Coal thawing system for wagon bottom

Abstract

The utility model discloses a kind of carriage bottom frozen coal thawing systems, it is related to coal transportation unloading technical field, it is mainly including steam supply source, steam pipeline, steam nozzle, steam supply source is connected with the steam exhaust line of thermal power plant and intercommunication, steam pipeline is connected with steam supply source and intercommunication, steam nozzle is set in the below of car dumper, steam nozzle is connected with steam pipeline and intercommunication, steam nozzle can inject hot steam to the bottom of car dumper.The carriage bottom frozen coal thawing system provided by the utility model makes frozen coal thawing efficiency high, and save resources, more environmental protection.

Description

Technical Field

[0001] This utility model relates to the field of coal transportation and unloading technology, and in particular to a system for melting frozen coal at the bottom of a truck bed. Background Technology

[0002] As a crucial tool for coal transportation, trains often experience significant challenges during winter transport. In low temperatures, coal at the bottom of the carriages freezes tightly to the steel plates, leading to problems such as low unloading efficiency of tippers, severe equipment wear, high unloading costs, and environmental hazards associated with traditional methods. Currently, there are four main methods to address the issue of incomplete unloading: First, mechanical vibration: This method uses vibration equipment to vibrate the carriages, separating the frozen coal from the coal. Its structure mainly includes a vibration motor and vibration supports. The vibration motor is installed at the bottom or side of the carriage and fixed by the supports. During operation, the vibration motor generates vibration, causing the carriage to vibrate and loosening the frozen coal. However, this method has limited vibration effectiveness and cannot guarantee complete loosening of the frozen coal, resulting in low unloading efficiency, with unloading times for a single carriage reaching 8-10 minutes. Frequent vibration also exacerbates wear on the tipper equipment, increasing maintenance costs; excessive vibration may even damage the carriage structure. Second, manual cleaning: This involves manually removing and cleaning the frozen coal from the bottom of the carriages using tools such as shovels and crowbars. The first method involves manual operation, which is extremely inefficient, consumes a large amount of manpower, and is costly. The cleaning process is slow, severely impacting coal unloading progress and failing to meet the needs of large-scale coal unloading. The second method is electric heating: electric heating elements are laid at the bottom of the car body, converting electrical energy into heat to melt the frozen coal. This method has high energy consumption and operating costs; the heating process is relatively slow and difficult to adapt to continuous coal unloading operations. The third method is chemical antifreeze: chemical antifreeze is sprayed onto the bottom of the car body before coal loading to prevent coal from sticking to the body. This method uses chemical antifreeze, which pollutes the environment and does not meet environmental protection requirements; furthermore, some chemicals may affect coal quality. Therefore, a frozen coal melting system for the bottom of the car body is urgently needed to solve the above-mentioned technical problems. Utility Model Content

[0003] The purpose of this invention is to provide a frozen coal melting system at the bottom of a train carriage to solve the problems existing in the prior art, thereby achieving high efficiency in melting frozen coal, saving resources, and being more environmentally friendly.

[0004] To achieve the above objectives, this utility model provides the following solution:

[0005] This utility model provides a system for melting frozen coal at the bottom of a wagon car, including a steam supply source, a steam pipe, and a steam nozzle. The steam supply source is connected to and communicates with the steam discharge pipeline of a thermal power plant. The steam pipe is connected to and communicates with the steam supply source. The steam nozzle is located below the tipper and is connected to and communicates with the steam pipe. The steam nozzle can spray hot steam onto the bottom of the tipper.

[0006] In some embodiments, the temperature of the steam in the steam supply source is 120°C-150°C, and the pressure of the steam is 0.4-0.6 MPa.

[0007] In some embodiments, an angle adjustment device is also included, which is connected to the steam nozzle and is capable of adjusting the spray angle of the steam nozzle.

[0008] In some embodiments, multiple steam nozzles are provided on both sides of the tippler's track.

[0009] In some embodiments, 4-6 sets of steam nozzles are provided under each car, and each set of steam nozzles includes two nozzles, which are located on the tracks on both sides of the tipper. The steam jet shape of each steam nozzle is fan-shaped, and the steam jets of the two opposing steam nozzles can cover the width of the car.

[0010] In some embodiments, the distance between any two adjacent steam nozzles is no greater than 0.5m.

[0011] In some embodiments, a temperature sensor is also included, which is located at the center of the bottom of the carriage.

[0012] In some embodiments, a control system is also included, wherein the temperature sensor is electrically connected to the control system, and the controller of the steam nozzle is electrically connected to the control system. If the output temperature of the temperature sensor is below 5°C, the control system can output an electrical signal to the controller of the steam nozzle to cause the steam nozzle to spray steam. If the output temperature of the temperature sensor is not below 5°C, the control system can output an electrical signal to the controller of the steam nozzle to cause the steam nozzle to stop spraying steam.

[0013] In some embodiments, a wastewater collection tank and a sedimentation tank are also included. The wastewater collection tank is located at the bottom of the carriage and is connected to the sedimentation tank, so that the melted coal-water mixture can flow from the wastewater collection tank to the sedimentation tank.

[0014] In some embodiments, the steam pipe is a stainless steel pipe or a galvanized steel pipe.

[0015] The present invention achieves the following technical advantages over the prior art:

[0016] The frozen coal melting system at the bottom of the train carriage provided by this utility model uses steam heating to melt frozen coal. The steam comes directly from a thermal power plant. On the one hand, steam has a better melting effect on frozen coal, ensuring high melting efficiency. Generally, each carriage can be melted in 4-5 minutes, while traditional electric heating or water conduction heating takes at least 8-10 minutes. On the other hand, since the steam comes from a thermal power plant, waste heat of the steam is recovered and utilized. If steam is not used to melt frozen coal, the steam will be directly discharged into the atmosphere, resulting in a significant waste of resources and cost savings. Generally, the steam energy cost is only 0.8-1.2 yuan / ton of coal. Moreover, steam heating does not produce chemical reactants and has no impact on the environment. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the frozen coal melting system at the bottom of the carriage in some embodiments of this utility model;

[0019] In the diagram: 1-Steam supply source; 2-Steam pipe; 3-Steam nozzle; 4-Control system; 5-Temperature sensor; 6-Wastewater collection tank; 7-Sedimentation tank. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] The purpose of this invention is to provide a frozen coal melting system at the bottom of a train carriage to solve the problems existing in the prior art, thereby achieving high efficiency in melting frozen coal, saving resources, and being more environmentally friendly.

[0022] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0023] like Figure 1As shown, this utility model provides a system for melting frozen coal at the bottom of a car body, including a steam supply source 1, a steam pipe 2, and a steam nozzle 3. The steam supply source 1 is connected to and communicates with the steam discharge pipeline of a thermal power plant. The steam pipe 2 is connected to and communicates with the steam supply source 1. The steam nozzle 3 is located below the tipper and is connected to and communicates with the steam pipe 2. The steam nozzle 3 can spray hot steam onto the bottom of the tipper. This method of melting frozen coal using steam heating, with the steam directly sourced from the thermal power plant, offers several advantages. Firstly, steam has a better melting effect on frozen coal, ensuring high melting efficiency; generally, each car body can be melted in 4-5 minutes, while traditional electric heating or water conduction heating takes at least 8-10 minutes. Secondly, since the steam comes from the thermal power plant, waste heat of the steam is recovered and utilized. If steam were not used to melt frozen coal, it would be directly discharged into the atmosphere, resulting in significant resource waste and cost savings. The energy cost of steam is generally only 0.8-1.2 yuan / ton of coal. Moreover, steam heating does not produce chemical reactants and has no impact on the environment.

[0024] In some embodiments, the temperature of the steam in the steam supply source 1 is 120℃-150℃, and the steam pressure is 0.4-0.6MPa. The steam temperature of 120℃-150℃ falls within the medium-high temperature range, which can quickly break through the freezing point of frozen coal while avoiding energy waste or localized overheating problems caused by excessively high temperatures (such as deformation or oxidation of metal parts in the carriage due to high temperatures). For frozen coal (especially hardened coal seams), this temperature allows for efficient melting of the surface layer and diffusion of heat into the interior through heat conduction and the release of latent heat from steam condensation, accelerating the overall melting speed. If the temperature is too low (e.g., below 100℃), the enthalpy of the steam is low, and the melting time of the frozen coal will be prolonged; however, the steam in this temperature range has a large heat capacity and can continuously release heat after contacting the frozen coal, ensuring a stable and efficient melting process. A pressure of 0.4-0.6 MPa falls within the low-to-medium pressure range. This pressure effectively propels steam through pipes and nozzles, creating a powerful jet stream that evenly covers the frozen coal surface at the bottom of the coal compartment (including gaps and corners). This prevents insufficient pressure from causing weak jetting or incomplete coverage. Waste heat steam discharged from thermal power plants typically falls within a similar temperature and pressure range (medium temperature and pressure). This parameter design directly adapts to the steam output characteristics of thermal power plants, eliminating the need for additional heating, pressurization, cooling, or depressurization of the steam. This reduces energy losses during conversion, maximizes the utilization of the original energy of the waste heat steam, and further enhances the economic efficiency of waste heat recovery.

[0025] In some embodiments, the frozen coal melting system at the bottom of the car body also includes an angle adjustment device connected to the steam nozzle 3, which can adjust the spray angle of the steam nozzle 3. Different types of car body bottoms may have different shapes, and the location and thickness of frozen coal accumulation may vary (e.g., some areas have thicker frozen coal, while others have gaps or depressions). The angle adjustment device allows for adjustment of the nozzle's spray direction (e.g., upward tilt, horizontal, or small-angle deflection) according to actual conditions, ensuring that steam accurately covers every corner of the car body bottom, avoiding problems such as incomplete melting of frozen coal and the formation of dead zones due to a fixed spray angle. When frozen coal in the car body becomes locally hardened during loading or transportation (e.g., ice accumulation on edges or corners), the nozzle angle can be adjusted to concentrate steam onto that area, enhancing local heating intensity, accelerating the melting of stubborn frozen coal, and improving overall processing efficiency. If the nozzle angle is fixed, some steam may be sprayed onto non-frozen coal areas such as the car body's metal frame and the tipper's mechanical structure, resulting in heat waste. The angle adjustment device can precisely lock the spray direction onto the surface of frozen coal, reducing the contact between steam and non-target objects, allowing more heat to be used for melting frozen coal, and improving energy utilization.

[0026] It should be noted that the angle adjustment device can be configured in various ways, as long as it enables the adjustment of the spray angle of the steam nozzle 3. For example, a hinge can be used, with one end of the steam nozzle 3 fixed to the hinge, and the other end of the hinge, not connected to the nozzle, fixed to the bottom of the tipper. The steam nozzle 3 rotates around the axis of rotation of the hinge, and after reaching the desired position, the hinge can be locked using nuts and bolts. Alternatively, a worm gear type adjustment structure or a stepper motor with gears can be used. The nozzle is connected to a gear set, and the stepper motor drives the gears to rotate. The rotation angle is controlled by the motor's pulse signals, and closed-loop control is achieved in conjunction with an angle sensor (such as an encoder). This can be integrated into the system's PLC (Programmable Logic Controller).

[0027] In some embodiments, multiple steam nozzles 3 are installed on both sides of the tipper track. Multiple nozzles on both sides of the track can create cross-spraying or complementary coverage from both sides of the car bottom towards the center area. Combined with the angle adjustment function of individual nozzles, this can thoroughly cover the lateral (track width direction) and longitudinal (track length direction) areas of the car bottom, avoiding localized frozen coal residue caused by insufficient coverage from a single or few nozzles. Different models of coal cars have different lengths (e.g., standard cars and extended cars). Multiple nozzles are arranged at intervals along both sides of the track, allowing for flexible activation of nozzles in corresponding areas based on car length (e.g., short cars only use the middle section nozzles, long cars use all nozzles), ensuring that frozen coal at the bottom is fully heated regardless of car length.

[0028] In some embodiments, 4-6 sets of steam nozzles 3 are installed under each car. Each set of steam nozzles 3 includes two nozzles, located on the tracks on both sides of the tipper. The steam jet shape of each steam nozzle 3 is fan-shaped, and the steam jet from two opposing steam nozzles 3 can cover the width of the car. Moreover, the distance between any two adjacent steam nozzles 3 is no more than 0.5m. Frozen coal often forms irregular clumps at the bottom of the car (especially at corners and seams). The small distance of 0.5m allows steam to reach the clumps more comprehensively. Through multi-directional, close-range steam injection, the melting of ice crystals inside the clumps is accelerated, avoiding the phenomenon of the outer layer melting while the core remains frozen due to uneven local heating.

[0029] In some embodiments, the frozen coal melting system at the bottom of the carriage further includes a temperature sensor 5, which is located at the center of the bottom of the carriage. Steam nozzles 3 are mounted on a track located at the edge of the carriage; the center of the carriage bottom in the width direction is the furthest point from the steam nozzles 3. If the temperature at this point meets the requirements, the temperatures at other points will generally also meet the requirements. Preferably, multiple temperature sensors 5 can be installed along the length direction at the center of the carriage bottom in the width direction.

[0030] In some embodiments, the frozen coal melting system at the bottom of the car also includes a control system 4. A temperature sensor 5 is electrically connected to the control system 4, and the controller of the steam nozzle 3 is also electrically connected to the control system 4. When the output temperature of the temperature sensor 5 is below 5°C, the control system 4 can output an electrical signal to the controller of the steam nozzle 3 to cause the steam nozzle 3 to spray steam. When the output temperature of the temperature sensor 5 is not lower than 5°C, the control system 4 can output an electrical signal to the controller of the steam nozzle 3 to stop the steam nozzle 3 from spraying steam. Traditional frozen coal melting relies on manual observation (such as checking if the edges are melted) or timed control, which can easily lead to insufficient heating (coal unloading blockage) or overheating (steam waste) due to insufficient experience. The control system 4 automatically completes the steam start and stop based on real-time data from the temperature sensor 5 (stopping at ≥5°C, starting at <5°C), eliminating manual dependence. This is especially suitable for nighttime operations or high-intensity continuous production scenarios, ensuring uniform heating standards for each car. Moreover, by activating steam when the temperature is below 5°C and stopping steam when the temperature is above 5°C, intermittent operation can be achieved, avoiding resource waste.

[0031] It should be noted that control system 4 is a PLC control system, and the tipper station is also equipped with an infrared sensor. The infrared sensor is electrically connected to the PLC control system. When the coal-carrying car arrives at the tipper station, the infrared sensor can detect it and send the signal to the PLC control system. After receiving the signal, the PLC control system controls the steam nozzle 3 to start spraying steam. When the temperature sensor 5 at the bottom of the car detects that the temperature is not lower than 5°C, the PLC control system controls the steam nozzle 3 to stop spraying steam.

[0032] In some embodiments, the frozen coal melting system at the bottom of the carriage also includes a wastewater collection tank 6 and a sedimentation tank 7. The wastewater collection tank 6 is located at the bottom of the carriage and is connected to the sedimentation tank 7. The melted coal-water mixture can flow from the wastewater collection tank 6 to the sedimentation tank 7. If the coal-water mixture (containing coal slime, coal powder, and melted ice water) formed after the frozen coal is melted is directly discharged, it will pollute the surrounding soil, water bodies, and air (coal powder is easily dispersed as dust after drying). The wastewater collection tank 6, located at the bottom of the carriage, can quickly collect the dripping coal-water mixture and then guide it into the sedimentation tank 7 through a pipeline, achieving source collection and centralized treatment, avoiding the spread of pollutants, and meeting the environmental protection standards of zero discharge or compliant discharge of industrial wastewater. The sedimentation tank 7 can separate the coal powder, coal slime, and water in the coal-water mixture through static settling or chemical sedimentation (such as flocculants). The upper layer of clear water can be recycled (e.g., for washing the carriage and cooling equipment), and the lower layer of settled coal slime can be dewatered and then re-mixed into raw coal, avoiding coal loss due to the melting process and indirectly improving the economic benefits of the enterprise.

[0033] In some embodiments, the steam pipe 2 is a stainless steel pipe or a galvanized steel pipe. Stainless steel pipes (such as 304 and 316 grades) contain alloying elements such as chromium and nickel, forming a dense oxide film on the surface, which can withstand the electrochemical corrosion of steam condensate, making them particularly suitable for scenarios involving long-term contact with high-temperature water vapor. Galvanized steel pipes, through the zinc coating on the surface (zinc has higher chemical reactivity than iron and preferentially undergoes oxidation), form a sacrificial anode protection, effectively isolating condensate from contact with the steel pipe substrate, slowing down the corrosion rate, and are suitable for medium and low temperature steam transmission scenarios.

[0034] This utility model uses specific examples to illustrate its principles and implementation methods. The above description of the embodiments is only for the purpose of helping to understand the method and core idea of ​​this utility model. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the idea of ​​this utility model. In summary, the content of this specification should not be construed as a limitation of this utility model.

Claims

1. A system for melting frozen coal at the bottom of a train carriage, characterized in that: It includes a steam supply source, a steam pipeline, and a steam nozzle. The steam supply source is connected to and communicates with the steam discharge pipeline of the thermal power plant. The steam pipeline is connected to and communicates with the steam supply source. The steam nozzle is located below the tipper and is connected to and communicates with the steam pipeline. The steam nozzle can spray hot steam onto the bottom of the tipper.

2. The frozen coal melting system at the bottom of the carriage according to claim 1, characterized in that: The temperature of the steam in the steam supply source is 120℃-150℃, and the pressure of the steam is 0.4-0.6MPa.

3. The frozen coal melting system at the bottom of the carriage according to claim 1, characterized in that: It also includes an angle adjustment device, which is connected to the steam nozzle and can adjust the spray angle of the steam nozzle.

4. The frozen coal melting system at the bottom of the carriage according to claim 1, characterized in that: Multiple steam nozzles are installed on both sides of the tippler's track.

5. The frozen coal melting system at the bottom of the carriage according to claim 4, characterized in that: Each car is equipped with 4-6 sets of steam nozzles. Each set of steam nozzles includes two nozzles, which are located on the tracks on both sides of the tipper. The steam jet shape of each steam nozzle is fan-shaped, and the steam jets from the two opposing steam nozzles can cover the width of the car.

6. The frozen coal melting system at the bottom of the carriage according to claim 5, characterized in that: The distance between any two adjacent steam nozzles shall not exceed 0.5m.

7. The frozen coal melting system at the bottom of the carriage according to claim 1, characterized in that: It also includes a temperature sensor, which is located at the center of the bottom of the carriage.

8. The frozen coal melting system at the bottom of the carriage according to claim 7, characterized in that: It also includes a control system, wherein the temperature sensor is electrically connected to the control system, and the controller of the steam nozzle is electrically connected to the control system. If the output temperature of the temperature sensor is lower than 5°C, the control system can output an electrical signal to the controller of the steam nozzle to make the steam nozzle spray steam. If the output temperature of the temperature sensor is not lower than 5°C, the control system can output an electrical signal to the controller of the steam nozzle to make the steam nozzle stop spraying steam.

9. The frozen coal melting system at the bottom of the carriage according to claim 1, characterized in that: It also includes a wastewater collection tank and a sedimentation tank. The wastewater collection tank is located at the bottom of the carriage and is connected to the sedimentation tank. The melted coal-water mixture can flow from the wastewater collection tank to the sedimentation tank.

10. The frozen coal melting system at the bottom of the carriage according to claim 1, characterized in that: The steam pipe is made of stainless steel or galvanized steel.

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