Title of Invention

A LANCE FOR INJECTING A FEED MATERIAL

Abstract

A lance (5) for injecting a feed material into a metallurgical vessel (3), comprises : i. an inlet (21) for the feed material ; ii. an outlet (23) at a forward end of the lance for discharging the feed material ; iii. an outer cooling jacket (35) extending to the forward end (23) of the lance; iv. a hollow elongate member (25) defining a passageway for the feed material between the inlet and the outlet and having passageways (33, 39) for a first cooling fluid, each passageway having an inlet and an outlet for cooling fluid at the forward end of the lance, and one of the passageways comprising an annular gap between an outer wall of the member and an inner wall of the jacket, and wherein the member extends beyond the jacket at the forward end of the lance ; and v. means for supporting the member so that it can move relative to the outer jacket in a lengthwise direction of the lance.

Full Text

-2- The present invention relates to a lance for injecting a feed material. "J The present invention relates particularly, although by no means exclusively, t to a lance that can be used in a metallurgical vessel on a continuous or batch basis and withstand substantial exposure to molten metal and slag in the vessel treat could chemically attack the lance and substantial variations in temperature in the vessel that could contribute to premature mechanical failure of the lance. The present invention relates more particularly, although by no means exclusively, to a lance that can be used in a range of operational positions to inject solid feed materials into a metallurgical vessel which contains a - 2A- bath of molten material having a layer of molten metal and a layer of slag with or without a mixture of molten metal and slag By the range of operational position includes but is noc limited to, positions in vhich the tip of the lance is: i. above the bath in a clear or splash zone; ii. immersed in the slag layer; or iii. immersed in the metal layer. The present invention relates inore particularly, although by no means exclusively, to a method of injecting solid feed materials into a metallurgical vessel that is based on the use of a lance of the present invention. The present invention relates more particularly, although by no means exclusively, to a lance that can be used to carry out the(HIsmelt) process for producing molten iron with top injection of solid feed materials, such aa coal, iron ore, and fluxes, to penetrate the surface of a bath of molten iron/slag in a metallurgical vessel. There is a wide range of known lances and tuyeres for injecting solid feed materials into metallurgical vessels for producing ferrous and non-ferrous metals and alloys. The known lances and tuyerea include by way of examplei i. The SAVARD-LEe bottom tuyere for the injection of oxygen through the refractory lining of metallurgical vessels. The tuyere comprises at least 2 concentric pipes. Typically, in use, oxygen is injected through the inner pipe and hydrocarbons (as coolant) are injected through the annular space(s) between the pipe(s). This type of tuyere is also used for injecting solids - 3 - entrained in & carrier gas instead of oxygen (Z-Bop, KS, KM3). Kortac AG has patented several particular concentric pipe combinations of th" tuyere which, in use, are cooled by hydrocarbon mixtures with water and a carrier aas. These combinations have been used in a wide range o£ applications. However, in general, the tuyere is sensitive to burn-back and erosion of refractories'around the tuyere. Typically, the burn-back velocity (and associated refractory erosion) is between 0.5 and 1.5 mm/hr. This rate of refractory loss limits tuyere life. ii. Kortec AG has also patented a horizontally or vertically movable tuyere with similar characteristics to the tuyere referred to in item i. The concentric pipes of the tuyere in this case are fixed in a round refractory sleeve and the resultant assembly of the sleeve and the pipes is progressively pushed into a metallurgical vessel to compensate for burn-back. By this method, erosion of refractories is minimised. iii. Inclined top lances, particularly for electric arc furnace applications, for the injection oE oxygen, coal, and other solids. These lances are water cooled and in a furnace operation are moved into a slag layer but are kept away from the molten metal layer to ensure that there is minimal contact withsmciten metal. Typically, the lances have A limited lifetime of 500-2000 heats (200-800 operational hours) before repairs and maintenance are retired. other known lances and tuyeres include, but are not limited to Cirosmeit lances, Ausmelt lances and steal pipes (and refractory coated steel pipes) used in. the iron and steel industries for injecting gas and solids. However; notwithstanding the wide range of known lances, the applicant is. not aware of a lance that is -4 - capable of withstanding substantial exposure to molten iron and substantialjong term and continuous temperature variations as would be required in order to be used in the Hlsmelt or similar process when operated with top injection of feed materials. An object of the present invention is to provide of operating under these conditions. According to the present invention there is provided a lance foK-injecting a feed material into a metallurgical vessel, said lance comprising : i. an inlet for introducing the feed material into the lance ; ii. an outlet at a forward end of the lance for discharging the feed material from the lance ; iii. an outer cooling jacket extending to the forward end of the lance ; iv. a hollow elongate member that defines a passageway for the feed material between the inlet and the outlet and having at least two cooling fluid passageways for a first cooling fluid, each cooling fluid passageway having an inlet for the first cooling fluid and an outlet for discharging the first cooling fluid at the forward end of the lance, and one of the cooling fluid passageways being in the form of an annular gap between an outer wall of the member and an inner wall of the outer jacket, and wherein the member extends beyond the outer jacket at the forward end of the lance ; and v. means for supporting the member so that the member can move relative to the outer jacket in a lengthwise direction of the lance to maintain initial relative positions of the outer jacket and the member at the forward end of the lance. -4A- In use, the jacket and the second cooling fluid that flows through the jacket acts as a shield for the enclosed section of the length of the member and prevents direct damage to this part of the member that could be caused by contact i with molten metal and/or slag and minimises adverse effects of high temperature and, variations in temperature along the length of the member. In addition, in use, the first cooling fluid chat flows through the member protects the member from adverse effects of the high temperature environment: (i) externally of the member,^including>where the member extends beyond the jacket at the forward end of the lance; and (ii) internally o£ the member in situations where tha feed material is preheated. It is preferred, although by no means essential, that the member be tubular. It is preferred that the member extend beyond the jacket at the forward end of the lance. It is preferred that the member comprise at least one passageway for the first cooling fluid. It is preferred that the member comprise an inlet for introducing the firot cooling fluid into the cooling fluid passageway and an outlet for discharging heated first Cooling fluid from the cooling fluid passageway. It is preferred that the cooling fluid passageway outlet be in the region of the forward end of the lance. It is preferred that the cooling.fluid passageway be in the form of an annular chamber. It is preferred that the first cooling fluid comprise a mixture of water and a gas, such as nitrogen or carbon monoxide or argon. - 5 - XUe first cooling fluid may also comprise one or more other gases that, in use, are of benefit in. a metallurgical process. It is preferred that the lance further comprised a means for a.toniisiny water in the water/gas mixture; It is preferred particularly that the atomising means be located at th(c) inlet of the cooling fluid passageway. It is preferred that the member have two or more of the cooling fluid passageways for the firgt cooling fluid. With such ari arr"angemenQit is preferred particularly that the cooling fluid pausageways be concentric annular chambers. Xb is preferred that the member 'Compromise an outer wall and an inner wall and that one of the annular cooling fluid chambers be between th(c) outer wall and the inner wall. With such an arrangement, it is preferred that the other or one of the other annular cooling fluid chambers be an annular gap between the outer wall of the member and an inner wall of the jacket .^ it is preferred that the lance further comprises a means for supporting the member so that the member can move relative to the jacket in the lengthwise direction of the lance. It is preferred that" the lance further comprises a means for moving the member relative to the jacket to compensate for erosion of the member the,forward end of - 7 - the l*nea and thereby maintain initial relative positions of the jacket and the member (c)t th(c) forward end of th" lance. It is preferred that the jacket be positioned around a section of the member that is at the forward end Of the lance. It is preferred that the jacket define a chamber for the second cooling fluid. It is preferred that the chamber be closed at the forward end of the lance. It is preferred particularly that the chamber be an annular chamber. With such an arrangement, it is preferred that the jacket comprises an inlet for introducing the second cooling fluid into the chamber and an outlet for discharging heated second cooling fluid from the chamber. It is preferred that the lance comprises a means for regulating the flow rate of the second cooling fluid to the chamber inlet. It is preferred particularly that in use of the lance the flow rate be regulated to form and maintain a freeze layer of molten metal/slag on the outer surface of the jacket. It is preferred that the 0econd cooling fluid be water. According to the present invention there is provided a method of injecting solid feed materials into a metallurgical vessel containing a bath of molten metal and slag which method comprison: - 8 - i. positioning the lance as described above in the metallurgical vessel to operate eelecfcivoiy in 3. range of operational positions which include: a. above the bath in a clear or splash zone; b. immersed in a slag layer in the bath; and c. immersed in a metal layer in the bath. ii. injecting the feed material to the bath via the passageway of the member of the lance; iii. supplying a firflt cooling fluid to tho member; and iv. supplying a second cooling fluid to the jacket of the lance so that the jacket and tho second > cooling fluid form a shield for the encloseci section of the length of the member. The present invention is described .(Sur-t-her, with reference to the accompanying drawings of which: , Figure 1 io a nketch illustrating a metallurgical vessel with a top injection lance extending through a side wall of the vessel;, and Figure 2 is a vertical section through a preferred embodiment of a top injection lance in accordance with the present invention, / The following description is in the context of smelting iron ore to produce molten iron and it is understood that the present invention is not limited to this application and is applicable generally-to the - 9 - production of ferrous and non-ferrous metals and alloys in metallurgical vessels. Figure 1 illustrates, albeit in simplified schematic form, on(c) possible embodiment of an apparatus for smelting iron or(c) in accordance with the HIeraelt process when operated with top injection of solid feed materials. The apparatus comprises a metallurgical vessel 3 having a metal shell and a lining of refractory material which is adapted to retain a bath 9 o£ moljten .material comprising layers of molten iron and alag and mixtures of molten iron and alag. Tho vessel 3 comprises a bottom 4, a cylindrical side wall 6, a roof 20 and a gas outlet 8. The apparatus also comprises a lance 5 for injecting.solid feed materials, such as iron ore (including pre-reduced iron ore), coal, and flux, in a hot or cold state, entrained in a suitable transport gas, such as air, nitrogen, and natural gas into the bath 9. The lance 5 is ¦arranged to extend through the side wall 6 of the vessel 3 and can be positioned in. a rang(c) of operational pooitionc including the position shown in Figure 1 in which a tip portion 13 of the lance 5 is a short distance above the surface of the bath $. Other operational positions, which Include submerging the tip portion 13 in the slag layer and in the slag/metal layers, can be adopted. The apparatusifurther compris3S a- top, lance 10 for injeoting oxygen-containing gas into the. vessel 3. The lance 10 is positioned to extend through th(c) roof 20 of the vessel. Typically, in use, the vessel 3 will contain temperature zones varying from 145O°C - 2000°c. Specifically, in order to function over the rang(c) of operational positions noted above, in use, the lance 5 -10- ¦ would have to withstand temperatures of the order of 1500°C in the bath 9 and up to 2000°C in the gas space above the bath 9. With reference to Figure 2, the lance 5 comprises an inlet end 21 for introducing solid feed materials into the lance 5 and an outlet end 23 for discharging ^ the solid feed materials from the lance 5. , ' The lance 5 also comprises a hollow elongate tubular member, generally us identified by the numeral 25, that defines a central passageway 19 that extends along the length of the lance 5 between the inlet end 21 and the outlet end 23. The outlet end 23 forms the forward end of the lance 5. In use, solid feed materials entrained in a suitable transport gas flow along the passageway 19 from the inlet end 21 and are discharged from the outlet or forward end 23 of the lance 5. The tubular member 25 comprises three concentric tubes, with an inner tube 27 formed from a ceramic material and an intermediate tube 29 and an outer tube 31 formed from stainless steel. The tubular member 25 is formed so that there is an annular gap between the intermediate tube 29 and the outer tube 31, and the gap defines an annular passageway 33 for a cooling fluid in the form of a mixture of atomised water and a gas, such as nitrogen, carbon monoxide, or argon. The lance 5 further comprises a water-cooled outer jacket 35 that is positioned around a section of the length of the tubular member 25 in the region of the forward or outlet end 23 of the lance 5. - 11 - The jacket 35 is formed so that there is an annular gap between the tubular member 25 and the jacket 35, and the gap defines another annular passageway 39 for the atomised water/gas mixture. The lance 5 further comprises manifold chambers 41, 43 which define inlets for tho atomised water/gas mixture to the cooling fluid passageways 33, 39. m use, th(c) atomised water/gas mixture that i" injected via the manifold chambers 41, 43 flows along the'passageways 33, 39 and is discharged at the forward or outlet end 23 of the lane(c) 5. The jacket 35 is formed from stainless steel and defines an annular chamber 37. The forward end of the chamber 37 is closed. Tho jacket 35 comprioefl an inlet 45 for cooling water and an outlet 47 for heated cooling water in diametrically opposed sections of the jacket 3 5 that are distal from the forward or outlet and 2 3 of the lance 5. In use, cooling water that is injected via the inlet 45 flows through th(c) chamber 37 and is discharged as heated water from the outlot 47. * The jacket 35ffurthe.it comprises an annular tube 49 positioned in the chamber 37 to divide the chamber 37 into inner and outer regions. The purpose of the tube 49 is to optimise neat transfer fco_thQ_e.O££j.ng water-, Th(c) lance S is formed so' .that tho tubular member 25 is alidable relative to the jacket 35. This feature is provided to allow the tubular member 25 to be moved progressively toward th(c) forward or outlet end 23 of the lance 5 to maintain the relative positions of the tubular member 25 and the jacket 35 as shown in Figure 2, rhia is necessary to compensate for tho progressive wearing away of the tubular member 2S at the forward or outlet end 23 of - 12 - the lance 5 which is an inevitable outcome of the use of the lance 5 in the metallurgical vessel 3. The applicant has found in trials of. the lance 5 described above in a metallurgical vessel 3 containing a bath 9 of a molten iron, and slag that the lance 5 could effectively withstand the environment of the vessel 3. Many modifications may the made to the preferred embodiment of the lance 5 described above without departing from the spirit and scope of the-present invention. WE CLAIM : 1. A lance for injecting a feed material into a metallurgical* vessel/ said lance comprising: i. an inlet for introducing the feed material into the lance it. an outlet at a forward end of the lance for discharging the feed material from the lance; iii. an outer cooling jacket extending to the forward end of the lance. iv. a hollow elongate member that defines a passageway for the feed material between the inlet and the outlet and having at least two cooling fluid passageways for a first cooling fluid, each cooling fluid passageway having an inlet for the first cooling fluid and an outlet for discharging the first cooling fluid at the forward end of the lance, and one of the cooling fluid passageways being in the form of an annular gap between an outer wall of the member and an inner wall of the outer jacket, and wherein the member extends beyond the outer jacket at the forward end of the lance ; and ^^'f ^ -v. means for supporting the member so that the member can move relative to the outer jacket in a lengthwise direction of the lance to maintain initial relative positions of the outer jacket and the member at the forward end of the lance. 2. The lance as claimed in claim 1, wherein the first cooling fluid comprises a mixture of water and a gas. -14- 3. The lance as claimed in claim 2, comprising means for atomising water in the water/gas mixture, said means being located at the inlet of each cooling fluid passageway. 4. The lance as claimed in claim 1, wherein one of the cooling fluid passageways comprises an annular gap formed between an inner wall and the ' outer wall of the member. 5. The lance as claimed in claim 1 comprising means for moving the member relative to the outer jacket to compensate for erosion of the member at the forward end of the lance and thereby maintaining initial relative positions of the outer jacket and the member at the forward end of the lance. 6. The lance as claimed in claim 1, wherein the outer jacket defines a chamber for a second cooling fluid. 7. The lance as claimed in claim 6, wherein the chamber is closed at the forward end of the lance. 8. The lance as claimed in claim 6, wherein the chamber is an annular chamber. 7. -15- 9. The lance as claimed in claim 6, wherein the outer jacket has an inlet for introducing the second cooling fluid into the chamber and an outlet for discharging the second cooling fluid from the chamber. 10. The lance as claimed in claim 9, comprising means for regulating the flow rate of the second cooling fluid to the chamber inlet. v •* * 11. A method of injecting solid feed materials into a metallurgical vessel * containing a bath of molten metal and slag, said method comprising : i. positioning the lance as claimed in any of claims 1 to 10 in the metallurgical vessel to operate selectively in a range of operational positions comprising : a. above the bath in a clear or splash zone ; b. immersed in a slag layer in the bath ; and c. immersed in a metal layer in the bath ; ii. injecting the feed material to the bath via the passageway of the member of the lance ; iit. supplying a first cooling fluid to the member ;.and iv. supplying a second cooling fluid to the jacket of the lance so that the jacket and the second cooling fluid form a shield for the enclosed section of the length of the member. 12. The method claimed in claim 11, wherein the flow rate of the second cooling fluid is regulated to form a freeze layer of metal/slag on an outer surface of the jacket. -16- 13. The method as claimed in claims 11 or 12, wherein the temperature of the bath is up to 1500°C and the temperature of the gas space above the bath is up to 2000°C. 14 . The method as claimed in any one of claims 11 to 13, wherein the, bath contains molten iron and slag and the solid feed materials comprise any one or more of coal, iron ore and fluxes. 15. A lance for injecting a feed material into a metallurgical vessel, substantially as herein described, particularly with reference to and as illustrated in the accompanying drawings. A lance (5) for injecting a feed material into a metallurgical vessel (3), comprises : i. an inlet (21) for the feed material ; ii. an outlet (23) at a forward end of the lance for discharging the feed material ; iii. an outer cooling jacket (35) extending to the forward end (23) of the lance; iv. a hollow elongate member (25) defining a passageway for the feed material between the inlet and the outlet and having passageways (33, 39) for a first cooling fluid, each passageway having an inlet and an outlet for cooling fluid at the forward end of the lance, and one of the passageways comprising an annular gap between an outer wall of the member and an inner wall of the jacket, and wherein the member extends beyond the jacket at the forward end of the lance ; and v. means for supporting the member so that it can move relative to the outer jacket in a lengthwise direction of the lance.

Documents:

01315-cal-1997-abstract.pdf

01315-cal-1997-claims.pdf

01315-cal-1997-correspondence-1.1.pdf

01315-cal-1997-correspondence-1.2.pdf

01315-cal-1997-correspondence-1.3.pdf

01315-cal-1997-correspondence.pdf

01315-cal-1997-description(complete).pdf

01315-cal-1997-drawings.pdf

01315-cal-1997-form-1.pdf

01315-cal-1997-form-13.pdf

01315-cal-1997-form-2.pdf

01315-cal-1997-form-3.pdf

01315-cal-1997-form-5.pdf

01315-cal-1997-p.a.pdf

01315-cal-1997-priority document.pdf

1315-cal-1997-granted-abstract.pdf

1315-cal-1997-granted-acceptance publication.pdf

1315-cal-1997-granted-claims.pdf

1315-cal-1997-granted-correspondence.pdf

1315-cal-1997-granted-description (complete).pdf

1315-cal-1997-granted-drawings.pdf

1315-cal-1997-granted-examination report.pdf

1315-cal-1997-granted-form 1.pdf

1315-cal-1997-granted-form 13.pdf

1315-cal-1997-granted-form 2.pdf

1315-cal-1997-granted-form 3.pdf

1315-cal-1997-granted-form 5.pdf

1315-cal-1997-granted-letter patent.pdf

1315-cal-1997-granted-pa.pdf

1315-cal-1997-granted-reply to examination report.pdf

1315-cal-1997-granted-specification.pdf

1315-cal-1997-granted-translated copy of priority document.pdf