DENSIFICATION METHOD AND APPARATUS

Abstract

A method of densification of refractory material in a gap between a tap hole sleeve of a furnace and a surround block of the furnace, the surround block surrounding the tap hole sleeve, the method comprising, includes positioning a tool in the gap, the tool including a support having opposing surfaces and a sidewall connecting the opposing surfaces, the opposing surfaces having an arcuate shape, a plurality of elongated members extending from one of the opposing surfaces, and a connector arranged on the other of the opposing surfaces. The gap is filled with dry material, and vibration is applied to the tool to densify the dry material.

Claims

1. A method of densification of refractory material in a gap between a tap hole sleeve of a furnace and a surround block of the furnace, the surround block surrounding the tap hole sleeve, the method comprising: positioning a tool in the gap, the tool including a support having opposing surfaces and a sidewall connecting the opposing surfaces, the opposing surfaces having an arcuate shape, a plurality of elongated members extending from one of the opposing surfaces, and a connector arranged on the other of the opposing surfaces; filing the gap with dry material; and applying vibration to the tool to densify the dry material.

2. The method according to claim 1, wherein filling the gap with dry material includes using at least one of magnesia, dolomitic magnesia or dolomitic material as the dry material.

3. The method according to claim 1, wherein applying vibration includes attaching a vibration machine to the connector, wherein the vibration machine applies a vibrating motion to the tool.

4. The method according to claim 1, wherein positioning the tool includes maneuvering the tool through a sump panel sanding hole of the furnace.

5. The method according to claim 1, wherein applying vibration includes using at least one of a mechanically-powered vibration device, a pneumatically-powered vibration device or an electrically-powered vibration device to apply the vibration to the tool.

6. The method according to claim 1, wherein filing the gap with dry material includes filing the gap in layers having a prescribed thickness.

7. The method according to claim 6, wherein the prescribed thickness is less than a length of elongated members.

8. The method according to claim 1, wherein the steps of filing the gap and applying vibration are performed simultaneously.

9. The method according to claim 1, wherein the steps of filing the gap and applying vibration are performed sequentially.

10. An tool for densification of refractory material in a tap-hole of a furnace, the tool comprising: a support having opposing surfaces and a sidewall connecting the opposing surfaces, the opposing surfaces having an arcuate shape; a plurality of elongated members extending from one of the opposing surfaces; and a connector arranged on the other of the opposing surfaces, the connector comprising a fastener configured to selectively and fixedly couple the connector to a vibrating member.

11. The tool according to claim 10, wherein at least some of the plurality of elongated members include a channel formed within the respective elongated member, the channel opening at an end of the respective elongated member distal from the support.

12. The tool according to claim 11, wherein at least some of the plurality of elongated members comprise a pipe.

13. The tool according to claim 10, wherein the arcuate shape is dimensioned to correspond to the tap hole of the furnace.

14. The tool according to claim 10, wherein the plurality of elongated members extend in a direction perpendicular to a major face of the opposing surfaces.

15. The tool according to claim 10, wherein the support comprises a metal plate.

16. The tool according to claim 10, wherein an end of at least some of the plurality of elongated members that is distal from the support is tapered.

17. The tool according to claim 10, wherein at least some of the plurality of elongated members are welded to the support.

18. The tool according to claim 10, wherein at least some of the plurality of elongated members are threadedly attached to the support.

19. The tool according to claim 10, wherein an end of at least some of the plurality of elongated members extends through the support, a first fastener is threadedly coupled to the respective elongated member and arranged on one of the opposing surfaces, and a second fastener is threadedly coupled to the respective elongated member and arranged on the other of the opposing surfaces.

20. The tool according to claim 10, wherein an outer radius of the opposing surfaces is between 14-16 inches, and an inner radius of the opposing surfaces is between 10-12 inches.

21. The tool according to claim 10, wherein the connector comprises a sleeve configured to receive to a vibrating member.

22. The tool according to claim 21, wherein the fastener comprises one of a clamp or a bolt.

23. The tool according to claim 10, further comprising a vibration device coupled to the connector.

24. The tool according to claim 10, wherein the opposing surfaces are planar surfaces that are substantially parallel to each other.

25. The tool according to claim 10, wherein the support has a length defined along a major axis of the support, and a width defined along a minor axis of the support, and a height defined between the opposing surfaces, the length being greater than the width, and the width being greater than the height.

26. The tool according to claim 10, wherein the fastener comprises a through hole formed in a portion of the connector.

27. The tool according to claim 26, wherein the fastener further comprises one of a threaded bolt configured for insertion into the through hole and a nut threadedly engagable with the bolt, or a pin configured for insertion into the through hole and a clip attachable to the pin.

28. A system for densification of refractory material in a tap hole, comprising: the tool according to claim 10; and a vibration device coupled to the tool.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:

[0044] FIG. 1 is a perspective view of an eccentric bottom tap electric arc furnace having a tap hole.

[0045] FIGS. 2A and 2B are cutaway views of the tap hole area of the furnace that may be used in the furnace of FIG. 1, the tap hole area shown in 2A has the tap hole sleeve, or replacement sleeve, in a fully installed position and in 2B has the tap hole sleeve, or replacement sleeve, in fully removed position.

[0046] FIG. 3A is a side view of an exemplary tool in accordance with an embodiment of the invention.

[0047] FIG. 3B is a bottom view of the tool of FIG. 3A.

[0048] FIG. 3C is a top view of the tool of FIG. 3A.

[0049] FIG. 4A is a side view of an exemplary tool in accordance with another embodiment of the invention.

[0050] FIGS. 4B and 4C illustrate embodiments of a fastening means for securing the tool to a vibration means.

[0051] FIG. 5 is a side view of an exemplary tool in accordance with yet another embodiment of the invention.

[0052] FIG. 6A is a side view of a threaded elongated member according to an embodiment of the invention that may be used with the tool of FIGS. 3-5.

[0053] FIG. 6B is a side view of a tapered elongated member according to another embodiment of the invention that may be used with the tool of FIGS. 3-5.

[0054] FIG. 6C is a side view of a hollow elongated member according to another embodiment of the invention that may be used with the tool of FIGS. 3-5.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

[0055] Various aspects now will be described more fully hereinafter. Such aspects may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art.

[0056] The word “about” when immediately preceding a numerical value means a range of plus or minus 10% of that value, e.g., “about 50” means 45 to 55, “about 25,000” means 22,500 to 27,500, etc., unless the context of the disclosure indicates otherwise, or is inconsistent with such an interpretation. For example, in a list of numerical values such as “about 49, about 50, about 55, “about 50” means a range extending to less than half the interval(s) between the preceding and subsequent values, e.g., more than 49.5 to less than 52.5. Furthermore, the phrases “less than about” a value or “greater than about” a value should be understood in view of the definition of the term “about” provided herein.

[0057] As used herein, the term “refractory material” refers to inorganic nonmetal materials utilized in various high-temperature equipment, e.g., steel production and the like. Refractory materials are characterized by a high melting point, and when exposed to high temperatures they do not lose their strength and of form.

[0058] An exemplary tap hole area 12 is shown in FIGS. 2A (in installed position) and 2B (in removed position), the tap hole 12 including several key components. Internally, there is a tap hole sleeve, or replacement sleeve 14, which may be formed from one piece, or series of segments. Externally, a surround block 16 supports the internally-arranged tap hole sleeve, or replacement sleeve 14. A dry monolithic material 18, which is arranged between the wall of the EAF 10 (see FIG. 1) and surround block 16, and magnesia bricks 20, which are arranged on a floor and walls of the EAF 10, surround the tap hole 12. An optional water-cooled ring 22 may be arranged around an end block 24 of the tap hole sleeve, or replacement sleeve 14 to provide cooling of the tap hole end block.

[0059] Formed between the internally-arranged tap hole sleeve 14 and the external surround block 16 is a gap 26 designed to be between about 2½ to 4 inches wide. The gap 26 is filled with the same, or similar, dry monolithic material used for the construction of the EAF bottom. Because the gap 26 is very narrow, existing tools for EAF repair are not used for the new installation of tap hole sleeve 14 or hot repair of the tap hole replacement sleeve 14.

[0060] A tool in accordance with the invention can be used to achieve a required density of dry refractory material in the gap 26 of the tap hole 12. In this regard, the required density is achieved by aerating the material through vibration of the tool as the dry material is installed into the gap 26 of the tap hole 12. The shape of the tool allows it to come in through the sump panel sanding hole and fit between the surround block 16 and the tap hole sleeve 14 to vibrate the dry material in the gap 26 as the dry material is being installed. The densification tool is positioned within the gap 26 between the internal tap hole sleeve 14 (also referred to simply as the “tap hole”) and the external surround block 16 (also referred to simply as the “surround block”), and the dry material (e.g., Americlase) is poured in to fill the gap 26 between the internally-arranged tap hole sleeve 14 and the surround block 16. A vibrating device attached to the tool aerates the dry material, thereby increasing the packing (density) of the dry material.

[0061] As will be discussed in further detail below, a head of the tool is complemented with a series of elongated members, e.g., pipes, dimensioned to allow easy placement within the gap 26. The tool includes a connection member for connection to the vibrating source, thereby enabling densification of the dry material by vibration force.

[0062] Referring to FIGS. 3A-3C, illustrated is an exemplary tool 30 for densification of refractory material in a tap-hole 12 of an EAF 10 in accordance with an embodiment of the invention. FIG. 3A illustrates a side profile of the tool 30, FIG. 3B is a bottom view of the tool 30, and FIG. 3C is a top view of the tool 30. The tool 30 includes a support 32 having opposing surfaces 32a, 32b and a sidewall 32c connecting the opposing surfaces. The support 32 can be formed from metal plate, such as a steel plate, aluminum plate, or other cast/forged metal/metallic materials. As best seen in FIGS. 3B and 3C, the opposing surfaces 32a, 32b have an arcuate shape that is dimensioned to correspond to the tap hole of the furnace. For example, an outer radius of the opposing surface's arcuate shape may be between about 14-16 inches, and an inner radius of the opposing surfaces arcuate shape may be between about 10-12 inches.

[0063] The tool 30 further includes a plurality of elongated members 34 extending from surface 32a, and a connector 36 extending from the surface 32b. As can be seen in FIG. 3A, the plurality of elongated members 34 and the connector 36 extend in a direction perpendicular to a major face of the opposing surfaces 32a, 32b (the major face being parallel to the surface of opposing faces 32a, 32b). The connector 36 is couplable to a vibrating means (not shown in FIG. 3A) so as to provide a vibrating action to the tool 30 as the refractory material is being densified. The elongated members 34 and the connector 36 may have a cross-section that is circular, oval, rectangular, or square in shape. Other shapes may be employed depending on the requirements of the specific application.

[0064] In the embodiment illustrated in FIGS. 3A-3C, an end 34′ of each elongated member 34 that is proximal to the support 32 extends through the support 32. A first fastener 36a, such as a threaded nut, is threadedly coupled to a respective elongated member 34 and arranged adjacent to the surface 32a, and a second fastener 36b is threadedly coupled to the respective elongated member 34 and arranged adjacent to the surface 32b. Accordingly, the fasteners 36a, 36b are threadedly coupled to a respective one of the elongated members 34, and the support 32 is sandwiched between the fasteners 36a, 36b. By utilizing fasteners on each side of the support 32, the fasteners 36a, 36b effectively clamp the support 32 between the fasteners 36a, 36b, thereby enhancing the strength of the assembly formed by the support 32, the elongated members 34 and fasteners 36a, 36b.

[0065] In use, the gap 26 is filled with the material to be densified, the connector 36 of the tool 30 is attached to the vibration device, and the tool is placed in the material within the gap 26. The vibration device, which may be a mechanically-powered vibration device, a pneumatically-powered vibration device, an electrically powered vibration device, or the like, is activated and the tool is held in place for a predetermined amount of time to densify the material.

[0066] Filling the gap and applying vibration may be done sequentially. For example, a layer of material may be deposited in the gap, the layer having a prescribed thickness. Preferably, the thickness of each layer is less than a length of the elongated members. Upon achieving a desired layer thickness, the tool may be inserted into the material and vibration applied to the tool to densify the layer of material. Once the material has been densified, the process may be repeated where another layer is deposited over the already densified layer, and vibration is again applied. This can be repeated until a desired thickness of densified material has been obtained.

[0067] As an alternative to the sequential approach described above, filling the gap with material and applying vibration may be done simultaneously. For example, vibration can be applied to the tool after the initial layer is deposited in the gap, thereby densifying the initial layer. While vibration is being applied to the tool, additional material may be deposited in the gap to build the thickness of the layer of material. The simultaneous application of material and vibration is advantageous in that it can speed up the densification process.

[0068] Moving to FIGS. 4A-4C, illustrated is another embodiment of a tool 30′ in accordance with the invention. The tool 30′ is similar to the tool 30 of FIGS. 3A-3C except for the connection to the vibration means. More specifically, the tool 30′ includes a connector 42, such as a sleeve or other connection means, the connector 42 configured to receive an actuator 44 of a vibration mechanism 46. The connector 42 is dimensioned such that an inside dimension of the connector 42 corresponds to an outside dimension of the actuator 44 (or vice-versa). The dimensions may be such that an interference fit is created between the connector 42 and the actuator 44, or such that the actuator may slide into the connector 42.

[0069] FIGS. 4B and 4C illustrate exemplary fastening means for securing the tool to a vibration means. More particularly, FIG. 4B illustrates connector 42 in the form of a sleeve with a fastening means 42a in the form of a through hole, while FIG. 4C illustrates a connector 42 in the form of a joint with a fastening means 42a in the form of a through hole. The fastening means 42 is adapted to receive a threaded fastener, a locking pin, or the like, so as to secure the connector to the vibration means. For example, and as best seen in FIG. 4C, fastener 48 is insertable through the fastening means 42a and configured to secure the connector 42 to the actuator 44. Although FIG. 4B does not illustrate fastener 48, it will be appreciated that such fastener is also applicable to the embodiment of FIG. 4B.

[0070] In the illustrated embodiments of FIGS. 4A-4C the fastening means is shown as a through hole 47 and bolt 48 that passes through both the connector 42 and the actuator 44. However, other fasteners are may be used, e.g., a clamp or any other suitable fastener.

[0071] Moving to FIG. 5, illustrated is another embodiment of the tool 30″ according to the invention. In the embodiments of FIGS. 3 and 4 the elongated members 34 are each fastened to the support 32 via fasteners 36a, 36b. FIG. 5 illustrates an alternative means for fastening the elongated members 34 to the support 32. In the embodiment of FIG. 5, fasteners 36 are not used and instead the elongated members 34 are welded to the support 32 and/or threadedly coupled to the support 32. For example, the elongated members 34 may be inserted into a respective bore of the support 32, and the elongated members 34 then may be welded to the support 32. Alternatively or additionally, a threaded end of each elongated member 34 may be cooperate with a respective threaded bore in the support 32 to secure the elongated member to the support (i.e., a screw connection).

[0072] Moving to FIGS. 6A-6C, illustrated are various embodiments of an elongated member 34 that may be used in any of the embodiments illustrated in FIGS. 3-5. FIG. 6A illustrates an elongated member 34a that includes threads 50 at the proximal end 34′, the threads configured to cooperate with threads of a bore in the support 32 to enable each elongated member to be threadedly attached to the support 32. The elongated member 34a may be used with or without the fasteners 36a, 36b.

[0073] FIG. 6B illustrates an elongated member 34b in which an end 52 of the elongated member 34 distal from the surface 32a is tapered such that the diameter of the elongated member decreases toward the distal end 52. The tapered configuration enables the elongated member to be more easily inserted into the refractory material.

[0074] FIG. 6C illustrates yet another embodiment of the elongated member. Specifically, the elongated member 34c is a pipe or similar elongated element in which a center portion 54 is hollow to form a channel within the respective elongated member. As shown in FIG. 6C, the channel open at an end of the respective elongated member distal from the support 32.

[0075] It should be noted that the features of the elongated member shown in FIGS. 6A-6C can be combined, e.g., the elongated member can be threaded, have a tapered distal end, and/or be formed with a hollow inner portion.

[0076] The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purposes of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.