Modular vault structure of pellet circular cooler and manufacturing method of modular vault structure

Abstract

The invention belongs to the technical field of pellet cooling equipment, and particularly discloses a modular arch crown structure of a pellet circular cooler and a manufacturing method thereof.The modular arch crown structure of the pellet circular cooler comprises a double-curvature arch crown formed by splicing a plurality of prefabricated arch crown modules along circular cooler trolley breast boards, orthogonal net-shaped steel bar frameworks are arranged in the arch crown modules, and nickel-chromium alloy embedded parts are embedded in the arch crown modules; the side edge of the module is provided with a tenon-mortise coupling system and a positioning pin hole, an abutted seam is filled with an aluminum silicate fiber felt and a high-temperature sealant, and factory prefabrication and on-site rapid assembly are achieved through layered pouring of a nanometer reinforced castable and a low-temperature self-curing adhesive. The problems that a traditional cast-in-place vault cracks, the air leakage rate is high, the construction period is long and the like are solved through double-curvature thin shell homogenization stress distribution, dovetail joint-sliding groove thermal expansion compensation and a static labyrinth sealing structure.

Description

Technical Field

[0001] The present invention relates to the technical field of pellet cooling equipment, and in particular to a modular dome structure of a pellet ring cooler and a manufacturing method thereof. Background Art

[0002] The sealing top of traditional pelletizing annular coolers generally utilizes a composite structure of on-site cast high-aluminum castables and metal anchors. During construction, temporary molds must be constructed on the annular cooler trolley railings for layer-by-layer casting. This requires long-term curing in high-temperature ovens, resulting in a long construction period of approximately 45 days and poor environmental adaptability. Because the on-site casting process makes it difficult to precisely control the density of the castable, air holes and microcracks are easily generated within the structure. Under high temperatures of 800-1000°C and frequent thermal shock conditions, the castables begin to crack and peel after about two years. Metal anchors are oxidized and deformed by high temperatures and fail, further exacerbating the risk of structural collapse. Furthermore, the joints between modules rely solely on simple overlap or bolting, lacking thermal expansion compensation, resulting in air leakage rates as high as 15%-20%, severely reducing cooling efficiency and increasing energy consumption.

[0003] Patent publication number CN201837254U discloses a pellet ring cooler for use in pellet production lines. It has corresponding inner and outer rings, and a refractory lining on the inner side of the guardrails of the inner and outer rings. The refractory lining is characterized by phosphate-bonded mullite bricks, a refractory fiber blanket lining between the phosphate-bonded mullite bricks and the guardrails, and high-temperature mortar filling the gaps between the phosphate-bonded mullite bricks. A refractory castable layer is provided above the guardrails, and the outer side of the refractory castable layer is a shell. The refractory castable layer contains anchors welded to the shell. Phosphate-bonded mullite bricks are highly wear-resistant, thermally shock-resistant, and erosion-resistant, giving the pellet ring cooler excellent durability, integrity, and service life.

[0004] The above solution adopts a composite structure of on-site cast high-aluminum castables and metal anchors, which has problems such as long construction period and poor environmental adaptability. Summary of the Invention

[0005] The object of the present invention is to provide a modular arch structure of a pellet ring cooler and a manufacturing method thereof, so as to solve the problems of long on-site pouring construction period and poor environmental adaptability.

[0006] In order to achieve the above-mentioned purpose, the basic solution provided by the present invention is: a modular arch structure of a pelletizing ring cooler, including an arch body, wherein the arch body is composed of a plurality of arch modules, and the plurality of arch modules are spliced ​​into a circular ring along the railing of the ring cooler trolley. A steel frame is provided in the arch module, and the steel frame is composed of longitudinal steel bars and transverse steel bars cross-welded. A tenon is provided on one side of the arch module, and a mortise is provided on the other side of the arch module. The fitting clearance between the mortise and the tenon is ≤0.5mm, and positioning pin holes are provided on the tenon and the mortise. Aluminum silicate fiber felt is filled between adjacent arch modules. The arch module is cast by nano-reinforced castable material, and the arch module is a hyperbolic arch.

[0007] The principles and beneficial effects of the present invention are: 1. Through the geometric design of double curvature, the load is evenly distributed as circumferential compressive stress, avoiding local stress concentration, and no additional reinforcement support is required, thereby reducing material consumption.

[0008] 2. Longitudinal and transverse steel bars are cross-welded to form a rigid grid, and embedded parts are anchored in the castable to form a composite reinforcement system. Nickel-chromium alloy is resistant to high temperatures ≥1000°C, solving the problem of high-temperature oxidation and deformation of traditional carbon steel anchors; nano ZrO2 particles (20-50nm) enhance the toughness of the castable and resist thermal shock cycles up to 32 times.

[0009] 3. After the stepped tenon is embedded in the mortise, the wear-resistant ceramic coating inside the mortise reduces friction resistance and allows thermal expansion displacement.

[0010] 4. There is no need to cast on the railing of the ring cooler trolley, no need to repeatedly disassemble and assemble the casting mold, and no need for furnace curing, which greatly shortens the construction time.

[0011] Option 2, a preferred alternative to the basic option, pre-embeds a nickel-chromium alloy component within the dome module. The component extends beyond the module surface and is provided with a lifting hole. This component enhances the structural strength of the dome module and can be used for lifting with a hoist, facilitating transportation and installation with lifting equipment.

[0012] Option 3, a preferred alternative to the basic solution, features a stepped structure with 3-5 steps, each with a height difference of 5-8mm. The inner wall of the tenon groove is sprayed with a wear-resistant ceramic coating. The multiple stepped protrusions create a tortuous airflow path, increasing leakage resistance. Aluminum silicate fiber felt fills the gaps, providing resistance to high-temperature airflow.

[0013] Option 4 is the preferred option of the basic option. The plane projection size of the dome module is 2m×2m to 3m×3m, the thickness is 200-300mm, and the curvature radius of the dome module ranges from 1200mm to 1500mm.

[0014] Option 5, a preferred alternative to the basic option, comprises a nano-enhanced castable material comprising, by mass, 75%-80% Al2O3, 10%-15% SiO2, and 3%-5% nano-ZrO2 particles with a particle size of 20nm to 50nm. The hyperbolic geometric design evenly distributes the load as hoop compressive stress, avoiding localized stress concentration.

[0015] Solution 6: A method for manufacturing a modular dome structure of a pellet ring cooler, characterized by comprising the following steps: S1: Casting the vault module: Nano-enhanced castables are cast in layers in the mold, with each layer ≤50mm thick. After each layer is cast, a high-frequency vibrator is used to remove bubbles. The next layer can be cast only after all bubbles are completely expelled. After two layers are cast, the steel skeleton is placed in the nano-enhanced castable, and the nickel-chromium alloy embedded parts are placed on the steel skeleton. The remaining layers are then cast. The curing conditions are a temperature of 20-30°C and a humidity of ≥90%. S2: Assemble the arch body: Use a bridge crane with a nylon lifting belt, pass the hook on the lifting belt through the lifting hole, and lift the arch module to the top of the circular cooler trolley railing. Apply self-curing adhesive on the joint surface of the arch module and the circular cooler trolley railing. The curing temperature should be ≥5°C. After curing, overlap the tenon of the other arch module on the tenon of the previous arch module. Use a hydraulic device to fine-tune the arch module. Fill the gap between the tenon and the tenon with aluminum silicate fiber felt, and apply high-temperature sealant on the joint between the tenon and the tenon.

[0016] 1. High-frequency vibration ≥50Hz can expel bubbles inside the castable, ensure density, and avoid uneven density caused by traditional manual vibration.

[0017] 2. Aluminum silicate colloid is cross-linked and solidified, and nano-silicon carbide particles fill the micropores to form a high-temperature resistant bonding layer. No oven maintenance is required, and construction can be achieved in all seasons.

[0018] 3. The hydraulic cylinder drive module can translate ±10mm and rotate ±1° on the X / Y / Z axis, replacing manual tapping adjustment and avoiding module damage.

[0019] Option 7, which is a preferred option of Option 6, the low-temperature self-curing adhesive is composed of aluminum silicate colloid and nano-silicon carbide particles with a particle size of 50-100 nm and a mass ratio of 5:1. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 This is a structural schematic diagram of a modular dome structure of a pellet ring cooler according to the present invention; Figure 2 This is a structural diagram of a dome module in a modular dome structure of a pellet annular cooler according to the present invention; Figure 3This is a perspective view of a dome module in a modular dome structure of a pellet ring cooler according to the present invention, viewed from above. Figure 4 This is a schematic diagram of the installation of a modular dome structure of a pellet ring cooler according to the present invention. DETAILED DESCRIPTION

[0021] The present invention will be further described in detail below through specific embodiments: The figure marks in the drawings of the specification include: 1-arch, 2-circular cooler trolley railing, 3-steel skeleton, 4-tenon, 5-mortise, 6-locating pin hole, 7-nickel-chromium alloy embedded part, 8-lifting hole, 9-circular cooler trolley, 10-arch module.

[0022] Example 1 like Figures 1 to 4 As shown: a modular arch structure of a pelletizing ring cooler, including an arch 1 and a ring cooler trolley railing 2, the arch 1 is assembled by multiple arch modules 10 along the ring cooler trolley railing 2, the plane projection size of the arch module 10 is 2m×2m to 3m×3m, the thickness is 200-300mm, the arch module 10 is a double curvature arch, the curvature radius of the arch module 10 ranges from 1200mm to 1500mm, a steel skeleton 3 is provided in the arch module 10, the steel skeleton 3 is composed of longitudinal steel bars and transverse steel bars cross-welded, the longitudinal steel bar diameter is 10mm, the spacing is 150mm, the transverse steel bar diameter is 8mm, the spacing is 200mm, the arch module 10 is pre-embedded with nickel-chromium alloy embedded parts 7, the nickel-chromium alloy embedded parts 7 extend out of the surface of the arch module 10, the nickel-chromium alloy embedded parts 7 are provided with lifting holes 8, the arch module A tenon 4 is provided on one side of 10, and a tenon groove 5 is provided on the other side of the arch module 10. The inner wall of the tenon groove 5 is sprayed with a wear-resistant ceramic coating. The fitting clearance between the tenon groove 5 and the tenon 4 is ≤0.5mm. The tenon 4 and the tenon groove 5 are a static stepped labyrinth sealing structure with 3-5 sealing layers and a height difference of 5-8mm per layer. Positioning pin holes 6 are provided on the tenon 4 and the tenon groove 5 with a hole diameter of 20mm±0.1mm and a spacing of 500mm. Stainless steel bushings are embedded in the positioning pin holes 6. Aluminum silicate fiber felt with a filling density of ≥220kg / m³ is provided between adjacent arch modules 10. The arch module 10 is cast by a castable, and the castable contains Al2O375%-80%, SiO210%-15%, and nano-ZrO2 particles 3%-5% by mass, and the particle size of the nano-ZrO2 particles is 20nm to 50nm.

[0023] The implementation method of this embodiment is as follows: During the operation of the annular cooler, the hyperbolic arch design converts vertical loads into uniform circumferential compressive stress, avoiding localized stress concentration. The orthogonal mesh steel skeleton 3 and nickel-chromium alloy embedded parts 7 form a composite reinforcement system with a bending stiffness of 35 kN·m², ensuring the stability of the arch under mechanical vibration and airflow pulsation. The arch module 10 undergoes thermal expansion due to high temperatures. The mortise 5-tenon 4 coupling allows for slight radial and circumferential displacement of the arch module 10, preventing deformation or cracking caused by thermal stress. The wear-resistant ceramic coating on the inner wall of the mortise 5 reduces frictional resistance, ensuring smooth module sliding while maintaining the overall sealing of the structure. The static stepped labyrinth seal structure at the joints of the arch module 10 has 3 to 5 layers, with a height difference of 5 to 8 mm between each layer, forming multiple tortuous flow paths. When the high-temperature air flows through, the tortuous path increases the pressure drop and reduces the flow rate, effectively reducing air leakage. The aluminum silicate fiber felt filling further absorbs residual airflow particles.

[0024] Example 2 A method for manufacturing a modular dome structure of a pellet ring cooler comprises the following steps: S1: Casting the vault module 10: Casting the nano-reinforced castable in layers in the mold, with each layer having a thickness of ≤50 mm. After each layer is cast, a high-frequency vibrator is used to remove bubbles. After the bubbles are completely expelled, the next layer is cast. After casting two layers, the steel skeleton 3 is placed in the nano-reinforced castable, and the nickel-chromium alloy embedded parts 7 are placed on the steel skeleton 3. The remaining layers are cast. The curing conditions are a temperature of 20-30°C and a humidity of ≥90%. The self-curing adhesive is composed of aluminum silicate colloid and nano-silicon carbide particles. The particle size of the nano-silicon carbide particles is 50-100 nm, and the mass ratio of aluminum silicate colloid to nano-silicon carbide particles is 5:1. The curing temperature is ≥5°C and the curing time is ≤24 hours. S2: Assemble the arch body: Use a bridge crane with a nylon lifting belt, pass the hook on the lifting belt through the lifting hole 8, and lift the arch module 10 to the top of the circular cooler trolley railing 2. After the module is lifted to the top of the circular cooler, insert the anti-deflection positioning pin into the positioning pin hole 6, and apply self-curing adhesive on the joint surface of the arch module 10 and the circular cooler trolley railing 2. The curing temperature is ≥5°C. After curing, overlap the tenon 4 of the other arch module 10 on the tenon 5 of the previous arch module 10, use the hydraulic device to fine-tune the arch module 10, fill the gap between the tenon 5 and the tenon 4 with aluminum silicate fiber felt, and apply high-temperature sealant at the joint between the tenon 5 and the tenon 4.

[0025] The above is only an embodiment of the present invention, and the common knowledge such as the specific structure and characteristics of the scheme is not described in detail here. It should be pointed out that for those skilled in the art, without departing from the structure of the present invention, several variations and improvements can be made, which should also be regarded as the scope of protection of the present invention, and these will not affect the effect of the implementation of the present invention and the practicality of the patent. The scope of protection required by this application shall be based on the content of its claims, and the specific implementation methods and other records in the specification can be used to interpret the content of the claims.

Claims

1. A modular dome structure of a pellet ring cooler, characterized in that: The invention comprises an arch body (1), wherein the arch body (1) is composed of a plurality of arch modules (10), wherein the plurality of arch modules (10) are spliced ​​into a circular ring along a ring cooling machine trolley railing (2), wherein a steel frame (3) is provided in the arch module (10), wherein the steel frame (3) is composed of longitudinal steel bars and transverse steel bars welded crosswise, wherein a tenon (4) is provided on one side of the arch module (10), and a tenon groove (5) is provided on the other side of the arch module (10), wherein the fitting clearance between the tenon groove (5) and the tenon (4) is ≤0.5 mm, and a positioning pin hole (6) is provided on the tenon (4) and the tenon groove (5), and aluminum silicate fiber felt is filled between adjacent arch modules (10), wherein the arch module (10) is cast by nano-reinforced castable material, and wherein the arch module (10) is a double curvature arch.

2. The modular dome structure of the pellet ring cooler according to claim 1 is characterized in that A nickel-chromium alloy embedded part (7) is embedded in the arch module (10), the nickel-chromium alloy embedded part (7) extends out of the surface of the arch module (10), and a hoisting hole (8) is opened on the nickel-chromium alloy embedded part (7).

3. The modular dome structure of the pellet ring cooler according to claim 1 is characterized in that The tenon (4) and the mortise (5) are both stepped structures, with 3-5 steps and a height difference of 5-8 mm between each step. The inner wall of the mortise (5) is sprayed with a wear-resistant ceramic coating.

4. The modular dome structure of a pellet ring cooler according to claim 1, characterized in that: The plane projection size of the dome module (10) is 2m×2m to 3m×3m, the thickness is 200-300mm, and the curvature radius of the dome module (10) ranges from 1200mm to 1500mm.

5. The modular dome structure of a pellet ring cooler according to claim 1, characterized in that: The nano-enhanced casting material contains Al2O3 75%-80%, SiO2 10%-15%, and nano ZrO2 particles 3%-5% by mass, and the particle size of the nano ZrO2 particles is 20nm to 50nm.

6. A method for manufacturing a modular dome structure of a pellet ring cooler, characterized in that: The steps include: S1: Casting the vault module (10): Cast the nano-enhanced castable in layers in the mold, with each layer being ≤50 mm thick. After each layer is cast, use a high-frequency vibrator to remove bubbles. After the bubbles are completely removed, cast the next layer. After casting two layers, place the steel skeleton in the nano-enhanced castable, place the nickel-chromium alloy embedded parts (7) on the steel skeleton, and then cast the remaining layers. The curing conditions are a temperature of 20-30°C and a humidity of ≥90%. S2: Assembling the arch body (1): Using a bridge crane with a nylon lifting belt, pass the hook on the lifting belt through the lifting hole (8), and lift the arch module (10) to the top of the ring cooler trolley railing (2). After the arch module (10) is lifted to the top of the ring cooler, insert the anti-deflection positioning pin into the positioning pin hole (6), apply self-curing adhesive to the joint surface of the arch module (10) and the ring cooler trolley railing (2), and the curing temperature is ≥5°C. After curing, the tenon (4) of another arch module (10) is overlapped on the tenon (5) of the previous arch module (10), and the arch module (10) is fine-tuned by a hydraulic device. The gap between the tenon (5) and the tenon (4) is filled with aluminum silicate fiber felt, and high-temperature sealant is applied to the joint between the tenon (5) and the tenon (4).

7. The method for manufacturing a modular dome structure of a pellet ring cooler according to claim 6, characterized in that The low-temperature self-curing adhesive described in S1 is composed of aluminum silicate colloid and nano-silicon carbide particles, the particle size of the nano-silicon carbide particles is 50-100nm, and the mass ratio of aluminum silicate colloid to nano-silicon carbide particles is 5:1.

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