Title of Invention	A DEVICE FOR MONITORING SYSTEM OF BLAST FURNACE TROUGH
Abstract	The present invention is provided with a device for monitoring system of blast furnace trough to avoid metal break out and erosion prediction through a furnace trough thermal modeling, the device comprises of a rectangular/square shaped copper plate having a plane front face and a thermocouple tip is brazed on the back through a stainless steel pipe, insertable in the back lining to measure the temperature of refractories at the interface; characterized in that said copper plate can be embedded on the back side of 1st back/2nd back refractory layer to collect refractory interface temperature over a larger surface area, wherein a comparison of rise of collected temperature data and thermal modeling of trough predicts the thickness of refractory lining already decayed.

Title of Invention

A DEVICE FOR MONITORING SYSTEM OF BLAST FURNACE TROUGH

Abstract

The present invention is provided with a device for monitoring system of blast furnace trough to avoid metal break out and erosion prediction through a furnace trough thermal modeling, the device comprises of a rectangular/square shaped copper plate having a plane front face and a thermocouple tip is brazed on the back through a stainless steel pipe, insertable in the back lining to measure the temperature of refractories at the interface; characterized in that said copper plate can be embedded on the back side of 1st back/2nd back refractory layer to collect refractory interface temperature over a larger surface area, wherein a comparison of rise of collected temperature data and thermal modeling of trough predicts the thickness of refractory lining already decayed.

Full Text	FIELD OF INVENTION The present invention relates to a device for- monitoring system of Blast Furnace Trough. BACKGROUND OF THE INVENTION Trough plays a vital role in Iron making, its main functions are to separate slag from hot metal and to carry the hot metal and slag to the ladle cars. Hence trough availability and life determines the throughput of the blast furnace. The life of trough depends on refractory design and quality, chemistry of hot metal and slag, casting duration etc. The trough refractory design basically consists of three different layers of refractory lining. First is insulation refractory layer adjacent to trough shell, followed by backup refractory layer and working or front lining which is exposing to hot metal and slag. The major reason affecting the blast furnace trough availability is untimely or unexpected failures due to erosion, corrosion and spading of working lining refractory results into reduction in lining thickness and deterioration of working lining refractory, may leads to failure of trough. Therefore a proper trough monitoring system is very essential to avoid any failure and helps in taking corrective action (repair of refractory lining) in time. An innovative trough monitoring system has been developed in order to create more reliability on trough refractory system. This innovative method of trough monitoring system is being used in TATA STEEL G-Blast furnace trough. In earlier Trough Monitoring systems thermocouples are inserted adjacent to the outer shell of the trough to capture any rise in the temperature either due to reduction in working lining thickness or penetration of hot metal-slag in refractory lining. But in spite of having this monitoring system there were many failures occurred which proves this system to be completely inefficient and non-reliable. The possible reasons of failure of above system are 1) localized sensing of thermocouple-since thermocouple tip sense localized small area only around the tip and can not sense any infiltration of metal or slag if it would be occur some distance away from thermocouple tip. 2) Position of thermocouple- As the thermocouple is mounted on the shell; the thermocouple is unable to show any significant increase in temperature due to the presence of low value of thermal conductivity of refractory layer (particularly insulation and back up refractory layer). The failure of the existing trough monitoring system drives the need to innovate more reliable and robust monitoring system. OBJECTS OF THE INVENTION It is therefore, an object of the present invention to propose a device for monitoring system of Blast furnace trough which eliminates the disadvantages of the existing system. Another object of the present invention is to, propose a device for monitoring system of Blast furnace trough which prevents accident due to its efficient functioning. A further object of the present invention is to propose a device for monitoring system of Blast furnace trough which is very economic. A still further object of the present invention is to propose a device for monitoring system of Blast furnace trough which is eco-friendly. SUMMARY OF THE INVENTION: The basic objective of the invented monitoring system is to create more reliable trough monitoring system in which drawback of the existing system can be removed. In the invented monitoring device the drawbacks of the existing system is overcome by the use of copper plate, which would enable monitoring the refractory interface temperature over a larger surface area. Thermocouples are installed in such a manner that the tip of the thermocouples rested on copper plates embedded at the interface of just after 1st backup refractory layer. By thermal modeling of trough it was discovered that the efficiency of the thermocouple would increase if it would be placed just after the 1st backup refractory layer. Fig-1 shows the cross sectional view of trough. In order to maintain structural integrity of the different refractory layer. Fig-2 shows the groove arrangement made at the back of the 1st backup refractory layer for placing copper plate (fig-4). Fig-3 shows the schematic diagram of the arrangement for laying thermocouple and copper plate. As the figure-3 is showing one end of cylindrical shaped pipe is brazed with copper plate while the other end which is coming out of trough shell is open to cast house floor. One of the advantages with this monitoring device is, in case of manufacturing of any thermocouple, it can be replaced easily. Here, the same number of thermocouples could sense temperature variations over a larger part of the trough. Thereby reducing the chances of failure in between two thermocouples. Based on thermal modeling result, the copper plates can be laid after 2nd or 3rd backup lining and above mentioned advantages can be achieved. BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS: Fig-1 shows the cross-sectional view of trough. Fig 2 shows the groove arrangement at the back of the 1st backup of refractory layer. Fig-3 shows the schematic diagram of the arrangement for laying thermocouple and copperplate. Fig-4 shows the copperplate mounted with a stainless steel pipe. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION: In order to achieve zero trough failure and maximum availability of trough the necessity of more robust trough monitoring system has been felt. Drawbacks of the existing trough monitoring system such as very localize sensing of thermocouple which limits the sensing ability of the trough only around the thermocouple tip as a result it cannot sense any infiltration of metal or slag if it would be occurred some distance away from thermocouple tip and position of thermocouple, since thermocouple is mounted on the shell, hence it will not be able to show any significant increase in temperature due to low value of thermal conductivity of refractory layers, proved its inefficiency of predicting many trough failure cases. Trough refractory mainly consists of 3-4 different quality of refractory layer depends on the trough geometry. Fig-1 shows the cross sectional view of trough. The refractory layer which is exposing to hot metal and slag is called as working lining refractory and the remaining layers are named as 1st backup, 2nd backup, etc refractory lining depends on the number of backup refractory layer. In invented device of trough monitoring system, copper plates have been used. The application of copper plate not only increases the efficiency of the thermocouple, also cover larger surface area of the trough, the gradual rise of temperature in the thermocouple during usages indicates the decay in lining has been started and an interpretation of the rise in temperature in thermocouple and thermal modeling of trough predicts the amount of thickness of lining has been changed and thereby reducing any chances of failure between two thermocouples. By thermal modeling of trough it was discovered that the efficiency of the thermocouple would increase if it would place just after the 1st backup refractory layer. Based on thermal modeling result, it was decided to place the rectangular/square shaped copper plate just after the first backup refractory layer. Fig. 2 shows the groove arrangement made at the back of the 1st backup refractory layer for placing the rectangular/square shaped copper plate. The advantage of groove shaped is that the rectanguiar/square shaped copper plate wouid completely lie inside the groove and will not disturb the structural integrity of the refractory layers. Fig. 3 shows the schematic diagram of the arrangement for laying thermocouple and the rectangular/square shaped copper plate. As the figure-3 is showing a stainless steel pipe is used for connecting thermocouple with the rectangular/square shaped copper plate. The end of the pipe is brazed with the rectangular/square shaped copper plate while the other end which is coming out of trough shell is open to cast house floor. Thermocouple is inserted through the open end of the steel pipe, passes through it and touches the rectangular/square shaped copper plate. WE CLAIM: 1. A device for monitoring system of blast furnace trough to avoid metal break out and erosion prediction through a furnace trough thermal modeling, the device comprises of: - a rectangular/square shaped copper plate having a plane front face and a thermocouple tip is brazed on the back through a stainless steel pipe, insertable in the back lining to measure the temperature of refractories at the interface; characterized in that said copper plate can be embedded on the back side of 1st back/2nd back refractory layer to collect refractory interface temperature over a larger surface area, wherein a comparison of rise of collected temperature data and thermal modeling of trough predicts the thickness of refractory lining already decayed. 2. The device as claimed in claim 1, is insertable in an engraving groove in the refractory layer or within the castable. 3. The device as claimed in claim 1, wherein the copper plate can be placed after any of refractory layer (1st, 2nd etc backup refractory layer) so that it can detect considerable rise of temperature with respect to decay of working lining refractory. ABSTRACT A DEVICE FOR MONITORING SYSTEM OF BLAST FURNACE TROUGH The present invention is provided with a device for monitoring system of blast furnace trough to avoid metal break out and erosion prediction through a furnace trough thermal modeling, the device comprises of a rectangular/square shaped copper plate having a plane front face and a thermocouple tip is brazed on the back through a stainless steel pipe, insertable in the back lining to measure the temperature of refractories at the interface; characterized in that said copper plate can be embedded on the back side of 1st back/2nd back refractory layer to collect refractory interface temperature over a larger surface area, wherein a comparison of rise of collected temperature data and thermal modeling of trough predicts the thickness of refractory lining already decayed.

Full Text

FIELD OF INVENTION
The present invention relates to a device for- monitoring system of Blast
Furnace Trough.
BACKGROUND OF THE INVENTION
Trough plays a vital role in Iron making, its main functions are to separate
slag from hot metal and to carry the hot metal and slag to the ladle cars.
Hence trough availability and life determines the throughput of the blast
furnace. The life of trough depends on refractory design and quality,
chemistry of hot metal and slag, casting duration etc. The trough refractory
design basically consists of three different layers of refractory lining. First is
insulation refractory layer adjacent to trough shell, followed by backup
refractory layer and working or front lining which is exposing to hot metal
and slag. The major reason affecting the blast furnace trough availability is
untimely or unexpected failures due to erosion, corrosion and spading of
working lining refractory results into reduction in lining thickness and
deterioration of working lining refractory, may leads to failure of trough.
Therefore a proper trough monitoring system is very essential to avoid any
failure and helps in taking corrective action (repair of refractory lining) in
time. An innovative trough monitoring system has been developed in order
to create more reliability on trough refractory system. This innovative
method of trough monitoring system is being used in TATA STEEL G-Blast
furnace trough.

In earlier Trough Monitoring systems thermocouples are inserted adjacent
to the outer shell of the trough to capture any rise in the temperature
either due to reduction in working lining thickness or penetration of hot
metal-slag in refractory lining. But in spite of having this monitoring system
there were many failures occurred which proves this system to be
completely inefficient and non-reliable. The possible reasons of failure of
above system are 1) localized sensing of thermocouple-since thermocouple
tip sense localized small area only around the tip and can not sense any
infiltration of metal or slag if it would be occur some distance away from
thermocouple tip. 2) Position of thermocouple- As the thermocouple is
mounted on the shell; the thermocouple is unable to show any significant
increase in temperature due to the presence of low value of thermal
conductivity of refractory layer (particularly insulation and back up
refractory layer). The failure of the existing trough monitoring system
drives the need to innovate more reliable and robust monitoring system.
OBJECTS OF THE INVENTION
It is therefore, an object of the present invention to propose a device for
monitoring system of Blast furnace trough which eliminates the
disadvantages of the existing system.
Another object of the present invention is to, propose a device for
monitoring system of Blast furnace trough which prevents accident due to
its efficient functioning.
A further object of the present invention is to propose a device for
monitoring system of Blast furnace trough which is very economic.
A still further object of the present invention is to propose a device for
monitoring system of Blast furnace trough which is eco-friendly.

SUMMARY OF THE INVENTION:
The basic objective of the invented monitoring system is to create more reliable trough
monitoring system in which drawback of the existing system can be removed. In the
invented monitoring device the drawbacks of the existing system is overcome by the
use of copper plate, which would enable monitoring the refractory interface
temperature over a larger surface area.
Thermocouples are installed in such a manner that the tip of the thermocouples rested
on copper plates embedded at the interface of just after 1st backup refractory layer. By
thermal modeling of trough it was discovered that the efficiency of the thermocouple
would increase if it would be placed just after the 1st backup refractory layer. Fig-1
shows the cross sectional view of trough. In order to maintain structural integrity of the
different refractory layer. Fig-2 shows the groove arrangement made at the back of the
1st backup refractory layer for placing copper plate (fig-4). Fig-3 shows the schematic
diagram of the arrangement for laying thermocouple and copper plate. As the figure-3
is showing one end of cylindrical shaped pipe is brazed with copper plate while the
other end which is coming out of trough shell is open to cast house floor. One of the
advantages with this monitoring device is, in case of manufacturing of any
thermocouple, it can be replaced easily. Here, the same number of thermocouples could
sense temperature variations over a larger part of the trough. Thereby reducing the
chances of failure in between two thermocouples. Based on thermal modeling result,
the copper plates can be laid after 2nd or 3rd backup lining and above mentioned
advantages can be achieved.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS:
Fig-1 shows the cross-sectional view of trough.
Fig 2 shows the groove arrangement at the back of the 1st backup of refractory layer.
Fig-3 shows the schematic diagram of the arrangement for laying thermocouple and
copperplate.
Fig-4 shows the copperplate mounted with a stainless steel pipe.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF
THE INVENTION:
In order to achieve zero trough failure and maximum availability of trough the necessity
of more robust trough monitoring system has been felt. Drawbacks of the existing
trough monitoring system such as very localize sensing of thermocouple which limits
the sensing ability of the trough only around the thermocouple tip as a result it cannot
sense any infiltration of metal or slag if it would be occurred some distance away from
thermocouple tip and position of thermocouple, since thermocouple is mounted on the
shell, hence it will not be able to show any significant increase in temperature due to
low value of thermal conductivity of refractory layers, proved its inefficiency of
predicting many trough failure cases.
Trough refractory mainly consists of 3-4 different quality of refractory layer depends on
the trough geometry. Fig-1 shows the cross sectional view of trough. The refractory
layer which is exposing to hot metal and slag is called as working

lining refractory and the remaining layers are named as 1st backup, 2nd backup, etc
refractory lining depends on the number of backup refractory layer.
In invented device of trough monitoring system, copper plates have been used. The
application of copper plate not only increases the efficiency of the thermocouple, also
cover larger surface area of the trough, the gradual rise of temperature in the
thermocouple during usages indicates the decay in lining has been started and an
interpretation of the rise in temperature in thermocouple and thermal modeling of
trough predicts the amount of thickness of lining has been changed and thereby
reducing any chances of failure between two thermocouples. By thermal modeling of
trough it was discovered that the efficiency of the thermocouple would increase if it
would place just after the 1st backup refractory layer. Based on thermal modeling result,
it was decided to place the rectangular/square shaped copper plate just after the first
backup refractory layer. Fig. 2 shows the groove arrangement made at the back of the
1st backup refractory layer for placing the rectangular/square shaped copper plate. The
advantage of groove shaped is that the rectanguiar/square shaped copper plate wouid
completely lie inside the groove and will not disturb the structural integrity of the
refractory layers. Fig. 3 shows the schematic diagram of the arrangement for laying
thermocouple and the rectangular/square shaped copper plate. As the figure-3 is
showing a stainless steel pipe is used for connecting thermocouple with the
rectangular/square shaped copper plate. The end of the pipe is brazed with the
rectangular/square shaped copper plate while the other end which is coming out of
trough shell is open to cast house floor. Thermocouple is inserted through the open end
of the steel pipe, passes through it and touches the rectangular/square shaped copper
plate.

WE CLAIM:
1. A device for monitoring system of blast furnace trough to avoid metal break out
and erosion prediction through a furnace trough thermal modeling, the device
comprises of:
- a rectangular/square shaped copper plate having a plane front face and a
thermocouple tip is brazed on the back through a stainless steel pipe,
insertable in the back lining to measure the temperature of refractories at
the interface;
characterized in that said copper plate can be embedded on the back side
of 1st back/2nd back refractory layer to collect refractory interface
temperature over a larger surface area, wherein a comparison of rise of
collected temperature data and thermal modeling of trough predicts the
thickness of refractory lining already decayed.
2. The device as claimed in claim 1, is insertable in an engraving groove in the
refractory layer or within the castable.
3. The device as claimed in claim 1, wherein the copper plate can be placed after
any of refractory layer (1st, 2nd etc backup refractory layer) so that it can detect
considerable rise of temperature with respect to decay of working lining
refractory.

ABSTRACT

A DEVICE FOR MONITORING SYSTEM OF BLAST FURNACE
TROUGH
The present invention is provided with a device for monitoring system of blast furnace
trough to avoid metal break out and erosion prediction through a furnace trough
thermal modeling, the device comprises of a rectangular/square shaped copper plate
having a plane front face and a thermocouple tip is brazed on the back through a
stainless steel pipe, insertable in the back lining to measure the temperature of
refractories at the interface; characterized in that said copper plate can be embedded
on the back side of 1st back/2nd back refractory layer to collect refractory interface
temperature over a larger surface area, wherein a comparison of rise of collected
temperature data and thermal modeling of trough predicts the thickness of refractory
lining already decayed.

Documents:

1364-KOL-2008-(19-12-2011)-ABSTRACT.pdf

1364-KOL-2008-(19-12-2011)-AMANDED CLAIMS.pdf

1364-KOL-2008-(19-12-2011)-CORRESPONDENCE.pdf

1364-KOL-2008-(19-12-2011)-DESCRIPTION (COMPLETE).pdf

1364-KOL-2008-(19-12-2011)-DRAWINGS.pdf

1364-KOL-2008-(19-12-2011)-FORM-1.pdf

1364-KOL-2008-(19-12-2011)-FORM-2.pdf

1364-KOL-2008-(19-12-2011)-OTHERS.pdf

1364-KOL-2008-ABSTRACT 1.1.pdf

1364-KOL-2008-ABSTRACT-1.2.pdf

1364-kol-2008-abstract.pdf

1364-KOL-2008-AMANDED CLAIMS-1.1.pdf

1364-KOL-2008-AMANDED CLAIMS.pdf

1364-KOL-2008-AMANDED PAGES OF SPECIFICATION.pdf

1364-kol-2008-claims.pdf

1364-KOL-2008-CORRESPONDENCE 1.1.pdf

1364-KOL-2008-CORRESPONDENCE 1.3.pdf

1364-KOL-2008-CORRESPONDENCE-1.2.pdf

1364-kol-2008-correspondence.pdf

1364-KOL-2008-DESCRIPTION (COMPLETE) 1.1.pdf

1364-KOL-2008-DESCRIPTION (COMPLETE)-1.2.pdf

1364-kol-2008-description (complete).pdf

1364-KOL-2008-DRAWINGS 1.1.pdf

1364-KOL-2008-DRAWINGS-1.2.pdf

1364-kol-2008-drawings.pdf

1364-KOL-2008-EXAMINATION REPORT REPLY RECIEVED.pdf

1364-KOL-2008-EXAMINATION REPORT.pdf

1364-KOL-2008-FORM 1 1.1.pdf

1364-KOL-2008-FORM 1-1.2.pdf

1364-kol-2008-form 1.pdf

1364-KOL-2008-FORM 18 1.1.pdf

1364-kol-2008-form 18.pdf

1364-KOL-2008-FORM 2 1.1.pdf

1364-KOL-2008-FORM 2-1.2.pdf

1364-kol-2008-form 2.pdf

1364-kol-2008-form 3.pdf

1364-kol-2008-gpa.pdf

1364-KOL-2008-GRANTED-ABSTRACT.pdf

1364-KOL-2008-GRANTED-CLAIMS.pdf

1364-KOL-2008-GRANTED-DESCRIPTION (COMPLETE).pdf

1364-KOL-2008-GRANTED-DRAWINGS.pdf

1364-KOL-2008-GRANTED-FORM 1.pdf

1364-KOL-2008-GRANTED-FORM 2.pdf

1364-KOL-2008-GRANTED-SPECIFICATION.pdf

1364-KOL-2008-OTHERS 1.1.pdf

1364-KOL-2008-OTHERS 1.3.pdf

1364-KOL-2008-OTHERS-1.2.pdf

1364-KOL-2008-REPLY TO EXAMINATION REPORT.pdf

1364-kol-2008-specification.pdf

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Patent Number

253475

Indian Patent Application Number

1364/KOL/2008

PG Journal Number

30/2012

Publication Date

27-Jul-2012

Grant Date

25-Jul-2012

Date of Filing

13-Aug-2008

Name of Patentee

TATA STEEL LIMITED

Applicant Address

RESEARCH AND DEVELOPMENT AND SCIENTIFIC SERVICES DIVISION, JAMSHEDPUR

Inventors:

#	Inventor's Name	Inventor's Address
1	MR. ATANU RANJAN PAL	TATA STEEL LIMITED RESEARCH AND DEVELOPMENT AND SCIENTIFIC SERVICES DIVISION, JAMSHEDPUR 831 001
2	MR. AMAN	TATA STEEL LIMITED RESEARCH AND DEVELOPMENT AND SCIENTIFIC SERVICES DIVISION, JAMSHEDPUR 831 001

PCT International Classification Number

C21B7/24

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1			NA