WO2015056142A1 - Lance d'injection submergée par le haut pour un transfert de chaleur augmenté - Google Patents

Lance d'injection submergée par le haut pour un transfert de chaleur augmenté Download PDF

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Publication number
WO2015056142A1
WO2015056142A1 PCT/IB2014/065248 IB2014065248W WO2015056142A1 WO 2015056142 A1 WO2015056142 A1 WO 2015056142A1 IB 2014065248 W IB2014065248 W IB 2014065248W WO 2015056142 A1 WO2015056142 A1 WO 2015056142A1
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WIPO (PCT)
Prior art keywords
lance
pipe
length
outermost pipe
outermost
Prior art date
Application number
PCT/IB2014/065248
Other languages
English (en)
Inventor
Jiliang Xia
Markus Reuter
Robert Walter Matusewicz
Neil Jacobson
Original Assignee
Outotec (Finland) Oy
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Filing date
Publication date
Priority claimed from AU2013903980A external-priority patent/AU2013903980A0/en
Application filed by Outotec (Finland) Oy filed Critical Outotec (Finland) Oy
Publication of WO2015056142A1 publication Critical patent/WO2015056142A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
    • C21C5/28—Manufacture of steel in the converter
    • C21C5/42—Constructional features of converters
    • C21C5/46—Details or accessories
    • C21C5/4606—Lances or injectors
    • C21C5/4613—Refractory coated lances; Immersion lances
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D3/00—Charging; Discharging; Manipulation of charge
    • F27D3/16—Introducing a fluid jet or current into the charge
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D3/00—Charging; Discharging; Manipulation of charge
    • F27D3/18—Charging particulate material using a fluid carrier
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C5/00—Manufacture of carbon-steel, e.g. plain mild steel, medium carbon steel or cast steel or stainless steel
    • C21C5/28—Manufacture of steel in the converter
    • C21C5/42—Constructional features of converters
    • C21C5/46—Details or accessories
    • C21C5/4606—Lances or injectors
    • C21C2005/4626—Means for cooling, e.g. by gases, fluids or liquids

Definitions

  • This invention relates to top submerged injecting lances for use in molten bath pyro-metallurgical operations.
  • Molten bath smelting operations utilize several different arrangements for the supply of the gas.
  • these operations involve direct injection into molten matte/metal. This may be by bottom blowing tuyeres as in a Bessemer type of furnace or side blowing tuyeres as in a Peirce-Smith type of converter.
  • the injection of gas may be by means of a lance to provide either top blowing or submerged injection. Examples of top blowing lance injection are the KALDO and BOP steel making plants in which pure oxygen is blown from above the bath to produce steel from molten iron.
  • Another example is the Mitsubishi copper process, in which injection lances cause jets of gas, such as air or oxygen-enriched air, to impinge on and penetrate the top surface of the bath, respectively to produce and to convert copper matte.
  • gas such as air or oxygen-enriched air
  • the lower end of the lance is submerged so that injection occurs within rather than from above a slag layer of the bath, to provide top submerged lancing (TSL) injection, a well-known example of which is the Outotec Ausmelt TSL technology that is applied to a wide range of metals processing.
  • the top blowing in the Mitsubishi copper process uses a number of relatively small steel lances which have an inner pipe of about 50 mm diameter and an outer pipe of about 100 mm diameter.
  • the inner pipe terminates at about the level of the furnace roof, well above the reaction zone.
  • the outer pipe which is rotatable to prevent it sticking to a water-cooled collar at the furnace roof, extends down into the gas space of the furnace to position its lower end about 500-800 mm above the upper surface of the molten bath. Particulate feed entrained in air is blown through the inner pipe, while oxygen enriched air is blown through the annulus between the pipes.
  • the outer pipe burns back by about 400 mm per day.
  • the outer pipe therefore is slowly lowered and, when required, new sections are attached to the top of the outer, consumable pipe.
  • TSL lances for TSL injection are much larger than those for top blowing, such as in the Mitsubishi process described above.
  • a TSL lance usually has at least an inner and an outer pipe, as assumed in the following, but may have at least one other pipe concentric with the inner and outer pipes.
  • Typical large-scale TSL lances have an outer pipe diameter of 200 to 500 mm, or larger.
  • the lance is much longer and extends down through the roof of a TSL reactor, which may be about 10 to 15 m tall, so that the lower end of the outer pipe is immersed to a depth of about 300 mm or more in a molten slag phase of the bath, but is protected by a coating of solidified slag formed and maintained on the outer surface of the outer pipe by the cooling action of the injected gas flow within.
  • the inner pipe may terminate at about the same level as the outer pipe, or at a higher level of up to about 1000 mm above the lower end of the outer pipe. Thus, it can be the case that the lower end of only the outer pipe is submerged.
  • a helical vane or other flow-shaping device may be mounted on the outer surface of the inner pipe to span the annular space between the inner and outer pipes.
  • the vanes impart a strong swirling action to an air or oxygen-enriched blast along that annulus and serve to enhance the cooling effect as well as ensure that gas is mixed well with fuel and feed material supplied through the inner pipe with the mixing occurring substantially in a mixing chamber defined by the outer pipe, below the lower end of the inner pipe where the inner pipe terminates a sufficient distance above the lower end of the outer pipe.
  • the outer pipe of the TSL lance wears and burns back at its lower end, but at a rate that is considerably reduced by the protective frozen slag coating than would be the case without the coating. However, this is controlled to a substantial degree by the mode of operation with TSL technology. The mode of operation makes the technology viable despite the lower end of the lance being submerged in the highly reactive and corrosive environment of the molten slag bath.
  • the inner pipe of a TSL lance may be used to supply feed materials, such as concentrate, fluxes and reductant to be injected into a slag layer of the bath, or it may be used for fuel.
  • An oxygen containing gas such as air or oxygen enriched air, is supplied through the annulus between the pipes.
  • the lance Prior to submerged injection within the slag layer of the bath being commenced, the lance is positioned with its lower end, that is, the lower end of the outer pipe, spaced a suitable distance above the slag surface.
  • Oxygen - containing gas and fuel such as fuel oil, fine coal or hydrocarbon gas, are supplied to the lance and a resultant oxygen/fuel mixture is fired to generate a flame jet that impinges onto the slag.
  • This causes the slag to splash to form, on the outer lance pipe, a coating of liquid slag that is solidified by the gas stream passing through the lance to provide the solid slag coating mentioned above.
  • the ongoing passage of oxygen- containing gas through the lance maintains the lower extent of the lance at a temperature at which the solidified slag coating is maintained and protects the outer pipe.
  • the relative positions of the lower ends of the outer and inner pipes that is, the distance the lower end of the inner pipe is set back, if at all, from the lower end of the outer pipe, is an optimum length for a particular pyro- metallurgical operating window determined during the design.
  • the optimum length can be different for different uses of TSL technology.
  • a two stage batch operation for converting copper matte to blister copper with oxygen transfer through slag to matte a continuous single stage operation for converting copper matte to blister copper, a process for reduction of a lead containing slag, or a process for the smelting an iron oxide feed material for the production of pig iron, all have different respective optimum mixing chamber length.
  • the length of the mixing chamber progressively falls below the optimum for the pyro-metallurgical operation as the lower end of the outer pipe slowly wears and burns back.
  • the lower end of the inner pipe can become exposed to the slag, with it also being worn and subjected to burn back.
  • the lower end of at least the outer pipe needs to be cut to provide a clean edge to which is welded a length of pipe of the appropriate diameter, to re-establish the optimum relative positions of the pipe lower ends to optimize smelting conditions.
  • the rate at which the lower end of the outer pipe wears and burns back varies with the molten bath pyro- metallurgical operation being conducted. Factors that determine the rate include feed processing rate, operating temperature, bath fluidity and chemistry, lance flows rates, etc. In some cases the rate of corrosion wear and burn back is relatively high and can be such that in the worst instance several hours operating time can be lost in a day due to the need to interrupt processing to remove a worn lance from operation and replace it with another, whilst the worn lance taken from service is repaired. Such stoppages may occur several times in a day with each stoppage adding to non-processing time. While TSL technology offers significant benefits, including cost savings, over other technologies, any lost operating time for the replacement of lances carries a significant cost penalty.
  • the proposal of Bennett et al while referred to as a lance, is more akin to a tuyere in that it injects, below the surface of molten ferrous metal, through the peripheral wall of a furnace in which the molten metal is contained.
  • concentric pipes for injection extend within a ceramic sleeve while cooling water is circulated through pipes encased in the ceramic.
  • provision for a cooling fluid is made only in an upper extent of the lance, while the lower extent to the submergible outlet end comprises a single pipe encased in refractory cement.
  • US patent 6,565,800 to Dunne discloses a solids injection lance for injecting solid particulate material into molten material, using an unreactive carrier. That is, the lance is simply for use in conveying the particulate material into the melt, rather than as a device enabling mixing of materials and combustion.
  • the lance has a central core tube through which the particulate material is blown and, in direct thermal contact with the outer surface of the core tube, a double-walled jacket through which coolant such as water can be circulated.
  • the jacket extends along a part of the length of the core tube to leave a projecting length of the core tube at the outlet end of the lance.
  • the lance has a length of at least 1 .5 metres and from the realistic drawings, it is apparent that the outside diameter of the jacket is of the order of about 12 cm, with the internal diameter of the core tube of the order of about 4 cm.
  • the jacket comprises successive lengths welded together, with the main lengths of steel and the end section nearer to the outlet end of the lance being of copper or a copper alloy.
  • the projecting outlet end of the inner pipe is of stainless steel which, to facilitate replacement, is connected to the main length of the inner pipe by a screw thread engagement.
  • the lance of US6, 565,800 to Dunne is said to be suitable for use in the HiSmelt process for production of molten ferrous metal, with the lance enabling the injection of iron oxide feed material and carbonaceous reductant.
  • the lance is exposed to hostile conditions, including operating temperatures of the order of 1400°C.
  • copper has a melting point of about 1085°C and even at temperatures of about 1 140°C to 1 195°C, stainless steels have very little strength.
  • Dunne is suitable for use in the context of the HiSmelt process, given the high ratio of about 8:1 in cooling jacket cross-section to the cross-section of the core tube, and the small overall cross-sections involved.
  • the lance of Dunne is not a TSL lance, nor is it suitable for use in TSL technology.
  • lances for use in pyro-metallurgical processes based on TSL technology are provided by US patent 4,251 ,271 and 5,251 ,879, both to Floyd and US patent 5,308,043 to Floyd et al.
  • slag initially is splashed by using the lance for top blowing top blowing onto a molten slag layer, to achieve a protective coating of slag on the lance that is solidified by high velocity top blown gas that generates the splashing.
  • the solid slag coating is maintained despite the lance then being lowered to submerge the lower outlet end in the slag layer to enable the required top submerged lancing injection within the slag.
  • annular tip of solid alloy steel that, at the outlet end of the lance, joins the outermost and innermost of those three pipes around the circumference of the lance.
  • the annular tip is cooled by injected gas and also by coolant fluid that flows across an upper end face of the tip.
  • the solid form of the annular tip, and its manufacture from a suitable alloy steel, result in the tip having a good level of resistance to wear and burn back.
  • the arrangement is such that a practical operating life can be achieved with the lance before it is necessary to replace the tip in order to safeguard against a risk of failure of the lance enabling cooling fluid to discharge within the molten bath.
  • Top submerged lancing (TSL) injection has applied widely in pyro- metallurgical processes because of its advantages over the top-blowing lance.
  • TSL smelting furnace one of the important issues is the design of the lance. Due to the aggressive nature of high temperature slag phase in which the submerged injection is conducted, as well as the usual presence of a combustion flame generated by combustion of fuel at or within the submerged end of the lance, the operational period of the top submerged lance between tip repairs can be short. Those conditions cause wear and burn-back at the outlet end of the lance, while wear can be further exacerbated by the injection of mineral concentrate in some TSL pyro-metallurgical operations.
  • lances for top submerged injection have been proposed in the above-mentioned US patents 4,251 ,271 and 5,251 ,879 to Floyd as well as in our pending applications WO2013/000017 and WO2013/029092.
  • these lances include helical swirlers that are used to constrain the gas to a helical flow path in a upper part of the length of the lance, in order to facilitate mixing of the injected gas and fuel in a combustion zone within an outlet end section of the lance or at least partly beyond that end.
  • the present invention relates to an improved top submerged injecting lance for use in TSL pyro-metallurgical operations.
  • the lance of the present invention provides an alternative choice to the lance of US patent 5,308,043 to Floyd et al that, at least in preferred forms, can provide benefits over the lance of that patent.
  • the present invention provides a lance for top submerged lancing (TSL) injection in a pyro-metallurgical operation.
  • the lance has at least two substantially concentric pipes, with an annular passage defined between an outermost one of the pipes and a next adjacent pipe and a further passage define within an innermost one of the pipes.
  • the outermost pipe has an inner surface that, over at least a lower part of its length from a submergible lower outlet end of the lance, is modified so as to enhance the heat transfer characteristics relative to the heat transfer characteristics of the inner surface of the outermost pipe in its as formed condition or without the modification, such as above that lower part of the length where the inner surface is modified only at the lower part.
  • the heat transfer modification comprises at least one or a combination of:
  • the heat transfer enhancement provide by the modification of the present invention is such that a solid slag layer can be maintained at a higher operating temperature or, for a longer operating life at a given operating temperature, than would be possible without the enhancement of the heat transfer characteristics of the lower part of the length of the inner surface.
  • the increased surface area and surface roughness can be applied to the lance separately, or together. These two parts could be used together.
  • the bulk increase in surface area is useful on a holistic level to increase heat transfer.
  • the surface roughness enhances heat transfer through modification of turbulence at the surface interface between the inner surface of the outermost pipe and a cooling fluid flowing through the outermost pipe. In the latter case surface roughness does not increase flow turbulence on the macro level (i.e does not impact Reynolds number).
  • the depth of submergence can vary from one pyro-metallurgical to another, and can range from about 150 mm to 1 m, so that the lower part of the length of the lance over which the inner surface of the outermost pipe is modified to enhance its heat transfer characteristics may range from as little as 150 mm, up to about 5 m. However, as indicated, the modification may be over a length greater than 5 m and may even extend over the full length of the outermost pipe.
  • the solid slag layer is formed and maintained principally by the cooling effect of gas passing along the annular passage of the lance in the course of the gas being injected within a molten slag phase in a pyro- metallurgical operation.
  • existence of the solid slag layer is dependent upon the gas extracting heat energy from the outermost pipe via the inner surface of that pipe.
  • some cooling also is attributable to radiation from the inner surface of the outermost pipe as a consequence of the emission of infrared energy from the outermost pipe, to gas and/or the next innermost pipe. It is found that the heat energy transfer characteristics of the lower part of the length of the inner surface of the outermost pipe can be enhanced sufficiently to provide an improved level of efficiency of heat energy extraction.
  • the improved efficiency of heat extraction is able to be achieved by factors that improve the transfer of heat energy to the gas from the outermost pipe, via the lower part of the length of its inner surface, by the heat energy transfer modes of convection, conduction, radiation and/or a boundary layer effect.
  • the heat energy transfer modes of convection, conduction, radiation and/or a boundary layer effect are available.
  • the lower part from the outlet end, of the inner surface of the outermost pipe is provided with an increased surface area, relative to a similar length of the inner surface of the outermost pipe above that lower part of the length.
  • the increased surface area increases the convective, conductive and radiation heat transfer effectiveness.
  • the surface area may be increased substantially uniformly around the circumference of the inner surface of the lower part, and along the length of the lance from the outlet end. The increased surface area enables enhanced heat energy transfer from the outermost pipe compared to the heat energy that would be possible with a lower part having the same heat transfer characteristics as the inner surface above the lower part, with the enhancement being directly related to the increase in surface area.
  • the surface area increase to increase convective heat transfer effectiveness, assisted by some conductive and radiation hear transfer, is provided by grooves or channels formed in the inner surface of the outermost pipe.
  • the grooves or channels may extend from the inner surface, partly into the thickness of the outermost pipe, with the outer surface of the lower part of the outermost pipe having substantially same relatively smooth cylindrical form as the outer surface above the lower part.
  • the grooves or channels may be formed through the thickness of the outermost pipe so that the outer surface of the lower part of the outermost pipe is provided with grooves or channels of complementary form to those of the inner surface.
  • the grooves or channels most conveniently are disposed in a substantially parallel layout, and most conveniently they are substantially uniformly spaced.
  • the grooves or channels may extend circumferentially, helically or longitudinally with respect to the outermost pipe; while the pipes of the lance typically are substantially circular in cross-sections perpendicular to the length of the lance.
  • the grooves or channels can be of any suitable transverse cross-section. Examples of suitable cross-sections for the grooves or channels include rectangular or other polygonal forms, U-shapes and V-shapes.
  • the ratio of the depth to the width of the grooves or channels, their actual depth and the spacing between successive grooves or channels can vary as necessary to provide the increased surface area for the required level of enhancement of the heat transfer characteristics they enable.
  • the surface area increase that increases convective heat transfer effectiveness, with some conductive and radiation heat transfer, is provided by beads of metal deposited on the inner surface of the outermost pipe.
  • the beads are the complement of the grooves or channels of the first form of the first arrangement, and details on disposition, cross- section, ratio of transverse dimensions and spacing can vary as described above in relation to grooves or channels.
  • the deposited metal beads typically can be of a similar steel composition to that used for the pipes of the lance but, if the beads are of a different steel composition, the steel preferably is closely similar in thermal expansion coefficient to the steel of the pipes. Also, the beads can be formed by a wide variety of deposition techniques, such as to comprise welding or hard facing deposits.
  • the surface area increase to provide an increase in heat transfer effectiveness is provided by an array of elongate, narrow fins secured over the inner surface of the outermost pipe. Again, the details on disposition, cross-section, ratio of transverse dimensions and spacing can vary as described in relation to grooves or channels.
  • the fins can be thin relative to their width and, while they can be arcuate in transverse cross-sections, they may be flat and have their width dimension substantially radial with respect to the inner surface of the outermost pipe.
  • the fins may be provided by being cast integrally with an end section for the outermost pipe which then is welded to the lower end of the remaining, upper extent of that pipe.
  • the fins preferably are welded or otherwise joined closely to the inner surface of the outermost pipe. Spot welding at intervals along the length of each fin can suffice, provided it retains substantially the full length edge of each fin in good thermal contact with the inner surface of the outermost pipe.
  • each fin preferably is welded to the inner surface along substantially the full length of the fin.
  • the fins preferably are of formed from a steel that is closely similar in composition to the steel of the pipes or, failing this, that is at least closely similar in thermal expansion coefficient to that of the steel of the pipes.
  • the fins differ significantly from swirler devices provided in the helical passage defined by the outermost pipe and the next innermost pipe.
  • the swirler device usually is helical but has a width substantially equal to the radial width of the annular passage. Also, as a practical matter, the swirler device is mounted on the outer surface of the next innermost pipe and terminates at or above the lower, outlet end of the next innermost pipe and, hence above the mixing and combustion chamber.
  • the fins are provided on the inner surface of the outermost pipe, essentially below the swirler device and the lower end of the next innermost pipe, so as to be within the mixing and combustion chamber, while the fins project from the innermost surface a distance that is a minor part of the radial width of the annular passage.
  • the lower part of the length from the outlet end, of the inner surface of the outermost pipe is modified in a manner that increases flow turbulence in the gas being injected through the annular passage defined between the outermost and next adjacent pipes.
  • the surface roughness enhances heat transfer through modification of turbulence at the surface interface between the inner surface of the outermost pipe and a cooling fluid flowing through the outermost pipe.
  • surface roughness does not increase flow turbulence on the macro level (i.e. does not impact Reynolds number). This aids in increasing heat transfer effectiveness, principally by convection.
  • the increase in flow velocity is achieved by imparting to, or providing on, the lower part of the length of the inner surface a sufficient level of surface roughness as to result in such turbulence and a required enhancement of heat transfer characteristics.
  • the surface roughness required is greater than that which characterises the steel of which the pipes are fabricated. While the provided surface roughness is to generate flow turbulence, it also can contribute to a degree to the enhancement of heat transfer characteristics by the mechanism of convection, conduction and radiation of the first arrangement. That is, the surface roughness increases the surface area of the inner surface on which it is provided, although this is on a micro- scale compared with the macro-scale of the forms of the first arrangement. Similarly, the grooves or channel, as well as the beads and the fins, of the respective forms of the first arrangement, can be such as to impart at least some increased degree of flow turbulence in the gas being injected through the annular passage defined between the outermost and next adjacent pipes.
  • the increase in surface roughness can be provided in a number of different ways.
  • the increase in surface can be imparted by sand or shot blasting of the lower part of the length of the inner surface of the outermost pipe.
  • the medium, and also the process conditions by which the medium is used for generating the increased roughness, can vary widely.
  • the sand or shot blasting is not merely to provide cleaning of micro-rough surface inherently present in the pipes as fabricated. Rather the sand or shot blasting is to impose a higher level of roughness to the lower part of the length of the inner surface of the outermost pipe than is present over that surface above the lower part.
  • the sand or shot blasting is to generate a sufficient increase in the roughness average necessary to provide the required increase in surface and thereby increase flow turbulence in the gas flowing through the annular passage.
  • the roughness average is most commonly expressed in micrometres or microns, designated by the symbol Ra, and is the arithmetic mean of departures in roughness of a profile from the mean line for the profile.
  • a suitable increase in surface roughness for achieving the increase in surface area can for example be attained in the manner disclosed in the paper by Khorasanizadeh, "The Effects of Shot and Grit Blasting Process Parameters on Steel Pipes Coating Adhesion", World Academy of Science, Engineering and Technology, 42, 2010, pages 1290-1298.
  • a suitable surface roughness for Ra in micrometers, for providing flow turbulence required for the present invention may be in excess of about 25 pm , such as in the range of from 25 pm to 50 pm, or higher, for example up to about 75 pm compared with an Ra value of from about 0.4 pm to 3.2 pm for the inner surface of the outermost pipe as produced.
  • the increase in surface roughness for imparting the required level of, or increase in, flow turbulence in gas being injected through the annular passage may be provided by metal laid down over the lower part of the length of the inner surface of the outermost pipe.
  • the metal laid down may be substantially uniformly provided over that lower part of the inner surface, or it may be provided non- uniformly, such as in accordance with a selected pattern.
  • metal may be laid down over the lower part if the inner surface may be provided by a metal deposition technique.
  • One suitable technique is that of cold spray technology by which metal powder material, such as steel powder, is deposited with the lower surface part substantially at or near ambient temperature by the powder being sprayed at supersonic velocity to form a metallurgical bond with that surface.
  • metal powder material such as steel powder
  • thermal spraying can be used.
  • a metal mesh of a suitable mesh size and gauge over the lower part of the inner surface of the outermost pipe.
  • the metal mesh may be a wire mesh or an expanded metal mesh, preferably of steel, and can be secured to the inner surface by mechanical devices, but preferably is secured by welding, such as at spots or locations spaced over the mesh.
  • the TSL lance of the invention necessarily is of large dimensions. Also, at a location remote from the outlet end, such as adjacent to an upper or inlet end, the lance has a structure by which it can be suspended so as to hang down vertically within a TSL reactor.
  • the lance may have a length as short as about 7.5 metres, such as for a small special purpose TSL reactor.
  • the lance may be up to about 25 metres in length, or even greater, for a special purpose large TSL reactor. More usually, the lance ranges from about 10 to 20 metres in length.
  • the next adjacent pipe, and the innermost and any other pipe for a lance with at least three substantially concentric pipes may extend to the outlet end and therefore be of substantially the same overall length as the outermost pipe.
  • each pipe other than the outermost pipe may terminate a short distance from the outlet end of the outermost pipe by, for example, up to about 1000 mm.
  • the lance typically has a large diameter, such as set by an internal diameter for the outermost pipe of from about 100 to 650 mm, preferably about 200 to 650 mm, and an overall diameter of from 150 to 700 mm, preferably about 250 to 550 mm.
  • a lance having only the outermost pipe extending to the outlet end enables oxygen-containing gas and fuel to mix for combustion of the fuel to generate a combustion flame that typically extends into the slag phase, beyond the outlet end.
  • the lance thus has a combustion chamber within the lower extent of the outermost pipe, below the end of each pipe that terminates short of the outlet end of the outermost pipe.
  • the lower extent of the lance that is submerged in the slag phase during a pyro-metallurgical operation to a depth of the same order of magnitude as the length of the combustion chamber, with the length of the combustion chamber and of the submerged lower extent of the lance being a minor part of the overall length of the lance.
  • the length of the lance on which a solid slag layer is formed and to be maintain is greater, but typically also a minor part of the overall length of the lance.
  • the lower part of the length from the outlet end, of the inner surface of the outermost pipe, over which the heat transfer characteristics are enhanced in accordance with the present invention relative to those characteristics of that surface above the lower part, also has a length that is a minor part of the overall length of the lance.
  • the length of that lower part of the inner surface may be of the same order of magnitude as the length of the combustion chamber for lances having such chamber.
  • the length of the lower part typically is less than the length of the lance over which the solid slag layer is formed and to be maintained, while the length of the lower part may be substantially the same as the depth to which the lower extent of the lance is to be submerged in a pyro-metallurgical operation for which the lance was designed.
  • the present invention provides a lance for top submerged injection that, due to the enhancement of heat transfer characteristics over the lower part of the length of the inner surface of the outermost pipe relative to those characteristics of that surface above that lower part, provides improved cooling of the lower extent of the outermost pipe of the lance.
  • a protecting layer of solidified slag can be more quickly formed on the outer surface of the lance.
  • the protecting layer of solidified can be maintained over a longer operating period at a given temperature or at a higher operating slag temperature, providing a reduction in the operating cost for the pyro-metallurgical operation in which the lance is used.
  • Figure 1 is a schematic perspective view, partly broken away, depicting a top submerged lancing (TSL) injection reactor;
  • TSL top submerged lancing
  • FIG. 2 illustrates one form of TSL lance according to the invention, suitable for use in a TSL reactor such as depicted in Figure 1 ;
  • Figure 3 is similar to Figure 2, but illustrating another form of TSL lance according to the invention.
  • Figure 4 illustrates one form of end section for the outermost pipe of a TSL lance according to the invention.
  • Figure 5 is a perspective view illustrating details of the arrangement of Figure 4.
  • FIG. 1 shows a TSL reactor or furnace 10 suitable for use in conducting a pyro-metallurgical operation, using top submerged lancing (TSL) injection with a TSL lance according to the present invention.
  • the furnace 10 is shown partly cutaway to reveal its interior, as if in the course of conducting a pyro-metallurgical operation.
  • the furnace 10 has a tall cylindrical base section 12 for containing a molten bath 14 comprising, or having an upper layer, of slag. Extending from the upper extent of the base section 12, the furnace 10 has an asymmetrical, frusto- conical roof 16 and, above roof 16, an off-take flue 18.
  • the section 12 and roof 16 of furnace 10 typically have an outer shell 20 of steel that is lined with suitable refractory 22.
  • a vertically suspended lance 24, shown in more detail in Figure 2 extends down into the base section 12 of furnace 10, through the roof 16 and close to the axis of section 12.
  • the lance 24 passes through the roof portion 16 and is able to be raised or lowered by a carriage (not shown) to which the upper end of lance 24 is adapted to be connected.
  • the carriage is moveable vertically on a guide structure (not shown).
  • an oxygen-containing gas and a suitable fuel can be injected into the bath 14.
  • the fuel may be entrained in a carrier gas, and typically is so entrained if it is a solid such as fine particulate coal.
  • the fuel also may be a suitable hydrocarbon gas or liquid.
  • at least part of feed material to be smelted can be charged to the furnace 10, to fall into the bath 14, via inlet port 26. Additionally or alternatively, such feed material, if in particulate fines, can be injected into the bath via an appropriate passage of lance 24. Sealing (not shown) is provided for substantially sealing around the opening in furnace portion 16 through which lance 24 passes, and at port 26. Also, furnace 10 is kept below atmospheric pressure to prevent gases from exiting from the furnace 10 other than via flue 18.
  • the lance 24 in the arrangement illustrated comprises a concentric arrangement of an outer pipe 28 and an inner pipe 30.
  • the lance 24 extends concentrically through a shroud tube 32 that terminates a substantial distance above the lower, tip end of lance 24 so that, in use of the lance, tube 32 also terminates a sufficient level above the bath 14.
  • the pipes 28 and 30 may be of substantially the same length.
  • the inner pipe 30 terminates above the tip end of the lance, as seen in Figure 2, to provide a mixing and combustion chamber 34 within pipe 28, below the end of pipe 30.
  • Process gas that provides external cooling for the outer pipe 28 is supplied via a conduit 36 to an annular space 38 between shroud device 32 and lance 24. Also, internal cooling of pipe 28 is achieved by an oxygen containing gas that is supplied via a conduit 40 for flow of the oxygen containing gas down an annular passage 42 defined between pipes 28 and 30 and communicating with chamber 34. Fuel can be supplied via a conduit 44 for flow into and down a passage 46 comprising the bore of pipe 30.
  • a swirler device 48 is provided in the passage between pipes 28 and 30, above the lower end of pipe 30 of lance 24.
  • Device 48 may be in the form of a single helical ribbon, as shown, or a system of multi-start helical ribbons.
  • a helical flow is imparted to the oxygen-containing gas passing down passage 42 and this enhances mixing of that gas and the fuel in the mixing and combustion chamber 34.
  • the swirler device 48 is mounted on the outer surface of pipe 30, such as by welding, after which pipe 28 is received as a sleeve along pipe 30 and the device 48 provided on pipe 30.
  • the device 48 has a width such that it has an outer helical edge closely adjacent to the inner surface of outer pips 28.
  • substantially all gas passing down passage 42 is constrained to a helical flow path prior to entering chamber 34, and this enhances mixing of the gas with fuel passing into chamber 34 from passage 46.
  • a resultant gas/fuel mixture is fired to generate a combustion flame issuing from chamber 34.
  • Not all material to comprise fuel need be combusted, as injection of some of the material into the molten bath may be required to provide a reducing agent or reductant and, where this is the case, it is usual to designate the material as "fuel/reductant" with that part not combusted as fuel able to function as reductant.
  • the lance 24 is lowered to a position in which its lower tip end is above the initially quiescent bath 14.
  • oxygen-containing gas via conduit 40 and fuel via conduit 44 are injected through the lance 24, the fuel is combusted by igniting the resultant mixture of oxygen-containing gas and fuel formed in the chamber 34 before issuing from the lower, tip-end of the lance 24.
  • the materials supplied through the lance for this combustion of the fuel are supplied at a high velocity resulting in generation of a very strong combustion jet or flame that impinges on the slag surface of bath 14, thereby causing strong splashing of the slag.
  • the top-submerged injection generates substantial turbulence in the slag such that splashing of the slag continues, and intimate mixing of feed material with the slag can be achieved.
  • the furnace 10 then is in a condition enabling a required pyro-metallurgical process to be conducted.
  • a cooling gas can be supplied via conduit 36 to the passage 38 between shroud tube 32 and outer pipe 28 of lance 24 so as to issue into a gas space 52 above the bath 14 with the outlet end of shroud device 32 up to about distance (N-L) above the slag.
  • the cooling gas further assists in cooling of the outer surface of pipe 28 of lance 24 and maintenance of the coating layer 34 of solidified slag.
  • the cooling gas may be an oxygen-containing gas such as air or oxygen-enriched air to enable recovery of heat energy to the bath 14 by post-combustion of gases, such as carbon monoxide and hydrogen, evolved from bath 14 during the pyro-metallurgical operation.
  • the cooling gas may be a non-oxidising gas such as nitrogen or an essentially non-oxidising, cooled process gas recovered from the flue gases.
  • FIG. 3 depicts a top submerged lance 124 similar to lance 24 of Figure 2, and corresponding parts have the same reference numerals, plus 100.
  • the lance 124 of Figure 3 includes an outermost pipe 128 through which an innermost pipe 130 extends co-axially, while lance 124 extends through a relatively short shroud device 132.
  • Lance 124 has a third pipe 54, as required for some pyro-metallurgical operations.
  • the pipe 54 extends co-axially within pipe 128, between the latter and pipe 130, such that pipe 54 comprises an intermediate pipe, or a next innermost pipe from pipe 128.
  • annular passage 138 is defined by pipe 128 and pipe 54.
  • an annular passage 52 is defined by pipe 54 and pipe 130.
  • pipe 130 of lance 124 terminates above the lower end of pipe 128, above a mixing and combustion chamber 134.
  • the lower end of intermediate pipe 54 terminates a short distance (M-L) above the lower end of pipe 130, so that feed material, such as concentrate to be smelted, can be injected along an annular passage 56 between pipes 128 and 54, via conduit 55, and caused to pass through the mixture of gas and fuel formed and being combusted in chamber 134.
  • the feed material can be heated in passing through the combustion flame in chamber 134, without impeding mixing of the gas and fuel.
  • the lower end of the lance 124 is designed for submergence in a slag phase layer of a molten bath contained in a top submerged lancing reactor, as described in relation to Figure 1 , with a protective coating layer of solidified slag maintained on the outer surface of pipe 128.
  • a swirler device 148 is provided in annular passage 138.
  • device 140 is secured around the outer surface of intermediate pipe 54, and has a width substantially spanning the space between pipes 128 and 54.
  • each of lance 24 of Figures 1 and 2, and lance 124 of Figure 3 a lower part H of the inner surface of the outer pipe 28 and of the outermost pipe 128, respectively, is provided with enhanced heat transfer characteristics relative to the remainder of the length of that surface.
  • the respective area H is shown by cross-hatching. As shown, each area H extends circumferentially around the lower outlet end of its lance 24, 124. The area H may have a length that is comparable to the length of the mixing and combustion chamber 34, 134.
  • the area may end below the upper end of the chamber 34,134 by a distance that is a minor part, such as about 5%, of the length of the chamber 34, 134, although the area H preferably has about the same length as, or a greater length than the chamber 34,134.
  • the area may have a length such that its upper end is a short distance above the lower end of the third or intermediate pipe 54.
  • the area H of each of lance 24 and lance 124 can be provided by any of the forms for the first or second arrangement detailed above, in the more general description preceding reference to the attached drawings. However, respective forms are illustrated in Figures 4 and 5.
  • Figure 4 shows an outlet end section S of a pipe P, suitable for the outer pipe 28 of lance 24 of Figure 2 or for the outermost pipe 128 of the lance 124 of Figure 3, respectively.
  • the main extent, or remainder of the length, of pipe P is only schematically depicted in broken outline.
  • the section S has an inner surface H having required enhanced heat transfer characteristics. Also, the section S has a length sufficient for it to provide a required inner surface area H for the outer pipe 28 or 128 for the respective lance 24 or 124.
  • the section S has enhanced heat transfer characteristics at surface area H as a result of section S being in according to the first form of the first arrangement detailed above in the more general discussion preceding reference to the drawings.
  • the section S has an increased inner surface area, and hence enhanced heat transfer characteristics, relative to other sections of substantially the same length of the remainder of a pipe 28 or 128 of which the section S is to form part.
  • the increased surface area is achieved by section S being circumferentially corrugated to define longitudinally extending ribs R and grooves G in the inner surface of section S..
  • the circumferential corrugations of section S can be produced, in a lower end section of suitable length of an outer or outermost pipe P, such as by a suitable roll forming operation conducted on the lower end section.
  • the operation need not change the remainder of the pipe P as formed, except for a short transition section (not shown) of the pipe P which grades from the corrugated profile of section S to the non-corrugated, circular cross-section of the main extent, or remainder of the length, of the pipe P.
  • the transition preferably has an a length or axial extent that is a minor part, such less than about 5%, of the length of the section S.
  • section S has longitudinal grooves G and ribs R on surface H (and the complement on the outer surface of section S), other arrangements can be provided.
  • the grooves G and ribs R may extend circumferentially or helically over surface H, with the complementary formations on the outer surface of section S extending in the same manner.
  • Figure 5 is a partial, sectional view through the end section S of the outer or outermost pipe Pas shown in Figure 4, although the main extent or remainder of the length of pipe P is only schematically shown.
  • Section S shows that the main extent or remainder in that section S has an inner surface in which a substantially parallel array of channels C is formed.
  • the view provided by Figure is of a relatively small section of so that the curvature of section S, as an outlet end section of a pipe 28 for the lance of Figure 2 or of a pipe 128 of a lance 124, is not apparent.
  • the channels C are provided over the inner surface H of the section S by a machining, profiling or other forming process.
  • the channels C have a width W and a depth D, with a spacing W between successive channels C.
  • the arrangement is such that the surface H has heat transfer characteristic due to channels C which are enhanced, relative to surface H without channels, to an extent determined by the relationship between W, D and W.
  • the surface area is twice that of a surface H without channels C, producing a corresponding increase in the heat transfer area.
  • the lance of the present invention there is improved cooling due to enhanced heat transfer from the increased area of the inner surface H.
  • the wall temperature of the lower end section of the outer or outermost pipe is kept at a level that enhances the formation and maintenance of a protective solidified slag layer on the outer surface of the end section.
  • the operational time of the lance is prolonged.
  • the enhanced heat transfer results in an increase in heat energy taken up by gas flowing along the annular passage defined in part by the outer or outermost pipe and into the mixing and combustion chamber, thereby increasing the temperature of that gas thereby improving combustion of the mixture formed in the mixing and combustion chamber.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Treatment Of Steel In Its Molten State (AREA)
  • Furnace Charging Or Discharging (AREA)

Abstract

L'invention concerne une lance (24, 124) pour une injection par des lances submergées par le haut (top submerged lancing - TSL) dans une utilisation pyrométallurgique (10) qui comprend au moins deux tuyaux sensiblement concentriques (28, 30, 128, 130), un passage annulaire (42, 142) étant défini entre le tuyau le plus externe des tuyaux (28, 128) et le tuyau adjacent suivant (30, 130) et un autre passage (46, 146) étant défini au sein du tuyau le plus interne des tuyaux (30, 130). Le tuyau le plus externe (28, 128) présente une surface interne qui, sur au moins une partie inférieure (H) de sa longueur à partir d'une extrémité de sortie (S) inférieure submersible de la lance (24, 124), est modifiée de manière à augmenter les caractéristiques de transfert de chaleur de cette zone (H) par rapport aux caractéristiques de transfert de chaleur de la surface interne du tuyau le plus externe (28, 128) dans son état tel quel ou sans la modification. La modification comprend au moins l'un parmi une superficie augmentée ou un niveau de rugosité de surface ou une combinaison de ceux-ci.
PCT/IB2014/065248 2013-10-16 2014-10-13 Lance d'injection submergée par le haut pour un transfert de chaleur augmenté WO2015056142A1 (fr)

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AU2013903980 2013-10-16
AU2013903980A AU2013903980A0 (en) 2013-10-16 A top submerged injection lance with enhanced heat transfer

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109182655A (zh) * 2018-10-23 2019-01-11 王子晨 一种用于液低偏吹的吹气棒
CN113846202A (zh) * 2021-10-26 2021-12-28 西安建筑科技大学 一种气基竖炉还原气喷嘴及气基竖炉

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US3269829A (en) 1963-09-24 1966-08-30 United States Steel Corp Method and apparatus for introducing steam and oxygen into a bath of molten steel
US3321139A (en) 1963-11-25 1967-05-23 Siderurgie Fse Inst Rech Apparatus for treating molten metals
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WO2013000017A1 (fr) 2011-06-30 2013-01-03 Outotec Oyj Lances d'injection immergées par le haut
WO2013029092A1 (fr) 2011-09-02 2013-03-07 Outotec Oyj Lances permettant une injection submergée par le haut
WO2013080110A1 (fr) * 2011-11-30 2013-06-06 Outotec Oyj Lances refroidies par un fluide pour injection immergée par le haut

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US3269829A (en) 1963-09-24 1966-08-30 United States Steel Corp Method and apparatus for introducing steam and oxygen into a bath of molten steel
US3338570A (en) 1963-10-23 1967-08-29 Zimmer Karl-Otto Oxygen lance with a centrally located orifice
US3321139A (en) 1963-11-25 1967-05-23 Siderurgie Fse Inst Rech Apparatus for treating molten metals
US3521872A (en) 1966-04-13 1970-07-28 Noranda Mines Ltd Apparatus for controlling the temperature of metal lances in molten baths
US3411716A (en) 1966-05-11 1968-11-19 United States Steel Corp Oxygen lance for steelmaking furnaces
US3488044A (en) 1967-05-01 1970-01-06 Nat Steel Corp Apparatus for refining metal
US3876190A (en) 1969-06-25 1975-04-08 Commw Ind Gases Method and apparatus for feeding particulate materials to furnaces and the like
US3730505A (en) 1970-07-01 1973-05-01 Centro Speriment Metallurg Double delivery lance for refining the steel in the converter processes
US3802681A (en) 1971-04-10 1974-04-09 Messer Griesheim Gmbh Self-cooling lance for oxygen blowing
US3828850A (en) 1973-07-12 1974-08-13 Black Sivalls & Bryson Inc High temperature material introduction apparatus
US3889933A (en) 1974-02-28 1975-06-17 Int Nickel Canada Metallurgical lance
US4097030A (en) 1976-01-07 1978-06-27 Rene Desaar Lance for desulphurizing cast iron or steel
US4023676A (en) 1976-09-20 1977-05-17 Armco Steel Corporation Lance structure and method for oxygen refining of molten metal
US4251271A (en) 1977-05-09 1981-02-17 Commonwealth Scientific And Industrial Research Organization Submerged injection of gas into liquid-pyrometallurgical bath
US4326701A (en) 1979-09-29 1982-04-27 Kaiser Steel Corporation Lance apparatus
US4396182A (en) 1980-12-22 1983-08-02 Institut De Recherches De La Siderurgi Francaise Lance for blowing an oxydizing gas, especially oxygen, onto a bath of molten metal
US4541617A (en) 1982-04-23 1985-09-17 Sumitomo Metal Industries Lance structure for oxygen-blowing process in top-blown converters
US5251879A (en) 1989-09-29 1993-10-12 Floyd John M Top submerged injection with a shrouded lance
AU647669B2 (en) * 1991-09-20 1994-03-24 Ausmelt Pty Ltd Top submergable lance
US5308043A (en) 1991-09-20 1994-05-03 Ausmelt Pty. Ltd. Top submergable lance
US6565800B2 (en) 2000-05-30 2003-05-20 Technological Resources Pty Ltd Apparatus for injecting solid particulate material into a vessel
WO2013000017A1 (fr) 2011-06-30 2013-01-03 Outotec Oyj Lances d'injection immergées par le haut
WO2013029092A1 (fr) 2011-09-02 2013-03-07 Outotec Oyj Lances permettant une injection submergée par le haut
WO2013080110A1 (fr) * 2011-11-30 2013-06-06 Outotec Oyj Lances refroidies par un fluide pour injection immergée par le haut

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109182655A (zh) * 2018-10-23 2019-01-11 王子晨 一种用于液低偏吹的吹气棒
CN113846202A (zh) * 2021-10-26 2021-12-28 西安建筑科技大学 一种气基竖炉还原气喷嘴及气基竖炉
CN113846202B (zh) * 2021-10-26 2022-07-19 西安建筑科技大学 一种气基竖炉还原气喷嘴及气基竖炉

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