Patent Publication Number: US-2017356689-A1

Title: Lance assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application Ser. No. 62/343,630, filed May 31, 2016, and U.S. Provisional Patent Application Ser. No. 62/416,100, filed Nov. 1, 2016, the disclosures of which are hereby expressly incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure relates to a lance assembly. More particularly, the present disclosure relates to a desulfurization lance. 
     BACKGROUND OF THE DISCLOSURE 
     When processing steel, sulfur is an unwanted element. The presence of sulfur affects both the internal quality and the surface quality of steel and can contribute to steel brittleness. The presence of sulfur in steel also forms undesirable sulfides, which promotes granular weakness and cracks in steel during solidification. Sulfur has an adverse effect on the mechanical properties of steel and lowers the melting point, intergranular strength, and cohesion of steel. Therefore, removal of sulfur in steel is desired. 
     One desulfurization process requires the use of a desulfurization station where a reagent and carrier gas are injected into a mixture of hot molten steel to remove sulfur that is present within the mixture. The reagent and carrier gas may be injected into solution via an injector instrument and then presented to a lance for injection into the molten mixture. In some applications, the lance is stationary with respect to the solution, while in other applications, the lance rotates to stir or agitate the mixture, which improves the efficiency of the system and reduces overall process time as compared to the stationary lance. However, while a stationary lance may be less effective and efficient, a rotating lance incurs additional operating costs, machinery/processing units, and maintenance costs. Therefore, an improvement in the foregoing is desired where a lance is efficient, effective, and low in operation and maintenance costs. 
     SUMMARY 
     The present disclosure provides a lance assembly which includes a core coupled to a manifold having a plurality of reagent outlet tubes from which a reagent and a carrier gas are expelled. The plurality of reagent outlet tubes inhibit clogging of the lance assembly and require less reagent for desulfurization. 
     In one form thereof, the present disclosure provides a lance assembly. The lance assembly includes: a refractory element having a length; a core coaxial with the refractory element and extending substantially through the length of the refractory element, the core including: a reagent pipe extending substantially through the core; a manifold coupled to the core, the manifold coupled to a plurality of reagent outlet tubes that extend from the manifold, wherein each reagent outlet tube has a curvature different from other reagent outlet tubes. 
     In another form thereof, the present disclosure provides a lance assembly including: a refractory element having a length; a core coaxial with the refractory element and extending substantially through the length of the refractory element, the core including: a reagent pipe extending substantially through the core; a manifold coupled to the core, the manifold coupled to a plurality of reagent outlet tubes that extend from the manifold, the plurality of reagent outlet tubes configured to substantially inhibit plugging of the lance assembly; a cage adjacent to the core, wherein the core is coaxial with the reagent tube and the reagent tube extends substantially through the cage, the cage including a plurality of apertures through which the reagent tube and the reagent outlet tubes each pass through one of the plurality of apertures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is a perspective view of a fully assembled lance assembly; 
         FIG. 2  is a cross-section, side elevation view taken along line II-II of an embodiment of the lance assembly of  FIG. 1 ; 
         FIG. 3  is a perspective view of an upper portion of the lance assembly embodiment of  FIG. 2 ; 
         FIG. 4  is a perspective view of an upper portion of the lance assembly embodiment of  FIG. 2 ; 
         FIG. 5  is a side view of the upper portion of the lance assembly embodiment of  FIG. 2 ; 
         FIG. 6A  is a portion of an alternate lance assembly embodiment; 
         FIG. 6B  is a front view of a bottom portion of the portion of lance assembly embodiment of  FIG. 6A ; 
         FIG. 7A  is a side, plan view of the lance assembly embodiment of  FIG. 6A  in a landscape orientation; 
         FIG. 7B  is an enlarged side, plan view of a lower portion of the alternate lance assembly embodiment of  FIG. 6A  in a landscape orientation; 
         FIG. 7C  is a bottom, perspective view of a lower portion of the lance assembly embodiment of  FIG. 6A ; 
         FIG. 7D  is a side, plan view of a portion of the alternate embodiment of the lance assembly of  FIG. 6A  in a landscape orientation; 
         FIG. 7E  is a cross-sectional side, plan view of the embodiment in  FIG. 7D  taken along line E-E in a landscape orientation; 
         FIG. 8  is a top view of the lance assembly embodiment of  FIG. 6A ; 
         FIG. 9  is a top view of the lance assembly embodiment of  FIG. 6A  with a gas inlet omitted; 
         FIG. 10  is an alternate, bottom view of the lance assembly embodiment of  FIG. 6A ; 
         FIG. 11  is a perspective view of an upper portion of an alternate lance assembly embodiment; 
         FIG. 12  is a side view of the upper portion of the alternate lance assembly embodiment; 
         FIG. 13  is a perspective view of a lower portion of the alternate lance assembly embodiment of  FIG. 2 ; 
         FIG. 14  is a top view of the alternate lance embodiment of  FIG. 12  with a gas inlet omitted; 
         FIG. 15  is a top view of the alternate lance embodiment of  FIG. 12 ; 
         FIG. 16  is a bottom view of the alternate lance assembly embodiment of  FIG. 12 ; 
         FIG. 17  is a top view of an upper portion of an alternate lance assembly embodiment according to the present disclosure; 
         FIG. 18  is a top view of an upper portion of the lance assembly embodiment of  FIG. 17  according to the present disclosure; 
         FIG. 19  is a perspective view of a lower portion of the lance assembly embodiment of  FIG. 17  according to the present disclosure; 
         FIG. 20  is a perspective view of the lower portion of the lance assembly embodiment of  FIG. 19  according to the present disclosure; 
         FIG. 21  is a bottom view of the lower portion of the lance assembly embodiment of  FIG. 19  according to the present disclosure; 
         FIG. 22  is a bottom view of the alternate lance assembly embodiment of  FIG. 17 ; 
         FIG. 23  is a perspective view of an alternate lance assembly; 
         FIG. 24  is a perspective view of a manifold shown in the alternate lance assembly of  FIG. 23  according to the present disclosure; 
         FIG. 25  is a bottom view of the manifold of  FIG. 24  shown in the alternate lance assembly of  FIG. 23  according to the present disclosure; and 
         FIG. 26  is a perspective view of an alternate configuration of the alternate lance assembly of  FIG. 23  according to the present disclosure. 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner. 
     DETAILED DESCRIPTION 
     The present disclosure relates to desulfurization lances, such as lance assembly  10  described further below, which allow for a more effective and efficient distribution of reagents within a hot metal solution. 
     Referring to  FIG. 1 , multiple lance assemblies  10  are shown. As shown in  FIGS. 1-4 , lance assembly  10  includes an upper portion  14  and a lower portion  16  with a core  12  spanning a substantial portion of both upper portion  14  and lower portion  16 . In the illustrated embodiment, core  12  is a cylinder made of steel. However, it is contemplated that in alternative embodiments, core  12  may be a rectangular prism, triangular prism, or any other suitable shape. In an alternate embodiment, core  12  is made of stainless steel, or other suitable metal. 
     As best shown in  FIGS. 2-10 , core  12  includes reagent tubes  26  that span at least the entire length of core  12 . Reagent tubes  26  also include reagent inlets  28  and reagent outlets  30  both of which extend outside of core  12  from top surface  36  of core  12  and bottom surface  38  of core  12 , respectively. Reagent tubes  26  also include caps  29  ( FIGS. 3-5 ) that can be removably coupled to reagent inlet  28  or gas inlet  20 , thereby closing reagent tube  26  when necessary (e.g., when lance assembly  10  is not in use or undergoing maintenance). In one embodiment, cap  29  is removably coupled to reagent inlet  28  or gas inlet  20  by a plurality of grooves positioned on reagent tube  26  near reagent inlet  28  or on gas inlet  20 . Cap  29  has a plurality of ridges that engage with the plurality of grooves on reagent tube  26  and gas inlet  20 , thereby removably coupling cap  29  with reagent tube  26 . In other words, in one embodiment, cap  29  and tube  26  have a threaded interface permitting removable coupling of cap  29  to tube  26 . 
     Reagent tubes  26  act as carrier tubes by providing a conduit for desulfurization reagents to flow through core  12  and into a molten solution, which could be provided in a ladle (not shown). In the illustrated embodiment, reagent tubes  26  are ¾ inch diameter tubes made of steel. However, it is contemplated that in alternate embodiments, reagent tubes  26  may have other suitable diameters or be made of other suitable materials, such as stainless steel. In one exemplary embodiment, desulfurization reagents include lime and magnesium. However, it is contemplated that in alternate embodiments, other suitable desulfurization reagents may be used, such as calcium carbide, calcium oxide, calcium fluoride, magnesium oxide, and crystalline silica, or a blend thereof such as lime/spar. 
       FIG. 2  shows a plate  34  coupled to core  12 . In one exemplary embodiment, plate  34  couples lance assembly  10  to a stationary mounting assembly (not shown). Plate  34  and stationary mounting assembly cooperate to stabilize lance assembly  10  such that there is limited excess movement of lance assembly  10  during operation. By limiting the movement of lance assembly  10 , less stress is placed on the internal components of lance assembly  10  resulting in a longer overall lifespan for lance assembly  10 . 
     As shown in  FIGS. 2-5 and 8 , gas inlet  20  is also coupled to core  12  adjacent to top surface  36  to form a “Y” shaped configuration with core  12  and reagent tubes  26 . In an alternate embodiment, gas inlet  20  is coupled to core  12  at a different position along core  12  that may not be adjacent to top surface  36 . For example, gas inlet  20  may be positioned further down and away from top surface  36  of core  12 . Additionally, in a further alternate embodiment, gas inlet  20  may be coupled to core  12  such that an alternate shaped configuration is formed with core  12  and reagent tubes  26 . In the illustrated embodiment, gas inlet  20  is shown to be welded to core  12  to create a closed chamber within core  12  as discussed further below. However, it is contemplated that in alternate embodiments, gas inlet  20  may be coupled to core  12  by other suitable means such as a fastener, couplers, etc. 
     Gas inlet  20  has corresponding gas outlets  22 ,  24  described further below. Gas inlet  20  provides a pathway for carrier gas to enter into core  12  such that carrier gas fills the annular region  23  ( FIG. 8 ) of core  12  outside of reagent tubes  26 . In an alternate embodiment, gas inlet  20  and gas outlets  22 ,  24  are connected to each other by a separate tube that spans a substantial portion of the length of core  12 . Carrier gas would enter though gas inlet  20  and travel through the tube and exit corresponding gas outlet  22 ,  24 . In an exemplary embodiment, the carrier gas includes nitrogen gas or argon gas. However, it is contemplated that in alternate embodiments, other suitable carrier gasses may be used, such as helium, hydrogen, or any other inert gas. 
     Upper portion  14  also includes a portion of support housing  32  with the other portion of support housing  32  included in lower portion  16 . Support housing  32  is coaxial with core  12 ; support housing  32  is also coupled to refractory element  18 . In the illustrated embodiment, support housing  32  is anchored to refractory element  18  ( FIG. 1 ) to provide a seal at the interface of support housing  32  and refractory element  18  and inhibit other materials from entering refractory element  18 . However, it is contemplated that in alternate embodiments, support housing  32  is coupled to refractory element  18  by other suitable means such as couplers, fasteners, etc. comprising different sizes and types of structural steel products. Support housing  32  also functions to provide additional support to core  12  to maintain the alignment between core  12  of upper portion  14  and refractory element  18  of lower portion  16 . Support housing  32  also helps to maintain the alignment between outlets  22 ,  24 ,  30  for the carrier gas and desulfurization reagents and the openings provided on refractory element  18  by coupling upper portion  14  with lower portion  16  of lance assembly  10 . 
     Like core  12 , in the illustrated embodiment, support housing  32  is in the shape of a cylinder. However, it is contemplated that in alternative embodiments, support housing  32  may be a rectangular prism, triangular prism frustoconical, or any other suitable shape. In an exemplary embodiment, support housing  32  is made of carbon steel. In an alternate embodiment, support housing  32  is made of stainless steel or other suitable metals. 
     Lower portion  16  of core  12  includes gas outlet  22 , upper gas outlets  24 , and reagent outlets  30 . Reagent outlets  30  and gas outlet  22  extend from the bottom surface  38  of core  12 . Bottom surface  38  and top surface  36  of core  12  are welded closed to create a pressurized chamber as discussed further below. By welding bottom surface  38  closed, gas outlet  22  and reagent outlets  30  are welded to bottom surface  38  with reagent tubes  26  spanning the length of core  12 . As shown in  FIGS. 6A-6B, 7A-7E, and 10 , reagent tube  26  extends downwardly away from bottom surface  38  and bends away from axis A ( FIG. 6B ) of core  12  defining an angle with axis A of core  12 . Reagent tubes  26  bend away from axis A of core  12  such that reagent outlets  30  engage with the periphery of refractory element  18  as described further below. In an exemplary embodiment, the angle defined between reagent tubes  26  and axis A of core  12  may be as little as 0°, 15°, 20°, 25°, 30°, as great as 45°, 50°, 55°, 60°, 90°, or within any range defined between any two of the foregoing values, such as 0° to 90°. 
     Gas outlet  22  ( FIG. 2 ) is welded to bottom surface  38  of core  12  and extends a distance away from bottom surface  38  such that gas outlet  22  engages with bottom surface  42  of refractory element  18 . In  FIG. 7 , an opening  44  is present along bottom surface  38  and may be configured to receive gas outlet  22 ; however, opening  44  may be welded closed as well. In an alternate embodiment, gas outlet  22  bends away from axis A of core  12  at an angle such that gas outlet  22  engages with the periphery of refractory element  18  where the angle defined between gas outlet  22  and axis A of core  12  may be as little as 0°, 15°, 20°, 25°, 30°, as great as 45°, 50°, 55°, 60°, 90°, or within any range defined between any two of the foregoing values, such as 0° to 90°. 
     Lower portion  16  of lance assembly  10  also includes upper gas outlets  24  positioned along the periphery of core  12  within refractory element  18 . Both gas outlet  22  and upper gas outlets  24  are shown as frustoconical plugs. In an alternate embodiment, gas outlet  22  and upper gas outlets  24  may take the shape of a cylindrical plug, rectangular plug, or other suitable shape. 
     Upper gas outlets  24  are positioned at a distance above bottom surface  38  of core  12 . In an exemplary embodiment, upper gas outlets  24  may be positioned at a distance above bottom surface  38  that is as little as 2 inches, 6 inches, 10 inches, 14 inches, as great as up to 4 inches below a top potion of lower portion  16 , 6 inches below a top portion of lower portion  16 , 8 inches below a top portion of lower portion  16 , or within any range defined between any two of the foregoing values. 
     Upper gas outlets  24  extend from core  12  forming an angle between axis A of core  12  and upper gas outlet  24 . In an exemplary embodiment, the angle defined between the reagent tubes  26  and axis A of core  12  may be as little as 0°, 15°, 30°, 45°, as great as , 55°, 60°, 75°, 90°, or within any range defined between any two of the foregoing values, such as 0° to 90°. In a further exemplary embodiment, upper gas outlets  24  may include as few as 1 outlet, 2 outlets, 3 outlets, 4 outlets, as great as 5 outlets, 6 outlets, 7 outlets, 8 outlets, or within any range defined between any two of the foregoing values. 
     As shown in  FIGS. 7A-7D  and  FIGS. 8-10 , upper gas outlets  24  are positioned along the periphery of core  12  such that the upper gas outlets are wrapped helically around core  12 . In this way, carrier gas can be injected into the molten mixture through upper gas outlets  24  in a greater number of directions and at different depths. The mechanism in which lance assembly  10  operates with respect to the gas outlets  22 ,  24  provides benefits to the overall desulfurization process as discussed further below. 
     Similar to reagent tubes  26 , gas outlet  22 , regent inlets  28 , and gas inlet  20 , upper gas outlets  24  are welded to core  12  so that core  12  remains sealed and provides a pressurized chamber when lance assembly  10  is in operation. Upper gas outlets  24  also extend from core  12  such that upper gas outlets  24  engage with the periphery of refractory element  18  as described further below. 
     As shown in  FIGS. 2-4 , core  12  is welded closed at top surface  36 , bottom surface  38 , and at the junctions where gas inlet  20 , and gas outlets  22 ,  24  couple to core  12 . By welding core  12  closed, a pressurized chamber is created when carrier gas is injected into core  12 . In an exemplary embodiment, the pressure within core  12  may be as little as 15 psi, 30 psi, 45 psi, 60 psi, 75 psi as great as 230 psi, 245 psi, 260 psi, 275 psi, or within any range defined between any two of the foregoing values, such as 30 psi to 260 psi. However, it is contemplated that in alternate embodiments, core  12  may operate at other suitable pressures. Pressurizing core  12  with carrier gas inhibits the molten mixture, within which lance assembly  10  is placed, from entering and potentially damaging refractory element  18  and reagent tubes  26  within core  12 . 
     Lower portion  16  also includes refractory element  18 . Refractory element  18  is coaxial with core  12  and includes a top surface  40  and a bottom surface  42 . In the illustrated embodiment, refractory element  18  is shown to be a large cylinder made of steel that encompasses a portion of core  12  and support housing  32 . In an alternate embodiment, refractory element  18  is of a spherical, rectangular prism, triangular prism, or any other suitable shape. In an alternate embodiment, refractory element is made of stainless steel or any other suitable metal. 
     Refractory element  18  also includes a plurality of openings around its periphery and bottom surface  42  that correspond with gas outlets  22 ,  24  and reagent outlets  30 . When lance assembly  10  is fully assembled, the openings along bottom surface  42  and the periphery of refractory element  18  substantially align with gas outlets  22 ,  24  and reagent outlets  30 . The openings are substantially the same size as reagent outlets  20  and gas outlets  22 ,  24 , which provides for effective delivery of desulfurization reagents and carrier gas while also inhibiting molten metal solution from entering refractory element  18  and damaging parts of lance assembly  10 . 
       FIGS. 11-16  show an alternate embodiment of lance assembly  10  in lance assembly  110  (not on figures). Lance assembly  110  utilizes similar design features and operational principles as lance assembly  10  described above, and corresponding structures and features of lance assembly  110  have corresponding reference numerals to lance assembly  10 , except with  100  added thereto. However, lance assembly  110  includes a core  112  and a support housing  132  that are different shapes than core  12  of lance assembly  10 . In the illustrated embodiment, core  112  and support housing  132  are coaxial rectangular prisms. However, it is contemplated that in alternate embodiments, core  112  and support housing  132  may include other suitable shapes, such as cylinders. 
     Lance assembly  110  may also include upper gas outlets  124  that are positioned differently along the periphery of core  112  than upper gas outlets  24  of lance assembly  10 . As shown in  FIG. 13 , upper gas outlets  124  are positioned on opposite surfaces of the periphery of core  112  while the remaining surfaces of core  112  may not have an upper gas outlet  124  positioned along the surfaces. In an alternate embodiment, upper gas outlets  124  may be disposed on the same surface or adjacent surfaces of core  112 . In the illustrated embodiment, similar to the gas outlet configurations of the embodiments shown in  FIGS. 7A-7E, 8-10, and 14-16 , carrier gas can be injected into the molten mixture through upper gas outlets  124  and corresponding openings on refractory element  118  in a greater number of directions and at different depths within the mixture, which provides benefits to the overall desulfurization as discussed further below. 
     In operation, lance assembly  10 ,  110  is inserted into a ladle (not shown) containing a hot molten metal mixture (not shown). A carrier gas and desulfurization reagents are provided to lance assembly  10 ,  110  via gas inlet  20 ,  120  and reagent tube  26 ,  126 , respectively. In an exemplary embodiment, the carrier gas comprises nitrogen gas or argon, and the desulfurization reagents are lime and/or magnesium. In alternate embodiments, other suitable carrier gases (e.g., helium, hydrogen, or any other inert gas) and desulfurization reagents (e.g., calcium carbide, calcium oxide, calcium fluoride, magnesium oxide, and crystalline silica, or a blend thereof such as lime/spar) may be used. The desulfurization reagents flow through reagent tubes  26 ,  126  into the molten solution via reagent outlets  30 ,  130  and their corresponding lance openings. The carrier gas that is fed through gas inlet  20 ,  120  remains within core  12 ,  112  as pressure within core begins to accumulate. When core  12 ,  112  becomes over pressurized with carrier gas, upper gas outlets  24 ,  124  and gas outlet  22 ,  122  serve as pressure releases by injecting carrier gas from core  12 ,  112  into the mixture. By this process, carrier gas is continually injected into the molten solution at different locations within the solution based on the location of the gas outlets  22 ,  24 ,  122 ,  124 . 
     Advantageously, the continual injection of the carrier gas keeps the previously injected desulfurization reagents within the molten mixture for a greater period of time. This allows the desulfurization reagents to react with the molten mixture for a longer period of time, resulting in a greater reaction yield. Further, less desulfurization reagents are needed for the desulfurization process, resulting in significant savings in raw material costs. In an exemplary embodiment, there is a  10 - 20 % reduction in the amount of desulfurization reagents needed for the desulfurization process with lance assembly  10 ,  110 . 
     Additionally, there is no need to rotate lance assembly  10 ,  110  as the reagent and carrier gas are injected in multiple directions and at different depths within the molten mixture. By not rotating lance assembly  10 , further savings on maintenance and operational costs are realized by the user as fewer moving parts and processing units are involved. 
       FIGS. 17-22  show an alternate lance assembly  200 . Lance assembly  200  includes an upper portion  201  ( FIGS. 17 and 18 ) and a lower portion  202  ( FIGS. 19-21 ). Upper portion  201  includes manifold  212  and reagent tube  203 . In one embodiment, reagent tube  203  is coaxial with manifold  212 . However, it is contemplated that in alternate embodiments, reagent  203  and manifold  212  are not coaxial with each other. Reagent tube  203  includes apertures  204  and edges  206  that are positioned at one end of reagent tube  203 . In the illustrated embodiment, three apertures  204  exist; each aperture making up one third of the area of reagent tube  203 . However, it is contemplated that in alternate embodiments, alternate configurations of apertures  204  may be used (e.g., a single aperture, dual apertures  204  each counting for half the area of reagent tube  203 , etc.). In one embodiment, each aperture  204  maybe an end of a cylindrical tube that runs the length of manifold  212 , where each cylindrical tube occupies the same volume within reagent tube  203 . In an alternate embodiment, apertures  204  provide openings for desulfurization reagents to enter manifold  212  where desulfurization reagents are mixed together after passing through one of apertures  204 . 
     Edges  206  are welded to reagent tube  203  and separate apertures  204  from each other. In an alternate embodiment, edges  206  are coupled to reagent tube  203  by other suitable means such as couplers, fasteners, etc. In the illustrated embodiment, edges  206  form a Y-shaped pattern at one end of the reagent tube  203 . Edges  206  are pointed and sharp to inhibit desulfurization reagents from coagulating and clogging manifold  212  while lance assembly  200  operates and desulfurization reagents pass through manifold  212 . In other words, edges  206  serve to break up clotting of desulfurization reagents. Edges  206  are also inclined such that the intersection of the edges within reagent tube  203  is the highest point of edges  206 , and each of edges  206  decrease in height with distance toward the edge of reagent tube  203 . The inclined configuration of edges  206  serves to further inhibit coagulation of the desulfurization reagents that could clot manifold  212  while in operation. 
     While an inclined Y-shaped configuration is shown for edges  206 , it is contemplated that alternate configurations for edges  206  may be used (e.g., a level T-shaped configuration, an inclined T-shaped configuration, a level Y-shaped configuration, etc.). 
     Reagent tube  203  also includes surfaces  208  surrounding apertures  204  that are positioned between apertures  204  and edges  206  of reagent tube  203 . In the illustrated embodiment, the highest portion of surfaces  208  are near edges  206  and surfaces  208  slope downwardly with distance toward apertures  204  to form a downward sloping configuration. The downward sloping configuration of surfaces  208  serves to inhibit coagulation and clotting of desulfurization reagents within manifold  212  and reagent tube  203  by using transport gas pressure and gravity to help move desulfurization reagents into apertures  204 . However, it is contemplated that in alternate embodiments, surfaces  208  are flat. 
     In one exemplary embodiment, desulfurization reagents entering reagent tube  203  include lime and magnesium with a carrier gas. In an exemplary embodiment, the carrier gas includes nitrogen gas or argon gas. However, it is contemplated that in alternate embodiments, other desulfurization reagents may be used, such as calcium carbide, calcium oxide, calcium fluoride, magnesium oxide, crystalline silica, or a blend thereof such as lime/spar, and other suitable carrier gases, such as helium, hydrogen, or any other inert gas. 
       FIGS. 19-21  show a lower portion  202  of lance assembly  200 . Lower portion  202  includes a continuation of manifold  212  and reagent tube  203  from upper portion  201 , a second cylinder  214 , and outlets  217  that each include an upper portion  216  and a lower portion  218 . 
     Reagent tube  203  and second cylinder  214  are coupled to each other. In the illustrated embodiment, second cylinder  214  frictionally engages with reagent tube  203 . However, it is contemplated that in an alternate embodiment, reagent tube  203  and second cylinder  203  are coupled to each other by other suitable means such as couplers, fasteners, etc. Second cylinder  214  is coupled to reagent tube  203  such that desulfurization reagents flowing through reagent tube  203  and into second cylinder  214  does not accumulate along the side walls of either cylinder  203 ,  214 . Second cylinder  214  has an outer diameter  207  that is greater than the inner diameter of reagent tube  203  but less than the outer diameter  205  of reagent tube  203 . When coupled together, the difference in diameters between reagent tube  203  and second cylinder  214  assist to inhibit coagulation and accumulation of desulfurization reagents along the side walls of either reagent tube  203  or second cylinder  214  as the transition between reagent tube  203  and second cylinder  214  is smooth. The smooth transition enables desulfurization reagents to flow through without adhering to the walls or the interface of second cylinder  214  and reagent tube  203 . 
     As desulfurization reagents move downward through second cylinder  214 , desulfurization reagents will split off into multiple outlets  217  which are coupled to the bottom surface of manifold  212 . Outlets  217  include an upper portion  216  and a lower portion  218 . In the illustrated embodiment, upper portion  216  is angled with respect to the central axis of second cylinder  214 . However, it is contemplated that in alternative embodiments upper portion  216  is parallel with the central axis of cylinder  214 . 
     Upper portion  216  funnels desulfurization reagents downward to lower portion  218 , which is coupled to upper portion  216  at junction  220 . As shown in  FIG. 19 , lower portion  218  is substantially parallel with the central axis of cylinder  214 . However, it is contemplated that in alternate embodiments ( FIG. 20 ) lower portion  218  is angled with respect to the central axis of cylinder  214 . 
     As mentioned earlier, upper portion  216  and lower portion  218  are coupled at junction  220 . In an exemplary embodiment, upper portion  216  is rounded so that a pointed edge is not formed at junction  220 . Enhancing the curvature of upper portion  216  at junction  220  eases the transition between upper portion  216  and lower portion  218  and enables desulfurization reagents to move from upper portion  216  to lower portion  218  without coagulating or attaching to the inner walls of either upper portion  216  or lower portion  218 . 
     Lower portion  218  includes an outlet cylinder  222  coupled to lower portion  218  as shown in  FIGS. 20 and 21 . In an alternate embodiment, outlet cylinders  222  may be integrally formed with lower portions  218 . As shown in  FIG. 21 , outlet cylinders  222  are positioned at different heights with respect to the bottom surface of manifold  212 . By varying the location of outlet cylinders  222  within manifold  212 , desulfurization reagents can be injected at various levels within the molten material for desulfurization as further described below. 
     The bottom surface of outlet cylinders  222  are coupled with reagent tubes  226  ( FIG. 22 ), which extend from the bottom surface of manifold  212 . Reagent tubes  226  serve to inject desulfurization reagents into the molten material for the purposes of desulfurization. In one embodiment, reagent tubes  226  are frictionally engaged with outlet tubes  222 . In an alternate embodiment, reagent tubes  226  may be coupled to outlet tube  222  by other suitable means such as fasteners, couplers, etc. 
     As shown in  FIG. 22 , each reagent tube  226  has its own curvature with respect to the central axis A ( FIG. 19 ) of manifold  212 . In one embodiment, reagent tube  226  extends a distance from manifold  212  and bends away from axis A of manifold  212  at an angle relative to axis A of manifold  212 . The angle may be as little as 0°, 15°, 20°, 25°, 30°, as great as 45°, 50°, 55°, 60°, 90°, or within any range defined between any two of the foregoing values, such as 0° to 90. 
     Each reagent tube  226  also varies in distance from the bottom surface of manifold  212 , which promotes improved application of the desulfurization reagents into the molten material during operation. Having different orientations of reagent tubes  226  at various heights within the molten mixture allow desulfurization reagents and carrier gas to be injected in multiple directions and at different depths within the molten mixture. As a result, there is no need to rotate lance assembly  200  as effective application of desulfurization reagents within the solution is achieved. By not rotating lance assembly  200 , further savings on maintenance and operational costs are realized by the user since fewer moving parts and processing units are involved. 
     The configuration of lance assembly  200  does not require a separate gas line. Desulfurization reagents, as described above, and can enter lance assembly  200  and be injected into the molten mixture for effective desulfurization. By having an assembly that does not require a separate gas line, savings in maintenance and equipment costs are realized. Furthermore, the configuration of reagent tubes  226  also permits continuous injection of desulfurization reagents into the molten mixture. This keeps the desulfurization reagents within the molten mixture for a greater period of time, which allows the desulfurization reagents to react with the molten mixture for a greater period of time, and improves the reaction yield. Also, less desulfurization reagents are needed for the desulfurization process, resulting in significant savings in raw material costs. In one exemplary embodiment, 15-20% less desulfurization reagents are needed for desulfurization. 
     In one embodiment, reagent tubes  226 , outlet tubes  222 , outlets  217 , second cylinder  214 , reagent tube  203 , and manifold  212  are made from stainless steel. However, it is contemplated that in alternate embodiments other suitable materials (e.g., iron) may be used. 
     Lance assembly  200  is encased by a refractory element (not shown). As shown in  FIG. 17 , bottom plate  242  is positioned below reagent outlet tubes  226 . In one embodiment, bottom plate  242  of refractory element is positioned as little as 2 inches, 4 inches, 6 inches, or as great as 8 inches, 10 inches, 12 inches below reagent tubes  226 , or within any range defined therebetween. Bottom plate  242  forms a bottom surface of the refractory element. In one embodiment, the refractory element is a cylinder. In an alternate embodiment, the refractory element is a rectangular prism. 
     The edges of the refractory element that extend vertically from bottom plate  242  engage with reagent tube  226  such that reagent tubes  226  are not exposed to the molten mixture by extending outside the vertical edges. In one embodiment, the vertical edges of refractory element and the outlets of regent tubes  226  are frictionally engaged. In an alternate embodiment, the vertical edges of the refractory element and the outlets of reagent tubes  226  may be coupled to each other by other suitable means such as fasteners, couplers, etc. The vertical surfaces and the outlets of reagent tubes  226  form a tight fit such that the refractory element cannot slideably move along lance assembly  200 . In one embodiment, the refractory element has a top surface that engages at a point along manifold  212  of lance assembly  200  leaving a portion of manifold  212  exposed. In an alternate embodiment, the refractory element envelopes manifold  212  such that manifold  212  is not exposed. 
     Referring to  FIG. 23 , a third embodiment of lance assembly  300  is shown. Lance assembly  300  includes a core  305 , having a reagent tube  304  passing therethrough. Reagent tube  304  extends from the bottom of core  305  and beyond bottom plate  342  of refractory element (not shown). Reagent tube  304  is configured to receive and pass desulfurization reagents and carrier gases through core  305 . In one embodiment, desulfurization reagents include lime and/or magnesium, and carrier gases include nitrogen gas or argon. In alternate embodiments, other suitable carrier gases (e.g., helium, hydrogen, or any other inert gas) and desulfurization reagents (e.g., calcium carbide, calcium oxide, calcium fluoride, magnesium oxide, and crystalline silica, or a blend thereof such as lime/spar) may be used. 
     Lance assembly  300  also includes manifold  312  coupled to core  305 . As shown in  FIG. 23 . manifold  312  is coupled to the side of core  305 . However, it is contemplated that in alternate embodiments, manifold  312  may be positioned within core  305  and coaxial with reagent tube  304  or within core  305  as shown in  FIG. 26 . As shown in  FIG. 26 , reagent tube  307  is provided within core  305 , and manifold  312  is coupled to reagent tube  307 . At lower portion  302  of core  305 , reagent outlet tubes  326  extend from outlets  322  of manifold  312  as discussed herein. 
     As shown in  FIGS. 24 and 25 , manifold  312  is similar in structure as manifold  212 . Manifold  312  includes an upper portion  301  ( FIG. 24 ) and a lower portion  302  ( FIG. 25 ). Upper portion  301  includes an interior reagent tube  303  within manifold  312 , which includes openings  314  that are configured to receive desulfurization reagents (e.g., magnesium, lime, or a mixture thereof, etc.) from a reagent tube  307  that is coupled to interior reagent tube  303 . 
     Openings  314  are separated from each other by edges  306  shown in  FIG. 24 . Similar to edges  206  ( FIG. 17 ), edges  306  separate apertures  314  from each other. In an alternate embodiment, edges  306  are coupled to reagent tube  307  by other suitable means such as couplers, fasteners, etc. In the illustrated embodiment, edges  306  form a Y-shaped pattern at one end of the interior reagent tube  303 . Edges  306  are pointed and have a sharp edge to inhibit desulfurization reagents from coagulating and clogging manifold  312  while desulfurization reagents pass through manifold  312  during operation of lance assembly  300 . In other words, edges  306  function to break up clotting of desulfurization reagents. Edges  306  are also inclined such that the intersection of the edges within reagent tube  307  is the highest point of the intersection of edges  306 , and each of edges  306  decrease in height with distance toward the edge of reagent tube  307 . The inclined configuration of edges  306  serves to further inhibit coagulation of the desulfurization reagents that could clot manifold  312  while in operation. 
     Lower portion  302  of manifold  312  includes a plurality of outlets  322  each of which correspond to at least one of apertures  314 . Outlets  322  are coupled to reagent outlet tubes  326  ( FIG. 23 ). Reagent outlet tubes  326  operate as conduits for injecting desulfurization reagents and/or carrier gas into the molten solution within which lance assembly  300  is inserted. Reagent outlet tubes  326  are made from plastic tubing, which can include compounds such as polyvinyl chloride (PVC) tubing, high density polyethylene (HDPE) plastic tubing, perfluoroalkoxy alkane (PFA) plastic tubing, and fluorinated ethylene propylene (FEP) plastic tubing. However, it is contemplated that other compositions may be used such as other ferrous materials or non-ferrous materials, which includes different grades of stainless steel, different grades of steel, aluminum, and iconel. 
     As shown in  FIG. 23 , reagent outlet tubes  326  curve outwards from lower portion  302  and extend such that the outlet of reagent outlet tubes  326  are flush with the refractory element (not shown). When initially assembled within the refractory element, portions of reagent outlet tubes  326  extend beyond the outer surface of the refractory element. Reagent outlet tubes  326  burn out during the firing process leaving a refractory outlet port. 
     Further, reagent outlet tubes  326  curve outwardly in different directions in order to improve distribution of desulfurization reagents within the molten solution within which lance assembly  300  is placed. Additionally, by varying the location of reagent outlet tubes  326 , rotation of the molten solution may result from the varied injection points of the desulfurization reagents, which yields improved desulfurization properties as discussed below. 
     Due to the materials used in reagent outlet tubes  326  (e.g., plastic tubing), reagent outlet tubes  326  experience substantially less plugging when desulfurization reagents pass through. This reduction in plugging yields improved desulfurization capabilities of lance assembly  300  as a reduced amount of desulfurization agents are needed to achieve sufficient desulfurization of the molten solution. In other words, in an exemplary embodiment, less lime and/or magnesium is needed. In one exemplary embodiment, 10-25% less reagent is needed. Furthermore, the resulting rotational motion of the molten solution from injection of desulfurization reagents also reduces the amount of desulfurization reagents used due to the improved distribution of desulfurization reagents within the molten solution. By requiring a reduced amount of reagents for the desulfurization process, a significant amount of savings in material costs is achieved. There also is a reduction in processing time. 
     Referring back to  FIG. 23 , a cage  315  is shown; cage  315  is adjacent to an end of core  305 . Cage  315  is co-axial with and coupled to reagent tube  304  and includes a plurality of discs  316   a - d  that are held in alignment with one another by a plurality of rods  317  that are coupled to discs  316   a - d . Each disc  316   a - d  includes apertures  318  that are positioned radially around the center of discs  316   a - d  and are in alignment with apertures  318  of other discs  316   a - d . As shown in  FIG. 23 , reagent outlet tubes  326  are fed through aligned apertures  318  to inhibit substantial movement of tubes  326  after assembly. However, it is contemplated that in alternate embodiments, reagent outlet tubes are fed through apertures  318  that are not in substantial alignment with one another. 
     Due to the configuration of cage  315 , additional manifolds  312  (with additional reagent outlet tubes  326 ) may be coupled externally to core  305  where the additional reagent outlet tubes  326  of the additional manifolds are fed through different or unoccupied aligned apertures  318  of cage  315  to inhibit entanglement. By having numerous manifolds  312  and reagent outlet tubes  326  positioned around core  305  of lance assembly  300 , there are additional outlet ports of lance assembly  300  such that a greater amount of desulfurization reagents and carrier gas can be injected into the molten solution, as needed, yielding the aforementioned advantages. 
     EXAMPLES 
     Example 1 
       
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 Average Amount of Reagent Used in Desulfurization 
               
            
           
           
               
               
               
               
            
               
                   
                 Maximum Average 
                 Average Magnesium 
                 Average Sulfur 
               
               
                   
                 Sulfur 
                 Used (pounds of 
                 Concentration 
               
               
                   
                 Concentration 
                 Magnesium per part 
                 After 
               
               
                 Lance 
                 Before Treatment 
                 of sulfur per ton 
                 Treatment 
               
               
                 Assembly 
                 (ppm) 
                 of hot metal) 
                 (ppm) 
               
               
                   
               
               
                 Assembly 1 
                 0.0051 
                 87 
                 0.0010 
               
               
                 Assembly 2 
                 0.0062 
                 96 
                 0.0014 
               
               
                   
               
            
           
         
       
     
     Example 1 tested two lance assemblies under the same conditions to measure their respective effectiveness in desulfurization applications. During operation, a carrier gas of nitrogen was injected into the core of the lance assembly to create a pressurized chamber of 80-85 psi within the core, and magnesium and lime were added to the lance assembly via the reagent tubes. Assembly 1 was the lance of the present disclosure, while Assembly 2 was a standard lance previously used. As shown in Table 1, Assembly 1 required an average amount of 87 pounds of magnesium per part of sulfur per ton of hot metal used, to achieve an approximate 80% reduction in sulfur content. Assembly 2 required 96 pounds of magnesium per part of sulfur per ton of hot metal used to achieve an approximate 77% reduction in sulfur content. The data showed that with Assembly 1, a greater amount of sulfur was removed while using approximately 10% less reagent (lime and magnesium) as compared to Assembly 2. 
     While this invention has been described as having exemplary designs, the present disclosure can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.