respective slanted flow guiding surface. Each of the other two sides of the hexagonal protrusion may extend in the Y direction. Alternatively, each of the other two sides of the hexagonal protrusion may extend in the X direction.

The protrusion may comprise an indentation.

The inserts received by each groove may be separated from each other along the groove by spacers slidably received in the groove. At least one of the spacers may be an integral part of at least one of the inserts. At least one of the spacers may be a separate element.

A spacer may be configured to cover the surface of each groove between each insert. Alternatively, the spacers may be configured to expose respective groove surfaces between each insert.

The stave may comprise a metallic material. Metal materials may include copper, copper alloys, steel, or cast iron.

At least one of the inserts may comprise a metallic material. Metal materials may include copper, copper alloys, steel, or cast iron. At least one of the inserts may comprise an abrasion resistant refractory material. The wear resistant refractory material may include silicon carbide or alumina.

At least one of the spacers may comprise a metallic material. Metal materials may include copper, copper alloys, steel, or cast iron. At least one of the spacers may comprise an abrasion resistant refractory material. The wear resistant refractory material may include silicon carbide or alumina.

Embodiments will now be described, by way of example, with reference to the accompanying figures.

1 shows a portion of a conventional stave for furnaces; FIG. 1 shows a conventional stave containing silicon carbide and graphite bricks; FIG. 1 shows a portion of a conventional stave with metal inserts; FIG. FIG. 1 shows a portion of a conventional stave with a metal insert and a protruding rectangular block; FIG. 10 shows an insert and spacer according to an implementation of the invention; FIG. 10 shows an insert and spacer according to an implementation of the invention; FIG. 3 shows a portion of a stave used in one embodiment of the invention; 6b shows a plurality of inserts and a plurality of spacers installed on the stave of FIG. 6a according to one embodiment of the present invention; FIG. 6b shows a plurality of inserts and a plurality of spacers installed on the stave of FIG. 6a according to one embodiment of the present invention; FIG. FIG. 10 illustrates flow channels formed between exemplary inserts; FIG. 10 illustrates placement of inserts in a stave according to another embodiment of the invention;

As can be seen with reference to FIG. 5a, the insert 100 comprises a protrusion 102 and a mounting portion 104. As shown in FIG. In this exemplary embodiment, insert 100 has a unitary construction, and thus each of projection 102 and mounting portion 104 are part of unitary insert 100 . In this embodiment, insert 100 comprises silicon carbide. Alternatively, insert 100 may comprise alumina, copper, copper alloys, steel, cast iron, or other suitable ceramics, metals, or metal alloys.

Protrusion 102 comprises a front surface 102a and a rear surface 102b connected together by a peripheral outer edge having six surfaces 102c1-102c6 forming a regular hexagon. In other words, protrusion 102 is a hexagonal prism. Vertices 102ci-102vi are formed at the intersections of faces 102c1-102c6 (only 102ci is shown in the figure).

A circular recess 102d extends from the front surface 102a into the body of the projection 102 and includes a floor 102d1 (not shown) and a peripheral wall 102d2. Circular indentation 102 d thus forms a blind hole or bore in the body of protrusion 102 . The bore has a central axis C, which coincides with the geometric center of insert 100 .

Mounting portion 104 extends rearward of projecting portion 102 . More specifically, each of the side surfaces 104a, 104b of the mounting portion 104 extends rearwardly from each of the opposing surfaces 102c2, 102c5 of the peripheral outer edge of the protrusion 102. As shown in FIG. The rear ends of the sides 104a, 104b are connected to each other by a rear surface 104c of the mounting portion 104 which lies parallel to the front surface 102a and rear surface 102b of the projection 102. As shown in FIG.

The top surface 104d of the mounting portion 104 extends laterally between the top edges of the side surfaces 104a, 104b and forward to the back surface 102b of the projection 102. As shown in FIG. Similarly, the lower surface 104e of the mounting portion 104 extends laterally between the lower edges of the side surfaces 104a, 104b and forward to the rear surface 102b of the projection 102. As shown in FIG.

Upper surface 104d and lower surface 104e of mounting portion 104 are slanted with respect to central axis C, thereby forming a tapered taper from rear surface 104c of mounting portion 104 to rear surface 102b of protrusion 102 . In other words, sloping upper surface 104d and lower surface 104e provides mounting portion 104 with a wedge-shaped cross-section, the thickest portion of the wedge being located at rear surface 104c of mounting portion 104, and the thinnest portion of the wedge being located at protruding portion 102. located on the rear surface 102b of the .

In another embodiment, protrusion 102 and mounting portion 104 are separate elements that can be permanently or removably attached to each other to form insert 100 . In such embodiments, each of protrusion 102 and mounting portion 104 may comprise silicon carbide, alumina, copper, copper alloys, steel, cast iron, or other suitable ceramic, metal, or metal alloy.

Referring now to Figure 5b, the spacer 200 comprises a rectangular front surface 200a and rear surface 200b connected by four sides 200c-200f. In this embodiment, spacer 200 comprises two longer sides 200c, 200d and two shorter sides 200e, 200f. Alternatively, the front surface 200a and back surface 200b may be rectangular, whereby the spacer 200 comprises four sides of equal length.

Each of the longer sides 200c, 200d is sloped so that the spacer 200 has a wedge shape when viewed in cross-section, with the thickest portion of the wedge being located on the back surface 200b and the thinnest portion of the wedge being Located on the front surface 200b.

In this embodiment, spacer 200 comprises a copper alloy. Alternatively, spacer 200 may comprise silicon carbide, alumina, copper, copper alloys, steel, cast iron, or other suitable ceramics, metals, or metal alloys.

Referring now to Figure 6a, a rectangular cold plate or stave 300 comprises a front (or hot face) 302, a back 304, and edges 306a-306d (bottom edge 306d shown in Figure 6a). are not shown). The stave 300 is intended to be one of a number of similar staves used in blast furnaces.

In this exemplary embodiment, the stave 300 has a width (in the X direction in FIG. 6a) of approximately 1.0 m, a height (in the Y direction in FIG. 6a) of approximately 1.5 m, and a height (in the Y direction of FIG. 6a). in the Z direction) is about 120 mm. It will be appreciated that the X, Y, Z designations of width, height and depth, respectively, are for convenience of reference and are not limitations on the claimed invention.

The stave 300 has a water cooling passage 310 inside. The stave 300 body is otherwise generally solid.

In this embodiment, stave 300 is constructed from a copper alloy. Alternative materials include, but are not limited to, copper, steel, and cast iron.

The front portion of stave 300 comprises a plurality of similar grooves 312 aligned in rows and separated from each other by projecting ribs 314 . In this exemplary embodiment, there are 12 grooves 312 and 13 ribs 314 (only some grooves 312 and ribs 314 are visible in FIG. 6a, and FIG. 6a shows only a portion of stave 300). be. Each groove 310 extends across the width of stave 300 and thereby has an open end at each of side edges 306 a , 306 c of stave 300 . Each of the grooves 310 has a long axis L (in the X direction in FIG. 6a) extending between each end of the groove.

In this embodiment, grooves 312 are formed by machining. Alternatively, grooves 312 may be formed by casting.

Each groove 312 includes a flat base or floor 312a. Each groove 312 further comprises a pair of mutually opposed walls 312b. Each opposing wall 312 b is the surface of one of two adjacent ribs 314 that define the groove 312 . Each of ribs 314 includes a planar surface 314a. Flat surface 314 a is parallel to floor 312 a of groove 312 . Thus, the front surface 302 of the stave 300 may be viewed as comprising two portions, a frontmost portion comprising the flat surface 314a of the protruding rib 314 and a recess comprising the flat floor 312a of the groove 312. .

Each of the two opposing walls 312b of each of the grooves 312 is slanted such that a tapered taper of the groove 312 from the floor 312a of the groove 312 to the flat surface 314a of each of the ribs 314 defining the groove 312 is formed. provided for each. Thus, each of the grooves 312 has a wedge-shaped cross-section (when viewed from the side edges 306a, 306c of the stave 300) with the thickest portion of the wedge located at the floor 312a of the groove 312 and the wedge's thickest portion. The thinned portion is located on the flat side 314a of the rib 314. As shown in FIG. The angles of inclination of the walls 312b facing each other are complementary to the inclined upper and lower surfaces 104d and 104e of the mounting portion 104 of the insert 100 and to the longer inclined side surfaces 200c and 200d of the spacer 200. is set

In addition, the depth of each groove 312 (i.e., the distance between the surface 314a of the two adjacent ribs 314 defining the groove 312 and the floor 312a of the groove 312) is determined by the thickness of the spacer 200 (i.e., the spacer 200) and the depth of the mounting portion 104 of the insert 100 (i.e., the distance between the rear surface 104c of the mounting portion of the insert 100 and the rear surface 102b of the protrusion 102). equal.

Referring now also to FIG. 6b, the insert 100 and spacer 200 described hereinabove are placed in the groove 312 of the stave 300, thereby providing the stave 300 with a protective cladding. When stave 300, insert 100, and spacer 200 are combined, they form a stave protection system.

The placement of insert 100 and spacer 200 in groove 312 will now be described with particular reference to Figures 6b and 6c. For the sake of brevity, the operation is shown with respect to only one pair of stave grooves 312a, 312b, but it is understood that the principles of insert 100 and spacer 200 installation are the same for other pairs of grooves 312. sea bream.

The staves 300 are most conveniently initially placed in an upright vertical position for installation of the inserts 100 and spacers 200 . That is, the front surface 302 lies in a vertical plane. It will be appreciated that in this position the longitudinal axis L of each of the grooves 312 extends horizontally, thereby being parallel to the floor and vertically perpendicular.

A first spacer 200 is aligned with the first exemplary groove 312 i and extends to the left side edge 306 a of the stave 300 . The orientation of the first spacer 200 is such that the longer sides 200c, 200d of the spacer 200 lie parallel to the long axis L of the first groove 312i, the front surface 200a of the spacer 200 faces forward, and the rear surface 200b of the spacer 200 faces forward. It is oriented so as to face the rear of the stave 300 .

The first spacer 200 is then moved to the right and slidably inserted into the open left end of the first groove 312i so that the rear surface 200b of the first spacer 200 is aligned with the first groove 312i. and the longer sides 200c, 200d of the first spacer 200 contact the respective opposing walls 312b of the first groove 312i. Accordingly, the first spacer 200 is slidably received by the first groove 312i. The dimensions of the first spacer 200 and the first groove 312i are such that the first spacer 200 fits snugly in the first groove 312i, but is sufficiently long along the first groove 312i under force applied by the operator. It will be appreciated that the dimensions are such that they can slide freely.

The first spacer 200 is slid further to the right along the first groove 312i in the first groove 312i. The lateral travel of the first spacer 200 across the stave 300 is guided by the floor 312a and opposing walls 312b of the first groove 312i. The first spacer 200 is stopped at the right end of the first groove 312i so that the right shorter side 200f of the first spacer 200 is aligned with the right side edge 306c (FIGS. 6b and 6b) of the stave 300. 6c).

In this position, the back surface 200b of the first spacer 200 abuts the floor 312a of the first groove 312i and the longer sides 200c, 200d of the first spacer 200 face each other of the first groove 312i. abut one of the walls 312b. In addition, the front surface 200a of the first spacer 200 forms the same plane as the planar surface 314a of the adjacent rib 314. As shown in FIG.

Due to the reverse taper of the wedge-shaped longer sides 200c, 200d of the first spacer 200 and the opposing walls 312b of the first groove 312i, the first spacer 200 falls off the front surface 302 of the stave 300. or prevented from being pulled out. That is, the reverse taper forms a strong "dovetail" joint that resists displacement of the first spacer 200 forward and away from the front surface 102 (ie, the Z direction in FIG. 6b). Accordingly, first spacer 200 is securely held or attached to front surface 302 of stave 300 .

Next, the first insert 100 is placed alongside the first exemplary groove 312i to the left side edge 306a of the stave 300. As shown in FIG. The orientation of the first insert 100 is such that the upper surface 104d and the lower surface 104e of the mounting portion 104 are parallel to the major axis L of the first groove 312i, the front surface 102a of the protrusion 102 faces forward, and the rear surface of the mounting portion 104 faces forward. 104c is oriented toward the rear of stave 300. FIG.

The first insert 100 is then moved to the right to slidably insert the mounting portion 104 into the open left end of the first groove 312i, whereby the rear surface 104c of the mounting portion 104 is aligned with the first groove 312i. Contacting the floor 312a of the groove 312i, the upper surface 104d and the lower surface 104e of the mounting portion 104 contact respective opposing walls 312b of the first groove 312i. Accordingly, the first insert 100 is slidably received by the first groove 312i. The dimensions of the mounting portion 104 and the first groove 312i of the first insert 100 are such that the mounting portion 104 fits snugly in the first groove 312i but does not follow the first groove 312i under force applied by the operator. It will be appreciated that the dimensions are such that they are sufficiently free to slide on.

The first insert 100 is slid further to the right along the first groove 312i within the first groove 312i. The lateral travel of the first insert 100 over the stave 300 is guided by the floor 312a and the opposing walls 312b of the first groove 312i. The first insert 100 is stopped at the left end of the first spacer 200 so that the right side 104 a of the mounting portion 104 contacts the left shorter side 200 e of the first spacer 200 .

In this position, the back surface 104c of the mounting portion 104 abuts the floor 312a of the first groove 312i, and the top surface 104d and bottom surface 104e of the mounting portion 104 are each aligned with the opposing walls 312b of the first groove 312i. abut one of them. Furthermore, the protrusion 102 of the first insert 100 protrudes (in the Z direction in FIG. 6b) from the planar surface 314a of the adjacent rib 314. As shown in FIG.

Due to the reverse taper of the wedge-shaped upper and lower surfaces 104d and 104e of the mounting portion 104 and the opposing walls 312b of the first groove 312i, the first insert 100 falls or is pulled out of the front surface 302 of the stave 300. is prevented. That is, the reverse taper forms a strong "dovetail" joint that resists displacement of the first insert 100 forward and away from the front surface 102 (ie, the Z direction in FIG. 6b). Accordingly, first insert 100 is securely held or attached to front surface 302 of stave 300 .

Next, a second spacer 200 is provided which is generally similar to the first spacer 200 described herein above. However, the length of the second spacer 200 is shorter than the length of the first spacer 200 . That is, the first spacer 200 is a full length spacer and the second spacer is a short spacer. The combination of full-length spacers and short spacers creates a shift between the geometric centers of the insert 100 of the first and second exemplary grooves 312a, 312b, as further described below.

A second spacer 200 is provided alongside the first exemplary groove 312i to the left side edge 306a of the stave 300 in the same orientation as described for the first spacer 200 above. A second spacer 200 is installed in the same manner as the first spacer 200 . However, the second spacer 200 is slid to the right along the first groove 312i so that the right shorter side 200f of the second spacer 200 contacts the left side 104b of the mounting portion 104 of the first insert 100. so as to stop. Accordingly, the second spacer 200 is securely held or attached to the front surface 302 of the stave 300 in the same manner as the first spacer 200 .

Next, a second insert 100 similar to the first insert 100 described herein above is provided. The second insert 100 is aligned with the first groove 312i up to the left side edge 306a of the stave 300 in the same orientation as described hereinabove with respect to the first insert 100 . A second insert 100 is installed in the same manner as the first insert 100 . However, the second insert 100 is slid to the right along the first groove 312i so that the right side 104a of the mounting portion 104 of the second insert 100 contacts the left shorter side 200e of the second spacer 200. so as to stop. Accordingly, the second insert 100 is securely held or attached to the front surface 302 of the stave 300 in the same manner as the first insert 100 .

Further, the short spacers 200 and inserts 100 are alternately installed until the desired number of inserts 100 are provided in the first grooves 312i. In this embodiment, four inserts 100 are secured in the first grooves 312i.

The leftmost spacer 200 that fits last into the first groove 312i is a full length spacer. Further, the right shorter side 200 f of the leftmost spacer 200 contacts the left side 104 b of the mounting portion 104 of the leftmost insert 100 while the left shorter side 200 e of the leftmost spacer 200 contacts the stave 300 . is coplanar with the left side edge 306a of the .

Spacer 200 and insert 100 are then placed in second groove 312ii. A second groove 312ii is located immediately adjacent to the first groove 312i. That is, the first and second exemplary grooves 312i, 312ii share a common rib 314 separating the two grooves 312i, 312ii.

A first spacer 200 , which is a short spacer of the type previously described herein, is provided alongside the second exemplary groove 312 ii to the left side edge 306 a of the stave 300 . A first spacer 200 is placed in the second groove 312ii as described hereinabove with respect to the first groove 312i.

Next, a first insert 100 similar to the insert 100 fitted in the first groove 312i is arranged in the second groove 312ii and provided up to the left side edge 306a of the stave 300. The first insert 100 is installed in the second groove 312ii as described hereinabove with respect to the first groove 312i.

Further, the short spacers 200 and inserts 100 are alternately installed until the desired number of inserts 100 are provided in the second grooves 312ii. Since the second grooves 312ii are not fitted with full-length spacers 200, the number of inserts 100 in the second grooves 312ii is less than the number of inserts 10 in the first grooves 312i.
1 less than the number of 0s. Thus, in this embodiment three inserts 100 are secured in the second grooves 312ii.

It will be appreciated that in this exemplary embodiment, stave 300 includes a total of twelve grooves 312, and pairs of grooves 312 are attached to spacer 200 and insert 100 as described hereinabove. .

In the exemplary embodiment described above, spacer 200 and insert 100 were inserted at left edge 306a of stave 300 and slid to the right; It will be appreciated that it could equally well be inserted at , and slid to the left.

After installation, spacer 200 and insert 100 are prevented from sliding laterally out of groove 312 by end caps (not shown) attached to the ends of groove 312 at edges 306a, 306c of stave 300. may Alternatively, at least spacers 200 proximate edges 306a, 306c of stave 300 are attached to stave 300, for example, by screws engaging threaded holes provided in the body of stave 300, or by welding to stave 300. It may be fixed at 300. Any of spacers 200 and inserts 100 or all spacers 200 and inserts 100 may be attached to stave 300 by such means.

The protrusion 102 of the insert 100 secured in the groove 312 will now be described in more detail with particular reference to Figure 6c.

Recall that the projection 102 of each insert 100 has a peripheral outer edge with six faces 102c1-102c6 forming a regular hexagon, with vertices 102ci-102vi formed at the intersections of the faces 102c1-102c6. In this exemplary embodiment, the six faces 102c1-102c6 lie perpendicular to the front surface 302 of the stave 300 (the Z direction in FIG. 6c). Six faces 102c1-102c6 form flow guide surfaces as further described herein below.

In this exemplary embodiment, four of the six faces (or flow guide faces) 102c1-102c6 of each of the installed inserts 100, 102c1, 102c3, 102c4, 102c6, respectively (X direction in FIG. 6c ) and inclined with respect to both the longitudinal axis L of the groove 312 and the direction perpendicular to the longitudinal axis L of the groove 312 (the Y direction in FIG. 6c). In other words, each of the four faces 102 c 1 , 102 c 3 , 102 c 4 , 102 c 6 lies at a non-zero angle from each of the long axis L of groove 312 and in a direction perpendicular to long axis L of groove 312 . In other words, the four faces 102c1, 102c3, 102c4, 102c6 are each located at an angle between the direction of the long axis L of the groove 312 and the direction perpendicular to the long axis L of the groove 312.

Furthermore, in this embodiment, the other two faces 102c2, 102c5 of the protrusion 102 extend in a direction perpendicular to the long axis L of the groove 312 (the Y direction in FIG. 6c). Accordingly, the front surface 102a of the protrusion 102 lies between the other two surfaces 102c2, 102c5 in the direction of the long axis L of the groove 312 (X direction in Figure 6c) and in a direction perpendicular to the long axis L of the groove 312 (Figure 6c). It also extends between the vertices 102ci and 102civ facing each other in the Y direction).

In an alternative embodiment, the other two faces 102c2, 102c5 of the projection 102 extend in the direction of the long axis L of the groove 312 (X direction in Figure 6c). Thus, in this alternative embodiment, the front surface 102a of the protrusion 102 is between the other two surfaces 102c2, 102c5 in a direction perpendicular to the long axis L of the groove 312 (the Y direction in FIG. 6c) and the long axis of the groove 312. It also extends between opposite vertices in the direction of L (the X direction in FIG. 6c).

As described herein above, the insert 100 of the first groove 312i and the insert of the second groove 312ii are offset from each other. Staggering or "staggering" the inserts 100 will now be described in more detail with continued reference to Figure 6c.

In this exemplary embodiment, the distance (in the X direction in FIG. 6c) between the geometric centers of adjacent or immediately adjacent inserts 100 fixed in one of the grooves 312 is D; On the other hand, between the geometric center of the insert 100 fixed in the adjacent groove 312 or the immediately adjacent groove 312 and the geometric center of the insert fixed in one of the grooves 312 (X direction) is one-half the distance D.

A first line L1 extends in the direction of the long axis L of the groove 312 (X direction in FIG. 6c), and a second line L2 extends in a direction perpendicular to the long axis L of the groove 312 (Y direction in FIG. 6c). It will be appreciated that lines L1 and L2 are provided for illustrative purposes only and are phantom lines that do not form any part of the structure of the described embodiment.

Each of the first and second lines L1, L2 intersects both surfaces of an exemplary pair of inclined surfaces 102c3, 102c6 (or inclined flow guide surfaces), one of the inclined surfaces 102c3 belongs to the protrusion 102 of the first insert 100 in one groove 312, and the other of the inclined surfaces 102c6 belongs to the protrusion 102 of the second insert 100 in the adjacent groove 312 or the immediately adjacent groove 312 . Therefore, the inclined surfaces 102c3 and 102c6 are arranged to (partially) overlap each other in each of the X and Y directions.

Referring now to FIG. 7, first groove 312i of stave 300 includes first exemplary insert 100i, and second groove 312ii of stave 300 includes second and third exemplary inserts 100i. inserts 100ii, 100iii, and the third groove 312iii of the stave 300 (immediately adjacent to the second groove 312ii) comprises a fourth exemplary insert 100iv.

The beveled surfaces of the protrusions 102 of the first insert 100i partially overlap (in each of the X and Y directions in FIG. 7) the beveled surfaces of the protrusions 102 of the second insert 100ii, thereby providing a defines a first channel C1 at . Similarly, another angled surface of the protrusion 102 of the first insert 100i partially overlaps (in each of the X and Y directions in FIG. 7) the angled surface of the protrusion 102 of the third insert 100iii, thereby , defining a second channel C2 between the two faces.

Furthermore, the angled surfaces of the projections 102 of the fourth insert 100iv partially overlap (in each of the X and Y directions in FIG. 7) the angled surfaces of the projections 102 of the second insert 100ii, thereby providing two A third channel C3 is defined between the faces. Similarly, another angled surface of protrusion 102 of fourth insert 100iv partially overlaps the angled surface of protrusion 102 of third insert 100iii (in each of the X and Y directions in FIG. 7), thereby , defining a fourth channel C4 between the two faces.

Additionally, the non-inclined surface of the second insert 100ii overlaps (in the X direction in FIG. 7) the non-inclined surface of the third insert 100iii, thereby defining a fifth channel C5 between the two surfaces. The first and second channels C1, C2 converge into a fifth channel C5, and the fifth channel bifurcates or diverges into a third channel C3 and a fourth channel C4.

It will be appreciated that each of the first through fifth channels has a base formed by one or both of the front surface 314a of the rib 314 and the front surface 200a of the spacer 200. FIG.

The use of stave protection systems in blast furnaces will now be described.

A panel-like stave 300 is installed upright on the inner wall of the furnace. A front surface (or hot face) 302 faces the interior of the furnace, whereby the protrusions 102 of the insert 100 project from the front surface 302 in a substantially horizontal direction.

While the furnace is in use, the load material passes downwards through the interior of the furnace. Loading materials may include, for example, condensed steam, solidified slag, and metals.

As indicated by the arrows in FIG. 7, the flow F of the load substance (the load substance itself is not shown) flows downward (in the Y direction in FIG. 7) under gravity. A portion of the load material flows around the first insert 100i and through each of the first and second channels C1, C2. At the junction between the first and second channels C1, C2, the parts of the flow F converge and combine with each other into the fifth channel C5.

The fifth channel C5 defines a zone T on the front surface 302 of the stave 300 bounded by three adjacent vertices, each apex corresponding to a second insert 100ii, a third insert 100iii and a fourth insert. 100iv. A portion of the load material is trapped in the zone T between the three vertices. The captured load material is held in contact with the cooling surface of the front face 302 of stave 300 (as well as the flow guiding surface of projection 102) and adheres to the surface, thereby forming a protective layer. The three vertices are therefore very effective "three-point anchors" for holding a portion of the load material delivered into the zone T by the first channel C1, the second channel C2 and the fifth channel C5. ” is formed.

In this exemplary embodiment, the distance between the apex of the fourth insert 100iv and each of the apexes of the second insert 100ii and the third insert 100iii is approximately 55 mm. The reason for this is that 55 mm is a typical particle size contained in the load material.

The remaining portion of load material flow F (ie, the portion of load material not trapped in zone T) flows from fifth channel C5 into third channel C3 and fourth channel C4.

It will be appreciated that the above-described flow pattern of load material occurs at and around additional similar groups of inserts 100 on front face 302 of stave 300 .

By offsetting each insert 100 (in each of the X and Y directions in FIG. 7) and providing slanted surfaces 102c1-102c6 (or slanted flow guide surfaces), the load material flow F is directed downwardly across the front surface 302 of the stave 300. , and simultaneously around the front surface (ie, in a direction having a component in each of the X and Y directions in FIG. 7). In this manner, the load material is filtered between inserts 100. FIG. Accordingly, the load material is very effectively distributed between the inserts 100 so that it is captured by the inserts 100 along substantially the entire length and width of the front surface 302 . Therefore, the stave 300 is fully protected by the load material.

Additionally, the portion of the load material that runs down across the front surface 102a of the protrusion 102 of the insert 100 is received in the recess 102d defined in the protrusion 102. As shown in FIG.

The extent of load material flow (F) across front surface 302 of stave 300 in each of the X and Y directions may be determined by flow conditions including, for example, load material volume and weight, load material flow rate, temperature, and viscosity. Please understand. In this case, the progress of a certain amount of load material flow (F) may be restricted such that said amount of load material does not cover substantially the entire length and width of the front surface 302 and only one of the front surfaces 302. or trapped between each insert 100 in multiple localized regions. Of course, additional amounts of loading material may be flowed throughout stave 300 and trapped between inserts 100 in other localized areas, thereby trapping substantially the entire length and width of front surface 302 over time. It is covered with a load substance.

Over time the insert 100 and spacer 200 wear due to the frictional action of the load material. The spacer 200 is constructed from a copper alloy in the previously described embodiment and may wear faster than the harder silicon carbide insert 100 . As spacer 200 wears, front surface 200a recedes in the depth direction of groove 312, thereby leaving a space within groove 312. FIG. Such a space is a "stone box" occupied by the load material. A similar stone box may be formed and occupied by the load material as the mounting portion 104 of the insert 100 eventually wears. In this way, the loading material protects stave 300 even after all spacers 200 and inserts 100 have been worn.

In the exemplary embodiment described above, spacers 200 each comprise a solid block having a thickness approximately equal to the depth of groove 312, but it will be appreciated that spacers can take different forms. For example, in alternative embodiments, at least one of the spacers comprises a rectangular (possibly square) frame. That is, the spacer resembles a picture frame such that when the spacer is placed in the groove 312, a portion of the floor 312 of the groove 312 is left exposed and visible without being covered by the spacer. This results in a stone box that can be occupied by load material before spacer wear occurs. In such embodiments, the thickness of the spacer may be less than or equal to the depth of groove 312 . The spacer may be configured in various ways to leave some portion of the floor 312a of the groove 312 exposed, all such configurations being within the scope of the claimed invention.

Moreover, the spacer need not be a separate element. In alternative embodiments, one or more of the spacers are an integral part of one or more of inserts 100 . For example, in one such embodiment, the spacer is constituted by a laterally extending flange portion of mounting portion 104 of insert 100 .

Additionally, any or all of the spacers may be omitted. The reason for this is that the inserts 100 are placed at the desired spacing and then (e.g., screwed as described hereinabove) to prevent the inserts 100 from moving laterally out of position. This is because they can be individually attached to the staves 300 (by contact or welding).

Although the embodiments described above relate to inserts having hexagonal projections, it will be appreciated that one or more of the projections can take on different shapes. Preferably each of the protrusions is a polyhedron. That is, each of the protrusions is a three-dimensional solid with flat polygonal faces, straight edges, and sharp corners and vertices. For example, a flat polygonal face may be triangular, rectangular (eg, square), pentagonal, heptagonal, octagonal, and the like. All of these shapes are within the scope of the claimed invention. Alternatively, one or more of the protrusions may have a circular flat surface, whereby the protrusions take the form of discs. Additionally, the protrusions of the insert may each have different shapes and/or sizes. Further, the protrusion indentation may be other than circular, or may be omitted in some cases.

As can be seen with reference to FIG. 8, in one embodiment at least one of the grooves 312 does not comprise a spacer. Sides 104 a , 104 b of mounting portion 104 of insert 100 may abut, thereby forming a continuous ledge that can prevent passage of load substances between inserts 100 . This can be particularly useful at or near the bottom of the stave 300, as shown in FIG. The reason is that it is desirable to try to retain as much of the load material on the stave as possible.

100, 100i -100IV insert 102 protruding part 102a front 102B back 102CI -102Vi propriet 102C1 to 102C6 sides 102D 102D2D2D2 D2D2 peripheral wall 104A, 104B side from the back 104D 上 前 前 下 下 下 下 下 下 下 下 下 下 下 下 下 下 下 下Sides 200e, 200f Shorter Sides 300 Stave 302 Front 304 Back 306a-306d Edge 310 Passage 312 Groove 312a Floor 312b Opposing Walls 312i First Groove 312ii Second Groove 314 Rib 314a Flat Face C1-C5 Channel

Claims (15)

A stave protection system for a metallurgical furnace, comprising:
A stave (300) comprising a front surface (302) having an X direction and a Y direction perpendicular to said X direction so as to define an XY plane, said front surface (302) being a groove extending in said X direction. a stave (300) comprising rows of (312);
Inserts (100) slidably received by said grooves (312), wherein said inserts (100) slidably received by respective grooves (312) are spaced apart from each other along said grooves (312). and the center of said insert (100) received by one of said grooves (312) is offset from the center of said insert (100) received by an adjacent groove (312) in said X direction and said Y direction. , each of said inserts (100) protruding from said front face (302) of said stave (300) and angled with respect to each of said X and Y directions in said XY plane. an insert (100) comprising flow guide surfaces (102c1-102c6) with a
, thereby providing
In use, the offset of the insert (100) in each of the X direction and the Y direction and the inclined flow guide surfaces (102c1-102c6) allow the furnace load material flow (F) to flow in a direction having a component in each of the X and Y directions, thereby distributing the furnace load material between the inserts (100) across the front surface (302) of the stave (300); and /or a stave protection system characterized by trapping said furnace loads between said inserts (100). Said offset in said X-direction is such that an imaginary line (L2) extending in said Y-direction is the flow guide surfaces (102c1-102c6) of said insert (100) accommodated by one of said grooves (312) and said The stave protection system of claim 1, wherein the offset is such that it intersects the flow guiding surfaces (102c1-102c6) of the insert (100) received by adjacent grooves (312). Said offset in said Y-direction is such that an imaginary line (L1) extending in said X-direction is the flow guide surfaces (102c1-102c6) of said insert (100) accommodated by one of said grooves (312) and said The stave protection system of claim 1, offset to intersect flow guide surfaces (102c1-102c6) of the insert (100) received by adjacent grooves (312). Said offset in said X-direction is such that an imaginary line (L2) extending in said Y-direction is the flow guide surfaces (102c1-102c6) of said insert (100) accommodated by said one of said grooves (312) and offset such that it intersects the flow guiding surfaces (102c1-102c6) of the insert (100) received by the adjacent grooves (312); and
Said offset in said Y-direction is such that an imaginary line (L1) extending in said X-direction forms a flow guide surface (102c1-102c6) of said insert accommodated by said one of said grooves (312) and said adjacent one of said grooves (312). The stave protection system of claim 1, wherein the offset is such that it intersects the flow guiding surfaces (102c1-102c6) of the insert (100) received by grooves (312). The deviation in the X direction is
D is the distance in the X direction between the centers of the inserts (100) received by one of the grooves (312), and
said X direction between said center of said insert (100) received by said adjacent groove (312) and said center of said insert (100) received by said one of said grooves (312); 5. A stave protection system according to any one of claims 1 to 4, wherein the distance at is offset such that it is D/2. The stave protection system of any one of claims 1 to 5, wherein each of said flow guiding surfaces (102c1-102c6) is perpendicular to said front surface (302) of said stave (300). Each of said inserts (100) comprises a protrusion (102) comprising said flow guiding surfaces (102c1-102c6), and a mounting portion (104) received by said respective groove (312), according to claim 1. A stave protection system according to any one of claims 1 to 6. The stave protection system of claim 7, wherein the insert (100) has a unitary construction such that the protrusion (102) and the mounting portion (104) are integrated. The stave protection system of claim 7, wherein the insert (100) has a non-unitary construction such that the protrusion (102) and the mounting portion (104) are separate elements. A stave protection system according to any one of claims 7 to 9, wherein said projection is polyhedral and the sides of said projection (102) comprise said flow guiding surfaces (102c1-102c6). The claim, wherein said protrusion (102) is hexagonal, and each of four of the six sides of said protrusion (102) comprises a respective inclined said flow guiding surface (102c1-102c6). 11. The stave protection system of claim 10. The stave protection system of claim 11, wherein each of the other two sides of the hexagonal protrusion (102) extends in the Y-direction. The stave protection system of claim 11, wherein each of the other two sides of the hexagonal protrusion (102) extends in the X direction. A stave protection system according to any one of claims 7 to 13, wherein said projection (102) comprises an indentation (102d). The inserts (100) received by each said groove (312) are separated from each other along said groove (312) by spacers (200) slidably received in said groove (312), and said The stave protection system of any of claims 1-14, wherein the spacer (200) is configured to expose a surface of the respective groove (312) between the inserts (100).

Images