Claims:We Claim:

1. A system (100) for determining a remnant length of a tuyere (5) in a metallurgical furnace, the system comprising:
an electric sensor (3) enclosed in a case (1);
wherein the case (1) is housed into an aperture (6) defined in the tuyere (5) and extending along a length of the tuyere (5) from a front end (5b) to a rear end (5c);
a transceiver (11) coupled to the electric sensor (3) wherein, the transceiver (11) is configured to:
transmit electric current through the electric sensor (3) and measure a resistance offered by the electric sensor (3); and
determine the measured resistance, wherein the measured resistance is indicative of the length of the sensor (3) which corresponds to the remnant length of the tuyere (5).

2. The system (100) as claimed in claim 1, wherein the transceiver (11) includes at least one of an ohmmeter and multimeter for measuring the resistance offered by the electric sensor (3).

3. The system (100) as claimed in claim 1, comprises a cover plate (7) positioned above the case (1) in the aperture (6) of the tuyere (5).

4. The system (100) as claimed in claim 1, wherein the case (1) accommodating the electric sensor (3) is filled with an electrically insulating material (2).

5. The system (100) as claimed in claim 1, wherein the electric sensor (3) includes a parallel electric circuit of a plurality of resistors (10).

6. The system (100) as claimed in claim 5, wherein the plurality of resistors (10) are positioned at equal distances from each other in the parallel electric circuit, extending along the length of the tuyere (5).

7. The system (100) as claimed in claim 6, wherein the distance between each of the plurality of resistors (10) in the parallel electric circuit is at least 2 mm.

8. The system (100) as claimed in claim 1, wherein the resistance offered by the electric sensor (3) is inversely proportional to the length of the electric sensor (3).

9. The system (100) as claimed in claim 1, wherein the electric sensor (3) is structured to deform corresponding to deformation of the outlet end of the tuyere (5).

10. A method for determining a remnant length of a tuyere (5) in a metallurgical furnace, the method comprising:
inserting an electric sensor (3) accommodated in a case (1), into an aperture (6) defined in the tuyere (5) and extending along a length of the tuyere (5);
coupling the electric sensor (3) to the transceiver (11), wherein the transceiver (11) is configured to;
transmit electric current through the electric sensor (3) and measuring a resistance offered by the electric sensor (3);
determine and indicate the measured resistance by the transceiver (11), wherein the determined resistance is indicative of the length of the sensor (3) and the remnant length of the tuyere (5).

11. The method (100) as claimed in claim 10, wherein the electric sensor (3) deforms corresponding to deformation of the outlet end of the tuyere (5).

Dated 30th day of March 2021.

GOPINATH A S
IN/PA 1852
OF K&S PARTNERS
AGENT FOR THE APPLICANT , Description:TECHNICAL FIELD

Present disclosure relates in general to a field of metallurgy. Particularly, but not exclusively, the present disclosure relates to metallurgical furnaces. Further, embodiments of the present disclosure discloses a system for measuring a remnant length of a tuyere used in the metallurgical furnace.

BACKGROUND OF THE DISCLOSURE

Generally, iron making process is a process in which coke is used as a fuel and an iron ore is used as a raw material. The raw materials are charged into an iron making furnace or a metallurgical furnace through a charging inlet and hot air is introduced into the furnace through a blast passage of a tuyere. A blast furnace is a metallurgical reactor used for ore smelting to produce industrial metals, especially iron. In the blast furnace, fuel, ores, and flux are supplied through the top of the furnace, while a hot blast of air (compressed air and oxygen) is blown into the lower section of the furnace through tuyeres, so that the chemical reactions take place throughout the furnace as the material falls downwards. Iron composite ores get reduced to liquid iron while descending from the top and is tapped out from the bottom and waste gases exits from the top of the furnace. The tuyere which supplies the hot blast of air is provided in a lower part of the furnace.

The tuyere is a conical body made of copper through which hot blast and fuels like pulverized coal are injected. The tuyere may be defined by a central body and a nose at the tip of the body. To introduce hot air into the iron making furnace, the tuyere is provided/integrated in the wall of the furnace. Here, to realize a desired airtight structure of the tuyere regardless of the internal pressure of the furnace, the tuyere is typically installed to protrude inwards into the furnace. Because the tuyere has an inward protruding structure as mentioned above, the tuyere must be prevented from being fused or damaged by heat inside the furnace. The tuyere is typically provided with a water-cooling system, in which cooling water is introduced into the tuyere through an inlet and circulates through a cooling passage while cooling the tuyere prior to being discharged from the tuyere through an outlet.

A tuyere nose extends into the blast furnace through the wall and faces the inner lining of the blast furnace, which is exposed to high temperatures and eroding environment. So, the chances of rupture of tuyere nose are high. The tuyere failure is a common industrial phenomenon which leads to breakdown and production loss. Burning of the tuyere nose is one of the reasons which leads to failure of blast furnace. It leads to leakage from water cooling circuit which increases the chances of water ingress in the blast furnace. The leakage of cooling water into the blast furnace, which if remains unnoticed for a longer time lowers down the local temperature and affects the quality of molten metal. The burning nose of tuyere will further lead to burning of tuyere body which will initiate leakage from body cooling circuit. Heavy water leakage poses a danger of explosion so it is very important to measure the tuyere nose burn quantitatively so that timely replacement can take place. Identification of tuyere nose burn at an early stage will prevent process disturbances and downtime due to water leakage in the blast furnace and burning of tuyere body.

The present disclosure is directed to overcome one or more limitations stated above or any other limitations associated with the conventional arts.

The information disclosed in this background of the disclosure section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.

SUMMARY OF THE DISCLOSURE

One or more shortcomings of the prior art are overcome by an assembly and a method as disclosed and additional advantages are provided through the assembly and the method as described in the present disclosure.

Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In a non-limiting embodiment of the disclosure, a system for determining a remnant length of a tuyere in a metallurgical furnace is disclosed. The system includes an electric sensor enclosed in a case where the case is housed in an aperture defined in the tuyere and extends along a length of the tuyere from a front end to a rear end. A transceiver is coupled to the electric sensor where, the transceiver is configured to transmit electric current through the electric sensor and measure a resistance offered by the electric sensor. The transceiver also determines the measured resistance, where the measured resistance is indicative of the length of the sensor which corresponds to the remnant length of the tuyere.

In an embodiment of the disclosure, the transceiver includes at least one of an ohmmeter and multimeter for measuring the resistance offered by the electric sensor.

In an embodiment of the disclosure, the system includes a cover plate is positioned above the case in the aperture of the tuyere.

In an embodiment of the disclosure, the case accommodating the electric sensor is filled with an electrically insulating material.

In an embodiment of the disclosure, the electric sensor includes a parallel electric circuit of a plurality of resistors.

In an embodiment of the disclosure, the plurality of resistors are positioned at equal distances from each other in the parallel electric circuit, extending along the length of the tuyere.

In an embodiment of the disclosure, the distance between each of the plurality of resistors in the parallel electric circuit is at least 2 mm.

In an embodiment of the disclosure, the resistance offered by the electric sensor is inversely proportional to the length of the electric sensor.

In an embodiment of the disclosure, the electric sensor is structured to deform corresponding to deformation of the outlet end of the tuyere.

In another non-limiting embodiment of the disclosure, a method for determining a remnant length of a tuyere in a metallurgical furnace is disclosed. The method includes steps of inserting an electric sensor accommodated in a case, into an aperture defined in the tuyere and extends along a length of the tuyere. Further, the electric sensor is coupled to the transceiver, where the transceiver is configured to transmit electric current through the electric sensor and measure a resistance offered by the electric sensor. The transceiver determines and indicates the measured resistance where the determined resistance is indicative of the length of the sensor and the remnant length of the tuyere.

It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the disclosure.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

The novel features and characteristics of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

Fig. 1 illustrates a perspective view of a tuyere, in accordance with some embodiments of present disclosure.

Fig. 2 illustrates a side sectional view of the tuyere with a system for determining a remnant length of the tuyere, in accordance with some embodiments of present disclosure.

Fig. 3 illustrates a rear view of a portion of the tuyere with the system for determining the remnant length of the tuyere, in accordance with some embodiments of present disclosure.

Fig. 4 illustrates a schematic view of the system for determining the remnant length of the tuyere, in accordance with some embodiments of present disclosure.

Fig. 5 illustrates a schematic view of a casing of the system for determining the remnant length of the tuyere, in accordance with some embodiments of present disclosure.

Fig. 6 illustrates a schematic view of an electric sensor in the system for determining the remnant length of the tuyere, in accordance with some embodiments of present disclosure.

Fig. 7 is a graph illustrating an equivalent resistance and number resistors in a system for determining a remnant length of a tuyere, in accordance with some embodiments of present disclosure.

Figure 8 is a flowchart for measuring the remnant length of the tuyere, in accordance with some embodiments of present disclosure.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the system for determining the remnant length of the tuyere illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other devices for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the scope of the disclosure. The novel features which are believed to be characteristic of the disclosure, as to its organization, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described below. It should be understood, however that it is not intended to limit the disclosure to the particular form disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.

The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a system that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such mechanism. In other words, one or more elements in the device or mechanism proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the mechanism.

Embodiments of the present disclosure discloses a system for determining a remnant length of a tuyere. A tuyere nose is exposed to high temperatures and eroding environment in the metallurgical furnace. Consequently, the tuyere failure is a common industrial phenomenon which leads to breakdown and production loss. Burning of the exposed tuyere nose is one of the reasons which leads to failure of metallurgical furnace such as blast furnace. Failure of tuyere nose leads to leakage of water from the cooling circuit which increases the chances of water ingress in the blast furnace. The leakage of cooling water into the blast furnace, which if remains unnoticed for a longer time lowers the local temperature and affects the quality of molten metal. The burning nose of tuyere will further lead to burning of tuyere body which will initiate leakage from the cooling circuit. Further, heavy water leakage poses a danger of explosion of the blast furnace so it is very important to measure the tuyere nose burn quantitatively so that timely replacement can take place.

Accordingly, the present disclosure discloses a system for determining a remnant length of a tuyere.

The following paragraphs describe the present disclosure with reference to Figures. 1 to 7. In the figures, the same element or elements which have similar functions are indicated by the same reference signs. For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to specific embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended, such alterations and further modifications in the illustrated methods, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention pertains.

The following detailed description is merely exemplary in nature and is not intended to limit application and uses. Furthermore, there is no intention to be bound by any theory presented in the preceding background or summary or the following detailed description. It is to be understood that the disclosure may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices or components illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions or other physical characteristics relating to the embodiments that may be disclosed are not to be considered as limiting, unless the claims expressly state otherwise. Hereinafter, preferred embodiments of the present disclosure will be described referring to the accompanying drawings. While some specific terms directed to a specific direction will be used, the purpose of usage of these terms or words is merely to facilitate understanding of the present invention referring to the drawings. Accordingly, it should be noted that the meanings of these terms or words should not improperly limit the technical scope of the present invention.

Fig. 1 illustrates a perspective view of a tuyere (5). The tuyere (5) is a part of tuyere arrangement in a metallurgical furnace such as blast furnace [not shown]. The tuyere arrangement may be designed for feeding hot blast air to an interior of the metallurgical furnace through the metallurgical furnace wall. In an embodiment, the tuyere (5) may be of converging nozzle shape or a conical shape. A converging end of the tuyere (5) may be defined with a nose (12). The nose (12) may be the tip of the tuyere and may be the region through which the hot blast air exits the tuyere (5). The nose (12) of the tuyere (5) may configured to be inside the metallurgical furnace. The tuyere (5) may be maintained in position by a holder and a cooling jacket may be configured within the tuyere (5) for maintaining the temperatures of the tuyere (5) at required levels. Referring now to Fig. 1, the tuyere (5) may include a tuyere body (5a). The tuyere body (5a) may be made of materials such as but not limiting to copper and alloys of copper. The tuyere body (5a) is defined with a front end (5b) and a rear end (5c) opposite to the front end (5b). In an embodiment, a passage (C) may be defined at a substantially central portion of the tuyere body (5a). The passage (C) may extend from the rear end (5c) to the front end (5b) of the tuyere body (5a). In an embodiment, the passage (C) may define an inner surface of the tuyere body (5a) and the tuyere body (5a) may be included on an outer surface. The rear end (5c) of the tuyere body (5a) may be configured to receive a blow pipe. In an embodiment, the rear end (5c) of the tuyere body (5a) may be fluidly connected to the blow pipe and may be configured to channelize hot blast of air from a hot blast air supply unit to the interior of the metallurgical furnace.

The portion of the outer surface of the tuyere body (5a) facing the interior of the metallurgical furnace may be designed to accommodate one or more coatings such as nickel-chromium [Ni-Cr] based super alloy coating. In an embodiment, the Ni-Cr based coating (9) may be provided on the entire outer surface of the tuyere body (5a) to prevent erosion of the tuyere (5).

Fig. 2 and Fig. 3 illustrates a side sectional view and a rear view of the tuyere (5) with a system (100) for determining a remnant length of the tuyere (5). The system (100) may include a case (1) with an electric sensor (3) housed within the case (1) [seen from Fig. 4]. Further, the tuyere body (5a) may be defined with an aperture (6) extending through-out the length of the tuyere (5). The aperture (6) may be defined below a pre-determined distance from the outer surface of the tuyere body (5a). The aperture (6) may be defined below a Ni-Cr coated (9) layer on the tuyere body (5a). The aperture (6) may extend from the rear end (5c) to the front end (5b) of the tuyere body (5a) and may be configured to house the system (100) for measuring the remnant length of the tuyere (5). The aperture (6) may be defined with an opening at the rear end (5c) of the tuyere (5) such that, the system (100) may be removably accommodated within the aperture (6). Further, the aperture (6) may also house a cover plate (7). The cover plate (7) may be defined with a width that is equivalent to the width of the case (1). The cover plate (7) may act as an enclosing member for firmly housing the system (100) inside the aperture (6) of the tuyere body (5a). The thickness of the cover plate (7) may vary and may be adapted based on the thickness of the system (100) such that the system (100) and the cover plate (7) are housed with minimal tolerance inside the aperture (6) of the tuyere body (5a). The configuration of the system (100) for measuring the remnant length of the tuyere (5) is explained with greater detail below.

Fig. 4 illustrates a schematic view of the system (100) for determining the remnant length of the tuyere (5) and Fig. 5 illustrates a schematic view of the casing (1) of the system (100) for determining the remnant length of the tuyere (5). The system (100) includes the case (1) which may be defined to house the electric sensor (3). The case (1) may be enclosed at one end whereas, the other end of the case (1) may be defined with a slot or an opening for accommodating the electric sensor (3). The case (1) may also be defined such that, a hollow region is defined within the case (1) for accommodating the electric sensor (3). The case (1) may be a metal cast body having similar thermal properties of tuyere (5) and may also be made of same material as that of the tuyere (5). In an embodiment, the case (1) may be a two-part component as seem from Fig. 5. Each part of the case (1) may be cast to define a hollow internal region of dimensions equivalent or larger than the dimensions of the electric sensor (3). The two parts may further be assembled together and may be fixedly connected together by any method known in the art including but not limited to welding, brazing etc. Further, the electric sensor (3) may be removably housed inside the case (1) and the case may be filled by an electrically insulating material (2). The electrically insulating material (2) may be filled between an inner surface of the case (1) and an outer surface of the electric sensor (3). In an embodiment, the electrically insulating material (2) may provide the required insulation against external electric currents and high temperatures for enabling the suitable functioning of the electric sensor (3). The electric sensor (3) may further be connected to a transceiver (11) by a plurality of leads (4) for transmitting and receiving electric current. The configuration of the electric sensor (3) is explained with greater detain below.

Fig. 6 illustrates a schematic view of an electric sensor (3) in the system (100) for determining the remnant length of the tuyere (5). The electric sensor (3) may include a first lead wire (13) and a second lead wire (14). The first lead wire (13) may extend longitudinally throughout the length of the electric sensor (3) and may be provided at one of the longitudinal end of the electric sensor (3). The second lead wire (14) may be connected with at least one resistor (10) [herein after referred to as “the resistor”] and may be configured to extend along the other longitudinal end opposite to the first lead wire (13). The second lead wire (14) may initially extend laterally defining a lateral rear end (14b). The second lead wire (14) may extend throughout the width of the electric sensor (3), defining the lateral rear end (14b). The second lead wire (14) may further extend longitudinally from the lateral rear end (14b) of the second lead wire (14) defining a longitudinal section (14a) of the second lead wire (14). The longitudinal section (14a) of the second lead wire (14a) may extend throughout the length of the electric sensor (3) as seen in the Fig. 6. Further, the second lead wire (14) may again extend in a direction perpendicular to the longitudinal section (14a) of the second lead wire (14) to define a lateral front end (14c) of the second lead wire (14). The lateral front end (14c) of the second lead wire (14) may again extend laterally encompassing the overall width of the electric sensor (3). The lateral front end (14c) of the second lead wire (14) may connect with the first lead wire (13), thereby forming a closed circuit. In an embodiment, the first lead wire (13) and the second lead wire (14) may be a single loop wire extending laterally and longitudinally throughout the electric sensor (3). In an embodiment, the first lead wire (13) and the second lead wire (14) may be configured to define a circuit with a shape including but not limited to a rectangular shape encompassing the overall area of the electric sensor (3). Further, the resistor (10) may be configured to the second lead wire (14) along at least one of the longitudinal section (14a) and the lateral front end (14c) of the second lead wire (14). Furthermore, a plurality of wires (15) with resistors (15) may be configured between the lateral rear end (14b) and first lead wire (13). The plurality of wires (15) with the resistors (10) may be configured with a parallel connection between each other. Each of the plurality of wires (15) may be connected to the first lead wire (13) at a pre-determined distance (X) from lateral front end (14c) of the second lead wire (14). The pre-determined distance (X) may be greater than 2 mm and the same must not be considered as a limitation. In an embodiment, each of the plurality of wires (15) may extend longitudinally from the lateral rear end (14b) of the second lead wire (14) to the pre-determined distance from the lateral front end (14c) of the second lead wire (14). Similarly, each of the plurality of wires (15) may further extend laterally and may be connected to the first lead wire (13). In an embodiment, the distance between each of the plurality of wires (15) at the region where they are connected to the first lead wire (13) may be equal throughout. In an embodiment, the electric sensor (3) with the first lead wire (13), the second lead wire (14) and the plurality of resistors (10) may be printed on a circuit board forming the electric sensor (3).

Further, measuring of the remnant length of the tuyere (5) through the system (100) is explained with greater detail below. The transceiver (11) connected to the electric sensor (3) may measure the resistance offered by the electric sensor (3) for determining the remnant length of the tuyere (5). Fig. 7 is a graph illustrating the relationship between an equivalent resistance and number resistors (10) embodied in the system (100) for determining the remnant length of the tuyere (5). When resistors (10) are connected between same two nodes, they are in parallel connection. Resistors (10) connected in parallel have same voltage drops, but the currents flowing through these resistors (10) depends on the resistance value of the resistors (10). The equivalent resistance of the electrical circuit is inversely proportional with the number of resistors (10) connected in the parallel circuit. In an embodiment, when ‘N’ number of resistors having equal resistance of R ohms are connected in parallel, the equivalent resistance of the electric circuit become R/N. Similarly, the equivalent resistance of the parallel circuit increases with the decrease in the number of resistors connected in the circuit. This tendency is exploited to detect the remnant thickness of tuyere nose (5b). As mentioned above, the electrical sensor (3) may be embedded in the tuyere body (5a) and the resistive behavior of the electric sensor (3a) may be monitored to detect the remnant thickness of the tuyere (5).

Figure 8 illustrates a flowchart for measuring the remnant length of the tuyere (5). The method of measuring the length of the tuyere (5) involves transmitting an electric current from the transceiver (11) to the electric sensor (3) through the leads at step 201. The transceiver (11) may also measure the resistance offered by the electric sensor (3) after the current is transmitted through the electric sensor (3) at the step 202. The transceiver (11) may include at least one of an ohmmeter and multimeter or any other devices known in the art for measuring the resistance offered by the electric sensor (3). The measured resistance may further be used to estimate or determine the length of tuyere (5) at the step 203. The determined resistance may also be suitably indicated by the transceiver (11) to a user. Upon exposure of the tuyere (5) to high temperature environment in the blast furnace, the tip, or the front end (5b) of the tuyere (5) may be consumed and the length of the tuyere (5) may consequently be reduced. Further, the lateral front end (14c) of the second lead wire (14) may also be consumed as the tip of tuyere (5) or the front end (5b) of the tuyere (5) is consumed. Consequently, the corresponding circuit may be disconnected and the resistor (10) in that particular circuit may also be disengaged. Therefore, the overall resistance offered by the electric sensor (3) may increase as one of the resistor (10) connected in parallel is disengaged. Further, when the electric current is passed by the transceiver (11) to the electric sensor (3), the equivalent resistance of the electric sensor (3) increases and this increase in the equivalent resistance may be detected by the transceiver (11). Since, the resistance offered by each resistor (10) is already known, the increase in equivalent resistance may be substituted with known values of the equivalent resistance for determining the length of tuyere (5). Further, as the tuyere (5) is further consumed in the blast furnace, a second lateral front end (14c2) may be consumed, and the equivalent resistance may further increase. This equivalent resistance may further be detected and measured by the transceiver (11) for measuring the length of tuyere (5).

The electric sensor (3) has a printed circuit of parallel connection of resistors (10) having equal resistances. The number of resistors (10) connected in the parallel circuit decreases with consumption of electric sensor (3) from the front end (5b) of the tuyere (5). In an exemplary embodiment, the distance (X) between each of the lateral front ends (14c) connected to the first lead wire (13) may be 5 mm.

In this exemplary embodiment, a number of ten resistors (10) having resistance of 1 kilo ohms each are fabricated to monitor remnant thickness of 45 mm of tuyere (5). The electric sensor (3) embedded in sensor case (1) is placed in blast furnace like environment. The electric sensor (3) gets eroded from the front end (5b) of the tuyere (5) facing the harsh environment. Consequently, the lateral front end (14c) may also be eroded inside the blast furnace. The equivalent resistance of the electric sensor (3) is constantly monitored. As the lateral front end (14c) is consumed, the equivalent resistance increases. The relation between remnant length of electric sensor (3) and its equivalent resistance is shown in the below Table 1.
Number of resistors connected Remnant length of electric sensor Resistance (ohm)
10 200 100
9 195 111.1111
8 190 125
7 185 142.8571
6 180 166.6667
5 175 200
4 170 250
3 165 333.3333
2 160 500
1 155 1000
Table 1. Relation between remnant length of electric sensor and equivalent resistance of the electric sensor
In an embodiment, the above illustrated system (100) may accurately measure the remnant length of the tuyere (5) and detect the complete failure of tuyere (5).

Equivalents

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding the description may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated in the description.

Referral Numerals:

Referral numeral Description
1 Case
2 Electrically insulating material
3 Electric sensor
5 Tuyere
5a Tuyere body
5b Front end of the tuyere
5c Rear end of the tuyere
6 Aperture
7 Cover plate
8 Compression fitting
9 Nickle chromium coating
10 Resistors
11 Transceiver
12 Nose of the tuyere
13 First lead wire
14 Second lead wire
14a Longitudinal section of the second lead wire
14b Lateral rear end of the second lead wire
14c Lateral front end of the second lead wire
15 Intermediate wire
100 System
C Channel