Claims:We Claim:

1. A system (100) for determining a remnant length of a tuyere (5) in a metallurgical furnace, the system (100) comprising:
a waveguide (3) enclosed in the tuyere (5) and extends along a length of the tuyere (5) from a front end (5b) to a rear end (5c);
a transducer (11) coupled to the waveguide (3) wherein, the transducer (11) is configured to:
transmit ultrasonic signals through the waveguide (3) and receive a reflected ultrasonic signal through the waveguide (3); and
a control unit (13) connected to the transducer (11), the control unit (13) is configured to:
determine a time of flight of the reflected ultrasonic signal from the transducer (11), wherein the time of flight of the reflected ultrasonic signal is indicative of the remnant length of a tuyere (5).

2. The system (100) as claimed in claim 1 comprises, a control unit (13) connected to the transducer (11) wherein, the control unit (13) transmits an electrical signal to the transducer (11) and the transducer (11) converts the electrical signal to the ultrasonic signal.

3. The system (100) as claimed in claim 1 wherein, the waveguide (3) enclosed in a case (1) and the case (1) is housed in an aperture defined in the tuyere (5).

4. The system (100) as claimed in claim 1 wherein, the case (1) accommodating the waveguide (3) is made of the same material as that of the tuyere (5).

5. The system (100) as claimed in claim 1, wherein the case (1) accommodating the waveguide (3) is filled with a thermally conductive material (2).

6. The system (100) as claimed in claim 1, wherein the time of flight of the transmitted ultrasonic signal in the waveguide (3) is directly proportional to the length of the waveguide (3).

7. The system (100) as claimed in claim 1, wherein the waveguide (3) is structured to deform corresponding to deformation of the tuyere (5).

8. A method for determining a remnant length of a tuyere (5) in a metallurgical furnace, the method comprising:
transmitting by a transducer (11), an ultrasonic signal through a waveguide (3) housed an aperture defined in the tuyere (5) and extends along a length of the tuyere (5) from a front end (5b) to a rear end (5c);
receiving by the transducer (11), a reflected ultrasonic signal from the waveguide (3),
determining by a control unit (13) connected to the transducer (11), a time of flight of the reflected ultrasonic signal wherein, the time of flight is indicative of the remnant length of a tuyere (5).
, 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 disclose 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, like iron. In the blast furnace, materials like fuel, ores, and flux are supplied from 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. 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 the body cooling circuit. Heavy water leakage poses a danger of explosion so it is 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 a waveguide enclosed in the tuyere and extends along a length of the tuyere from a front end to a rear end. A transducer is coupled to the waveguide where, the transducer is configured to transmit ultrasonic signals through the waveguide and receive a reflected ultrasonic signal through the waveguide. Further, a control unit is connected to the transducer and the control unit is configured to determine a time of flight of the reflected ultrasonic signal from the transducer. The time of flight of the reflected ultrasonic signal is indicative of the remnant length of a tuyere.

In an embodiment of the disclosure, a control unit is connected to the transducer where, the control unit transmits an electrical signal to the transducer and the transducer converts the electrical signal to the ultrasonic signal.

In an embodiment of the disclosure, the waveguide enclosed in a case and is housed in an aperture defined in the tuyere.

In an embodiment of the disclosure, the case accommodating the waveguide is made of the same material as that of the tuyere.

In an embodiment of the disclosure, the case accommodating the waveguide is filled with a thermally conductive material.

In an embodiment of the disclosure, the time of flight of the transmitted ultrasonic signal in the waveguide is directly proportional to the length of the waveguide.

In an embodiment of the disclosure, the waveguide is structured to deform corresponding to deformation of the tuyere.

In a 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 transmitting by a transducer, an ultrasonic signal through a waveguide housed an aperture defined in the tuyere and extends along a length of the tuyere from a front end to a rear end. The transducer further receives a reflected ultrasonic signal from the waveguide. Further, a control unit is connected to the transducer to determine a time of flight of the reflected ultrasonic signal where, the time of flight is indicative of the remnant length of a tuyere.

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:

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

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

Figure 3 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.

Figure 4 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.

The following paragraphs describe the present disclosure with reference to Figures. 1 to 4. 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.

Figure 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 designed to impart a 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 be 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 to Figure 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 may be provided on the entire outer surface of the tuyere body (5a) to prevent erosion of the tuyere (5).

Figure 2 illustrates a perspective view of a system (100) for determining a remnant length of the tuyere (5) and Figure 3 illustrates a schematic view of the casing (1) of the system (100) for determining the remnant length of the tuyere (5). The system (100) may include a case (1) with a waveguide (3) housed within the case (1). The configuration of the system (100) for measuring the remnant length of the tuyere (5) is explained with greater detail below. 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 waveguide (3).

In an embodiment, the waveguide (3) is embedded within the tuyere (5) without the case (1). The case (1) may include a hollow region that is defined within the case (1) for accommodating the waveguide (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 seen from Figure 3. 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 waveguide (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 waveguide (3) may be removably housed inside the case (1) and the case may be filled by a thermally conductive material (2). The thermally conductive material (2) may be filled between an inner surface of the case (1) and an outer surface of the waveguide (3). In an embodiment, the thermally conductive material (2) may provide the required conditions for enabling the suitable functioning of the waveguide (3). The waveguide (3) may further be connected to a transducer (11) for transmitting and receiving ultrasonic signals. The configuration of the waveguide (3) is explained with greater detain below. At least one waveguide (3) [hereinafter referred to as the waveguide] may be positioned within the case (1). The waveguide (3) is positioned in the case (1) such that the waveguide (3) extends throughout the length of the case (1) and till the tip of the case (1). One end of the waveguide (3) is enclosed in the case (1), whereas the other end the waveguide (3) is connected with a transducer (11). The transducer (11) may be further connected to a control unit (13). The transducer (11) may be configured to transmit and receive ultrasonic signals. The control unit (13) may be configured to transmit electrical signal to the transducer (11) and the transducer (11) converts the electrical signal to the ultrasonic signal. The transducer (11) may generate a required mode of guided waves using an ultrasonic transducer. The ultrasonic transducer may be a piezoelectric transducer where the vibrations of the piezoelectric crystals generate the required ultrasonic signals. The transmitted ultrasonic signals may travel along the length of the waveguide (3) and may be reflected back when the transmitted waves reach the end of the waveguide (3). The transmitted ultrasonic signal may initially reach the tip of the waveguide (3), and the ultrasonic signal may get reflected back. The reflected ultrasonic signals are detected by the transducer (11) and is further converted to electric signal and transmitted to the control unit. The control unit (13) comprises an indication unit. The indication unit being configured to show the reading of length of the waveguide. In an embodiment, the control unit (13) may be an oscilloscope which indicates the ultrasonic signals being transmitted and reflected through the waveguide (3). The indication unit may be a monitor of the oscilloscope. In an embodiment of the disclosure, the transducer (11) may receive the reflected ultrasonic signals from the waveguide (3) and may automatically indicate the reflected ultrasonic signals in a suitable waveform. Further, the time of flight (TOF) of the reflected ultrasonic signal to travel back to the transducer (11) is calculated by the control unit (13). The ultrasonic signal is transmitted through the waveguide (3) at a pre-determined velocity. Accordingly, from the above two factors of the TOF and the velocity at which the ultrasonic signals is transmitted through the waveguide (3), the length of the waveguide (3) may be calculated. The ultrasonic signal travels to and fro through the waveguide (3) (i.e., during transmission and while being reflected). Since the ultrasonic signal that is received by the transducer (11) travels twice the length of the case (1) (once during being transmitted and once while reflected), the length is calculated by dividing the obtained value by 2.

In an embodiment of the disclosure, modes of excitation of the ultrasonic signals in the waveguide (3) by the transducer (11) may be piezoelectric, laser, magneto strictive and electromagnetic based transduction. In an embodiment, the waveguide (3) may be made of the same material as that of the case (1). In an embodiment of the disclosure, the waveguide (3) may be provisioned with suitable support means such that the waveguide (3) extends along a substantially central portion of the case (1). In an embodiment, the waveguide (3) may be defined with a shape including but not limited to a rectangular shape encompassing the overall area of the case (1). In an embodiment, the tuyere (5) may be defined with an aperture. The aperture may be defined to extend along the length of the tuyere (5). The aperture may be configured with dimensions that is equivalent to the dimensions of the case (1). The case (1) may be accommodated within the aperture defined in the tuyere (5).

It is to be appreciated that the waveguide (3) is extended from the tuyere (5) at the rear end (5c). Once the length of the waveguide (3) is calculated, the extended length is subtracted to calculate remnant length of the tuyere (5). Further, measuring of the remnant length of the tuyere (5) through the system (100) is explained with greater detail below. Figure 4 illustrates a flowchart for measuring the remnant length of the tuyere (5). The control unit (13) may initially transmit electric signal to the transducer (11) in the first step of 201. This electric signal is further converted into the ultrasonic signal by the transducer (11). The transducer (11) further transmits the ultrasonic signal through the waveguide (3).

Upon exposure of the tuyere (5) to high temperature environment in the blast furnace, the tip, or the front end of the tuyere (5) may be consumed and the length of the tuyere (5) may consequently be reduced. Further, the tip of the case (1) accommodating the waveguide (3) may also be consumed as the tip of tuyere (5) or the front end (5b) of the tuyere (5) is consumed. When an ultrasonic signal is transmitted through the waveguide (3), the ultrasonic signals get reflected back when it reaches the tip of the waveguide (3). Since the length of the case (1) and the length of the waveguide (3) is reduced due to harsh operating conditions in the furnace, the ultrasonic signals is reflected more quickly and the TOF of the reflected ultrasonic signals is also reduced. Further, as long as the waveguide (3) lies inside the case (1), the waveguide (3) remains intact without breakage or any damage and represents the correct length of the tuyere (5). When thinning and breakage of the tuyere (5) occurs, the waveguide (3) will be exposed to the harsh conditions in the combustion zone and corrosive environment causes the waveguide (3) to be consumed away. . Thus, the waveguide (3) whose length is reduced as it is exposed to the corrosive environment sans the extended length of waveguide (3) will represent the true length of the reduced case (1).

The transducer (11) is configured to receive the reflected ultrasonic signal and the time of flight between the transmission and the reception of the ultrasonic signal is measured by the control unit (13) at the step 202. Since the case (1) disintegrates proportionally with the disintegration of the tuyere (5), the waveguide (3) accommodated within the case (1) also disintegrates or reduces in length proportionally. As the ultrasonic signal is transmitted through the waveguide (3), the ultrasonic signal travels through the waveguide (3) which is of reduced length and is reflected back to the transducer (11). Since the length of the waveguide (3) is reduced, the time of flight of the ultrasonic signal for being transmitted, reflected and received by the transducer (11) is also reduced. The length of the waveguide (3) which is disintegrated may further be from the determined time of flight. The remnant length of the waveguide (3) determined by the control unit (13) may further be indicated by the indication unit in the step 203. The determined length of the waveguide (3) sans the extended length of waveguide (3) is indicative of the remnant length of the tuyere (5). Accordingly, the operator may suitably replace or repair the tuyere (5) based on the remnant length of the tuyere (5).

In an embodiment of the disclosure, transmission of the ultrasonic signals is completely dependent on the waveguide (3) and not on the internal or the external surfaces of the case (1). Consequently, the reflection of the ultrasonic signal is accurate and the there exists no possibilities of attenuation of the ultrasonic signal.

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 Thermally conductive material
3 Waveguide
5 Tuyere
5a Tuyere body
5b Front end of the tuyere
5c Rear end of the tuyere
11 Transducer
12 Nose of the tuyere
13 Control unit
100 System