Material gate for an industrial plant

Abstract

The invention relates to a material gate (1) for an industrial plant (50), comprising - a housing (2) with a funnel (7) which defines material channel (12) extending from an inlet opening (13) to an outlet opening (14), and - at least one valve assembly (20) with a valve element (21) and a coupler element (22) which are connected to each other so that by actuation of the coupler element (22), the valve element (21) is movable in a closing movement from an open position for enabling material flow through the material channel (12) into a closed position for blocking material flow through the material channel (12), the valve element (21) comprising a plurality of valve-element edges (21.2-21.5), one of which is a leading edge (24) with respect to the closing movement. In order to provide improved means for handling wear in a material gate of an industrial plant (50), the invention provides that the valve element (21) is adapted to be connected to the coupler element (22) in a plurality of different configurations so that for each configuration, a different valve-element edge (21.2-21.5) is the leading edge (24).

Description

MATERIAL GATE FOR AN INDUSTRIAL PLANTTechnical Field

[0001] The invention relates to a material gate for an industrial plant and to an industrial plant.Background Art

[0002] In metallurgical plants, specifically in steel producing plants, particulate material is oftentimes transferred from one device, e.g., a hopper, to another device, e.g., a furnace, through pipes by force of gravity. I.e., the material falls or slides downwards due to its own weight. Commonly the material flow needs to be controlled in that it can be temporarily reduced or blocked. For this purpose, a material gate can be interposed between two pipes or within a pipe. The material gate can also be referred to as a material valve. It usually has at least one movable valve element that can be positioned to either enable or block the material flow. Especially when the valve element transitions between an open position and a closed position, it is subjected to substantial abrasional forces. This is because the material starts to move along the valve element before it can reach the open position, or the material continues to move along the valve element until it has reached its closed position. These problems are enhanced if the particulate material has an elevated temperature. Irrespective of the material of which the valve element is made, abrasion, possibly in combination with oxidation, necessitates a replacement of the valve element after some time. This means that the plant has to be shut down at least partially until the valve element has been replaced. The relatively heavy valve element has to be removed and transported away from the material gate, while a new one has to be transported to the material gate and installed thereto. These processes are laborious and time-consuming. Furthermore, the valve element sometimes needs to be replaced even though the worn portion only represents a small part of the entire valve element. For instance, the wear may be concentrated to a leading edge of the valve element, which is the foremost part with respect to the closing movement, and is comparatively small. In such cases, a full replacement may seem somewhat wasteful. Similar problems arise in other industrial plants, wherever a material gate is used to control the transfer of materials.Technical Problem

[0003] It is thus an object of the present invention to provide improved means for handling wear in a material gate of an industrial plant. This object is solved by a material gate according to claim 1 and by an industrial plant according to claim 15.General Description of the Invention

[0004] The invention provides a material gate for an industrial plant, in particular for a metallurgical plant. The material gate can be used in an industrial plant. Preferably, it can be used in a metallurgical plant, i.e., it is made of materials that are usable in a metallurgical plant, e.g., steel or refractory materials. The metallurgical plant may in particular be an iron-producing plant or steel-producing plant. The material gate is adapted for controlling a material flow. When installed in the industrial plant, it can be interposed between an upstream component and a downstream component. During operation, the material flow runs from the upstream component through the material gate to the downstream component. Although the invention is not restricted to this working principle, the material flow may be driven by gravity. In some cases, the material gate may be adapted for installation downstream of a component that delivers hot material. In such a case, least some parts of the material gate may be made of material that is heat resistant up to at least 300°C, at least 500°C, or at least 800°C. For instance, it could be installed downstream of a DRI (directly reduced iron) plant or a reservoir that receives and temporarily stores DRI material. While the invention is particularly suitable for metallurgical plants, it can also be beneficial in other industries, e.g. oil shale industry or cement industry.

[0005] The material gate comprises a housing with a funnel which defines material channel extending from an inlet opening to an outlet opening. The housing may be adapted for connection to the abovementioned upstream and downstream components. For this purpose, it may comprise dedicated connection portions, like connection flanges or the like. The housing is preferably at least partially made of steel, although other suitable materials are possible. The housing comprises a funnel which defines a material channel. The funnel preferably has a closed wall that circumferentially surrounds the material channel. It may also comprise an inner wall and an outer wall. The funnel and the material channel may be straight, extending along a channel axis. However, it is within the scope of the invention that the funnel is at least partially curved and / or angled. The material channel extends from an inletopening to an outlet opening. During operation, material enters through the inlet opening and may exit through the outlet opening. It should be noted that although there is usually only one inlet opening and one outlet opening, it is conceivable that the funnel has a branching structure with more than one inlet opening and / or outlet opening. For some applications, the funnel may comprise a material that is especially heat resistant and / or wear resistant, like a refractory material. When installed in the industrial plant, the inlet opening is an upper opening and the outlet opening is a lower opening, with respect to the vertical direction defined by the direction of gravity. The channel axis may be parallel to the direction of gravity. Optionally, the funnel may comprise a cooling system. For instance, the funnel may comprise at least one cavity or pipe that is connectable to a coolant supply. The cavity may be formed between an inner wall and an outer wall of the funnel. The coolant can be water. As the coolant flows through the cavity, it absorbs heat and protects the funnel from overheating.

[0006] The material gate also comprises at least one valve assembly with a valve element and a coupler element which are connected to each other so that by actuation of the coupler element, the valve element is movable in a closing movement from an open position for enabling material flow through the material channel into a closed position for blocking material flow through the material channel, the valve element comprising a plurality of valve-element edges, one of which is a leading edge with respect to the closing movement. Preferably, the material gate comprises only a single valve assembly, but there could be a plurality of valve assemblies. The valve assembly is movable with respect to the housing. It comprises a valve element, which could also be referred to as a flap element, a gate element, a shutter element, or the like. The valve element is designed to either enable or disable the material flow through the material channel. In a closed position, it is disposed to block the material flow. It should be noted that “blocking” the material flow does not imply a completely tight sealing effect between the valve element and the funnel. Firstly, since the material is usually a solid material, gas-tightness or liquid-tightness is usually not required. Furthermore, small leakage e.g. of dust or fines is usually not relevant either. Generally speaking, the material flow can be considered as “blocked” if it is reduced by at least 99% with respect to the open position. In case of a plurality of valve assemblies, the valve elements of all valve assemblies may cooperate to block the material channel. Although there are other possibilities within the scope ofthe invention, it is preferred that in the closed position, the valve element is disposed downstream of the outlet opening. In other words, the at least one valve element is adapted to close the outlet opening. The movement from the open position to the closed position is referred to as the closing movement. The opposite movement can be referred to as the opening movement.

[0007] The valve element is connected to a coupler element. Both the valve element and the coupler element can be made of one piece or a plurality of pieces. In the latter case, the pieces can be connected in a detachable or non-detachable way. The valve element and the coupler element are connected so that the valve element can be moved between the open and closed position by actuating the coupler element. In other words, the coupler element can be used to indirectly actuate the valve element. Generally speaking, the coupler element is connected or coupled to the valve element in a force-transmitting manner. As a rule, the coupler element is either directly or indirectly connectable to an actuator or drive motor. Thus, the drive force of the actuator is transferred through the coupler element to the valve element. In some embodiments, the coupler element is adapted to support the valve element. In these cases, it may also be referred to as a support element or a carrier element.

[0008] The valve element comprises a plurality of valve-element edges. These are edges of the valve element. In general, the shape of the valve element is not limited within the scope of the invention, but it may have a plate-like shape, wherein a width of the material channel is considerably greater than a thickness of the valve member, e.g., at least three times or five time greater. In the closed position, an inner surface of the valve element faces the material channel, e.g., the outlet opening. Then, the valve-element edges can be located at an outer perimeter of this inner surface. One of the valve-element edges is a leading edge with respect to the closing movement. This means that due to the orientation of the valve element and the direction of the closing movement, one of the valve-element edges is the foremost edge. With respect to the opening movement, on the other hand, this is the trailing edge. During operation, material flows, i.e., slides and / or falls through the material channel unless the material channel is fully closed. During the closing movement, the leading edge is the part of the valve element that is mostly subjected to the abrasional forces exerted by the material flow. It is the part that first comes into contact with the material flow. During the opening movement, it is the part that staysin contact with the material flow for the longest time. All in all, it is the part that is affected by wear and abrasion most strongly.

[0009] According to the invention, the valve element is adapted to be connected to the coupler element in a plurality of different configurations so that for each configuration, a different valve-element edge is the leading edge. In other words, there is not one specific configuration in which the valve element and the coupler element can be connected, but a plurality of configurations. Any of these configurations is valid, i.e., the valve element can perform its function in every configuration. Specifically, in every configuration, the valve element can assume a closed position for blocking the material flow. However, for each configuration, a different valve-element edge is the leading edge. This implies that the orientation of the valve element is different depending on the configuration. In one configuration, with a first orientation, a first valve-element edge is the leading edge. In another configuration, a second valve-element edge is the leading edge, while the first valveelement edge could be facing, e.g., sideways or backwards with respect to the closing movement. Therefore, if the leading edge has been subjected to a certain amount of wear, the configuration of the valve element can be changed, thereby making another valve-element edge the leading edge. This valve-element edge, which has not been the leading edge up to this point, can be expected to be largely intact. It can therefore be used as the leading edge for some time. The previous leading edge is moved into a position where it is subjected to less wear, so that it can be used further. All in all, the valve element does not need to be exchanged every time the leading edge is worn. Rather, by changing the configuration, the lifetime of the valve element can be extended. The lifetime increases approximately be a factor equal to the number of configurations, i.e., the number of available valve-element edges.

[0010] In some embodiments, the valve element could be movable with respect to the coupler element, albeit to a limited extent. Such movability could include at least one translational and / or rotational degree of freedom. It is preferred, though, that the valve element is rigidly connected to the coupler element. “Rigidly connected” means that the connection fixes the relative position of the valve element on the coupler element or reduces any mobility to a negligible extent. In this embodiment, the valve assembly can be regarded as a single rigid body. It will beunderstood that the term “rigid” does not exclude that the valve assembly may still undergo some elastic deformation, e.g. due to the weight of material acting on the valve element.

[0011] There are various options how the coupler element and the valve element can be connected. According to a preferred embodiment, the coupler element and the valve element have corresponding connecting features which are adapted for connecting the valve element to the coupler element in different orientations relative to the coupler element, each orientation corresponding to one configuration. The connecting features are any features or structures that can be used to directly or indirectly connect the coupler element and the valve element. Specifically, at least one connecting feature can be a bore that is adapted to at least partially receive a connector element. This may be a blind opening or a through opening. The connector element may be a screw, a rivet, or the like. The opening may be threaded or unthreaded. In any case, the connecting features correspond to each other, i.e. , at least one connecting feature of the valve element corresponds to at least one connecting feature of the coupler element. Such corresponding features may be corresponding openings, like a through opening in the coupler element and a corresponding through opening or blind opening in the valve element. For connecting the coupler element and the valve element, a screw, a rivet, or other connector element can be inserted into both openings. At least one of the coupler element and the valve element comprises more connecting features that enable a connection in different orientations, corresponding to different configurations. This includes the possibility that in each configuration at least one connecting feature is unused.

[0012] It is highly preferred that the valve element is detachably connected to the coupler element. “Detachably” means that the valve element can be disconnected from the coupler element in an essentially non-destructive manner, i.e., without the need to actually damage or destroy any part of the valve assembly. As a rule, this is possible if the valve element is connected to the coupler element by connector elements like screws. Such a detachable connection facilitates the connecting and disconnecting process and reduces material waste. In another embodiment, a connection could be employed that can be released without damaging the valve element and the coupler element while destroying a connector element. This would be the case if rivets are used as connector elements.Alternatively or additionally, the valve element can be connected to the coupler element by welding, as welding connections are easy to remove in an essentially non-destructive manner.

[0013] The valve element preferably comprises a plurality of equally shaped valve-element edges which are pairwise offset from each other by a rotation angle with respect to a configuration axis. The configuration axis preferably goes through the valve element. The valve element may at least partially be symmetrical with respect to the configuration axis. Since in this embodiment, two equally shaped valve-element edges are offset from each other by the rotation angle, one valveelement edge can be moved into the position of the other valve-element edge by rotating the valve element about this rotation angle. By the rotation, one worn valveelement edge can be moved out of the position of the leading edge, while another valve-element edge can be moved into said position, thereby becoming the new leading edge. Although reference is made to “a” rotation angle, this rotation angle may be different for different pairs of valve-element edges.

[0014] While the valve-element edges are expected to be worn after some time during operation, the connection between the valve element and the coupler element should remain unaffected by wear, if possible. It is therefore preferred that all valveelement edges are offset from a connection portion of the valve element which is connected to the coupler element. The connection portion may be a center portion of the valve element, with all valve-element edges being disposed around the connection portion. In any case, since all valve-element edges are offset from the connection portion, this is also true for the current leading edge, which is subjected to the most intensive wear. Due to the distance between the leading edge and the connection portion, the latter can be expected to remain intact even when the leading edge needs to be replaced. It is also preferred that the coupler element is connected to the valve element opposite the funnel. Thus, the valve element is interposed between the funnel and the coupler element, thereby protecting the latter from the material in the funnel.

[0015] On the one hand, the valve element could be completely detached from the coupler element when the configuration is changed. According to another embodiment, the valve assembly comprises rotation-support means which connect the valve element to the coupler element while enabling a rotation of the valveelement relative to the coupler element about the configuration axis. In other words, by the rotation-support means, the valve element and the coupler element can remain connected while the valve element is rotated to assume another configuration. On the one hand, this makes it easier to properly align the valve element, since there is only one (rotational) degree of freedom. On the other hand, the weight of the valve element may still be supported by the coupler element, which may also help a maintenance worker while he changes the configuration by rotating the valve element. Preferably, the rotation-support means are disposed on the configuration axis, i.e., the configuration axis goes through the rotation-support means.

[0016] As mentioned above, the valve element and the coupler element can be connected by a plurality of connector elements. In one embodiment, the rotationsupport means comprise a central connector element disposed on the configuration axis, and at least one off-center connector element is disposed offset from the configuration axis to prevent rotation about the configuration axis. As mentioned above, the connector elements can preferably be detachable elements like screws. When the configuration needs to be changed, the at least one off-center connector element can be removed, while the central connector element can stay in place. In case of a screw, this screw can be loosened to allow for a relative rotation of the valve element while still maintaining a connection with the coupler element. Then, when the new configuration has been reached, the central connector element can be tightened again, and the off-center connector element(s) can be applied to prevent any further rotation and to enhance the connection between the valve element and the coupler element. In some embodiments, the valve element and / or the coupler element may be provided with additional aligning means, like edges, notches, etc., that facilitate finding the exact intended relative position between valve element and coupler element. While this would prevent a free rotation of the valve element if the central connector element is only slightly loosened, a more significant loosing will allow a slight translational movement of the valve element along the configuration axis, thereby allowing the rotation of the valve element around its configuration axis.

[0017] Preferably, the valve element is adapted to be connected to the coupler element in a total of two to eight, preferably three to six, more preferably four different configurations. Each configuration can correspond to a different orientation of thevalve element with respect to the coupler element. On the one hand, a higher number of configurations is desirable since this extends the total lifetime of the valve element. On the other hand, as the number of configurations increases, the possible effective size of one valve-element edge becomes smaller. For example, in case of eight different configurations, two neighboring valve-element edges can only be offset from each other by a rotation angle of 45°, or less. If any significant wear extends over a greater angle, a lower number of configurations has to be used.

[0018] It is preferred that the valve-element edges are disposed symmetrically about the configuration axis. This means that the rotation angle between two valveelement edges is the same for all neighboring valve-element edges. In case of four valve-element edges, the angle is 90°, in case of eight valve-element edges, it is 45° etc. Moreover, the entire valve element can be symmetrically shaped with respect to the configuration axis. Also, it is preferred that at least one of the coupler element and the valve element comprises a plurality of connecting features that are symmetrically disposed about the configuration axis. For example, if the valve element has four connecting features that are offset from each other by an angle of 90°, one of these connecting features can be aligned with a corresponding connecting feature of the coupler element in one configuration, while another one can be aligned therewith in another configuration that corresponds to a 90° rotation about the configuration axis.

[0019] In some embodiments, the valve assembly could be movable in a translational movement or a combined translational and rotational movement. However, one preferred embodiment provides that the valve assembly is pivotable relative to the housing about a valve-pivot axis. Specifically, the coupler element may be pivotally connected to the housing. It is also possible that the coupler element is fixed to a transmission element, like a transmission shaft, that is pivotally connected to the housing. The transmission element can also be regarded as part of the valve assembly. The valve-pivot axis may be disposed perpendicular to the abovementioned channel axis. Also, it may be disposed horizontally with respect to the installed position of the material gate in the industrial plant.

[0020] It is advantageous if the shape of the valve element is adapted to the closing movement in that an inner surface of the valve element, which faces the material channel in the closed position, is disposed tangential to the closingmovement. Then, the inner surface can pass along the outlet opening at a close distance, or even in sliding contact therewith, without any risk of colliding with the funnel. In case of a linear movement, the inner surface would have to be parallel to the direction of said movement and could e.g. be planar. In case of a pivoting movement as described above, a different shape is preferred. Specifically, the valve element may have an arcuate inner surface. Here, “arcuate” refers to a shape that corresponds to a portion of a circle. Specifically, the arcuate inner surface can be centered about a center point on the valve-pivot axis. Then, as the valve assembly rotates about the valve-pivot axis, the distance of the inner surface from the valvepivot axis does not change. Also, the inner surface can preferably be spherical. In case of a cylindrical inner surface, re-positioning of the valve element would result in a misalignment of the inner surface. However, if the inner surface is spherical, the valve element can be rotated about an arbitrary angle and the inner contour will always remain centered about the center point. The spherical inner surface may at least partially be delimited by the abovementioned valve-element edges. The inner surface corresponds to a portion of a (virtual) sphere, and the center point is the center of this sphere. In this embodiment, the abovementioned configuration axis intersects the valve-pivot axis. In this context, it should be noted that a minor distance between the center point and the valve-pivot axis, as well as a minor deviation from the spherical shape, may not have any significant disadvantages. It will be understood that the geometry of the funnel near the outlet opening may be adapted to closely match the spherical shape of the inner surface of the valve element.

[0021] According to one embodiment, the housing comprises a main body defining a housing cavity, wherein the funnel is connected to the main body, and the funnel and the valve assembly are at least partially disposed inside the housing cavity. The main body may be made of one piece or a plurality of pieces. In the latter case, the pieces are preferably rigidly connected. The main body may be adapted for connection to an upstream component and a downstream component of the industrial plant, wherein “upstream” and “downstream” refer to the material flow. The main body defines a housing cavity, i.e., it is at least partially hollow. The funnel is connected to the main body. In some embodiments, the connection may be rigid, while in other embodiments the funnel could be movable with respect to the main body, e.g., tiltable. The funnel is at least partially, or even entirely, disposed insidethe housing cavity. The same goes for the valve assembly. Specifically, the valve element is preferably disposed entirely inside the housing cavity. The coupler element, on the other hand, may be partially disposed outside of the housing cavity.

[0022] Preferably, the main body comprises an access opening communicating with the housing cavity, a closure element is connected to the main body to close the access opening in an access-closed position, and the coupler element is connected to the closure element to be pivotable about the valve-pivot axis. Apart from the access opening, the main body may comprise additional openings, specifically two openings corresponding to the inlet opening and the outlet opening of the material channel. These openings may be surrounded by connector flanges or the like by which the material gate can be connected to an upstream component and a downstream component of the industrial plant. The access opening can also be referred to as a revision opening or a maintenance opening. In the access-closed position, the closure element is connected to the main body, thereby closing the access opening. The closure element is adapted to be removed from the access opening, e.g., in an access-open position. Thus, the access opening enables access to the housing cavity, i.e. , to the inside of the main body. It may also enable transfer of a component between the outside and the inside. Specifically, it is preferred that the funnel is removable from the housing cavity through the access opening. Therefore, when the funnel needs to be replaced, there is no need to disassemble the entire housing, but only to open the access opening. The coupler element is pivotally connected to the closure element. In other words, it is not directly connected to the main body, but only via the closure element. A pivot bearing, e.g., a ball bearing, may be interposed between the closure element and the coupler element. Any forces acting on the valve assembly, specifically gravitational forces, may be transferred to the main body via the closure element. One could regard the closure element and the valve assembly as parts of a single assembly, which could be referred to as a closure-valve assembly or the like.

[0023] As long as the valve assembly is connected to the closure element, moving the closure element also moves the valve assembly. According to one preferred embodiment, the closure element is removable from the access opening, whereby that the valve assembly is at least partially moved through the access opening out of the housing. In other words, as the closure element is removed fromthe access opening, the valve assembly is either partially or entirely moved through the access opening to the outside of the housing, without the need to disconnect it from the closure element. The dimensions of the valve assembly and its position on the closure element, and the dimensions of the access opening are adapted so that when the closure element is removed from the access opening, the valve assembly at least partially passes through the access opening. Thus, at least a portion of the valve assembly is positioned outside the housing and can be easily accessed for inspection, maintenance and / or replacement without the need to remove it from the closure element first. This greatly facilitates the respective procedures. Removing the closure element from the access opening may refer to fully disconnecting it from the main body. In other embodiments, the closure element may be pivotally connected to the main body like a door, so that it can be removed from the access opening while remaining connected to the main body via at least one hinge or the like. If the respective pivot axis is vertical, neither the closure element nor the valve assembly need to be lifted or lowered in the process, which minimizes the amount of force necessary to move the valve assembly into (and out of) the housing cavity.

[0024] The invention also relates to a industrial plant, which comprises a material gate as described above. Preferred embodiments of the inventive industrial plant correspond to those of the inventive material gate. As already mentioned, the industrial plant may preferably be a metallurgical plant, which may in particular be an iron-producing plant or steel-producing plant. The material gate is interposed between an upstream component and a downstream component. The upstream component may be a DRI (directly reduced iron) source, i.e., a plant or a reservoir that receives and temporarily stores DRI material. The downstream component could be an electric arc furnace where the DRI is used for steel production.Brief Description of the Drawings

[0025] Preferred embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:Fig.1 is a perspective view of an inventive material gate;Fig.2 is a perspective view of the material gate from fig.1 with some components removed;Fig.3 is a sectional view of the material gate from fig.1 ;Fig.4A-4C are sectional views along the line IV-IV in fig.3 with a valve element in different positions;Fig.5 is a perspective view of the material gate from fig.1 in a partially disassembled state;Fig.6 is a perspective view of the valve element;Fig.7 is a top view of the valve element;Fig.8 is a sectional view along the line VIII-VI 11 in fig.7;Fig.9 is a sectional view along the line IX-IX in fig.7; andFig.10 is a schematic side view of a steel-producing plant with the material gate from fig.1 .Description of Preferred Embodiments

[0026] Figs.1 and 2 show perspective views of an inventive material gate 1 , which can be used in an industrial plant, e.g. in a steel-producing plant 50. In such a plant 50, which is shown schematically in fig.10, the material gate 1 is disposed downstream of a hopper 51 for DRI material, to which it is connected by a first material pipe 52, and upstream of an open bath furnace 54, to which it is connected by a second material pipe 53. The material gate 1 comprises a housing 2 made of steel. A main body 3, which constitutes a major part of the housing 2, defines a housing cavity 3.4, which can be seen in the sectional view of fig.3. As can also be seen in fig.2, in which parts of the main body 3 have been removed, a funnel 7 is disposed within the housing cavity 3.4. The funnel 7 defines a material channel 12 that extends along a channel axis A from an inlet opening 13 to an outlet opening 14. In this embodiment, the channel axis A is parallel to a vertical Z-axis. The Z-axis is antiparallel to the direction of gravity with respect to an installation position of the material gate 1 . For sake of reference, the figures also show an X-axis and a Y-axis, both of which are horizontal. The main body 3 comprises two connection flanges 3.1 , 3.2, which are adapted for connecting the material gate 1 to upstream and downstream components. As can be seen in fig.3, the funnel 7 comprises an inner shell 8, which can be made of or lined with heat-resistant materials, such as refractory material or heat-resistant steel, and an outer shell 9 made of steel. Specifically, the outer shell 9 may have a double-walled structure and define a coolant cavity 10 that is disposed between these two walls. The coolant cavity 10 isconnected via coolant pipes 11 to a plurality of coolant ports 3.3 on an outer side of the housing 2. When the coolant ports 3.3 are connected to a coolant circuit (not shown), a liquid coolant, preferably water, can be guided through the coolant cavity 10 to protect the funnel 7 from overheating. On one side of the main body 3, a platelike closure element 4 is connected to the main body 3 to close an access opening 3.5 (visible in fig.5). A transmission portion 5 and a motor portion 6 of the housing 2 are attached to the closure element 4.

[0027] The material gate 1 also comprises a valve assembly 20, with a valve element 21 , a coupler element 22, and a transmission element 23. The transmission element 23, which can also be referred to as a transmission shaft, is mostly disposed in the transmission portion 5 and is coupled to a drive motor 40 disposed in the motor portion 6. The coupler element 22, which is L-shaped arm, is fixed to one end of the transmission element 23. With respect to figs. 2 and 3, the coupler element 22 extends from a position laterally of the funnel 7 to a position beneath the outlet opening 14. Here, it is connected to the valve element 21 by a plurality of connector elements 25, 26. In this embodiment, the connector element 25, 26 are screws, which are combined with nuts. To realize the connection, the valve element 21 comprises a plurality of first connection features 21.7 and the coupler element 22 comprises a plurality of second connecting features 22.1. All connecting features 21.7, 22.1 are through-openings adapted to receive one of the connector elements 25, 26.

[0028] Figs. 2 and 3 show the valve element 21 in a closed position, in which it is disposed in close proximity of the outlet opening 14, thereby preventing material flow through the material channel 12. However, the valve assembly 20 is pivotally connected to the housing 2 so that it can be pivoted by the motor 40 about a valvepivot axis P. Thus, the valve element 21 can be moved into an open position shown in fig.4A, in which it is moved away from the outlet opening 14 to enable material flow through the material channel 12. The pivot movement between the open position and the closed position is illustrated in figs. 4A - 4C. The movement of the valve element 21 is facilitated by its plate-like shape with an inner surface 21.1 that is spherical and centered around a center point C on the valve-pivot axis P. As mentioned before, fig.4A shows the valve element 21 in an open position in which it is fully removed from the outlet opening 14. By activation of the motor 40, a closing movement isinitiated. With respect to the closing movement, one valve-element edge 21.2 - 21.5 of the valve element 21 is a leading edge 24, which is the foremost part of the valve element 21. It will be understood that as hot and abrasive material falls through the material channel 12, the leading edge 24 is subjected to severe abrasion until the material channel 12 is fully closed as shown in fig.4C. In an opening movement, which is the inversion of the closing movement, material will first start to move by sliding and falling past the leading edge 24, which also leads to abrasion and wear.

[0029] The very structure of the valve element 21 and the housing 2 account for the problem of wear, which may shorten the lifetime of the affected components. As can be seen in fig.5, the closure element 4, together with the transmission portion 5, the motor portion 6 and the valve assembly 20, can be removed from the main body 3. While figs.1-3 show the closure element 4 in an access-closed position, in which it closes the access opening 3.5, fig.3 shows an access-open position, in which it is removed from the access opening 3.5. In this state, the closure element 4 with the other components 5, 6, 20 can be supported by a hoist (not shown). The size of the access opening 3.5 is adapted so that the valve element 21 can be moved therethrough to the outside of the housing 2. Also, as indicated in fig.5, the entire funnel 7 can be removed from the housing cavity 3.4 through the access opening 3.5. These features greatly facilitate inspection, maintenance and replacement procedures.

[0030] If the valve element 21 needs to be replaced, this can relatively easily be achieved by removing the 3 connector elements 25, 26. However, a replacement of the valve element 21 is only necessary after a relatively long time. Before that, the lifetime of the valve element 21 can be extended by changing its configuration. As illustrated in figs. 6 - 9, the valve element 21 is symmetrical about a configuration axis B. The above-mentioned center point C is located on the configuration axis B and - in assembled state - on the valve-pivot axis P. As viewed parallel to the configuration axis B like in fig.7, the valve element 21 has a square shape with four identically shaped valve-element edges 21.2 - 21 .5. These valve-element edges 21 .2 - 21 .5 are pairwise offset by a rotation angle a of 90°. Accordingly, while a first valveelement edge 21.2 is designated as the leading edge 24 in figs. 6 - 9, the valve element 21 can be moved into a new orientation, corresponding to a new configuration, by rotating about the rotation angle a around the configuration axis B.Then, a second valve-element edge 21.3 becomes the leading edge 24. The change of configuration is facilitated by the number and position of the first connection features 21.7. There is a total of five first connection features 21.7, only three of which are needed for the connection to the coupler element 22. All first connection features 21 .7 are disposed in a connection portion 21 .6 of the valve element 21 . This connection portion 21.6 is sufficiently offset from the valve-element edges 21.2 to 21 .5 to be not significantly affected by wear. One connection feature 21 .7 receives a central connector element 25, while two other connection features 21.7 receive off- center connector elements 26. The central connector element 25 is disposed on the configuration axis B, while the off-center connector elements 26 are offset thereto.

[0031] As the configuration is changed, the central connector element 25 may remain in its position, although it needs to be loosened to a certain degree. The off- center connector elements 26, on the other hand need to be removed completely. The central connector element 25 may serve as a rotation-support means 27 by which the valve element 21 and the coupler element 22 remain connected during a rotation about the configuration axis B. On the one hand, this facilitates the alignment of the valve element 21 , on the other hand the weight of the valve element 21 continues to be supported by the coupler element 22. Then, after a rotation about the rotation angle a, the central connector element 25 can be tightened again and the off- center connector elements 26 can be reapplied. This time, they are placed in first connection features 21.7 that are offset by the rotation angle a from the ones previously used. In the new configuration, the second valve-element edge 21.3, which has not been subjected to substantial wear up to this point, is the leading edge 24. The first valve-element edge 21 .2, on the other hand, is moved into a position where it is subjected to no significant wear and therefore does not detrimentally affect the lifetime of the valve member 21. The process described above can be repeated for the third and fourth valve-element edge 21.4, 21.5, thereby increasing the lifetime of the valve element 21 by a factor of 4.Legend of Reference numbers:1 material gate 2 housing3 main body3.1 , 3.2 connecting flange 3.3 coolant port 3.4 housing cavity 3.5 access opening4 closure element 5 transmission portion 6 motor portion 7 funnel 8 inner shell 9 outer shell10 cavity 11 coolant pipe12 material channel 13 inlet opening 14 outlet opening20 valve assembly 21 valve element21.1 inner surface 21.2-21.5 valve-element edge21.6 connection portion21.7, 22.1 connecting feature 22 coupler element 23 transmission element 24 leading edge 25, 26 connector element27 rotation-support means 40 motor 50 industrial plant, e.g. steel-producing plant 51 hopper 52, 53 material pipe54 furnace A channel axis B configuration axis C center point P valve-pivot axis X X-axis Y Y-axis Z Z-axis

Claims

Claims1 . A material gate (1 ) for an industrial plant (50), comprising- a housing (2) with a funnel (7) which defines material channel (12) extending from an inlet opening (13) to an outlet opening (14), and- at least one valve assembly (20) with a valve element (21 ) and a coupler element (22) which are connected to each other so that by actuation of the coupler element (22), the valve element (21 ) is movable in a closing movement from an open position for enabling material flow through the material channel (12) into a closed position for blocking material flow through the material channel (12), the valve element (21 ) comprising a plurality of valve-element edges (21.2-21.5), one of which is a leading edge (24) with respect to the closing movement, wherein the valve element (21 ) is adapted to be connected to the coupler element (22) in a plurality of different configurations so that for each configuration, a different valve-element edge (21 .2-21 .5) is the leading edge (24).

2. The material gate according to claim 1 , wherein the valve element (21 ) is rigidly connected to the coupler element (22).

3. The material gate according to any of claims 1 or 2, wherein the coupler element (22) and the valve element (21 ) have corresponding connecting features (21.7, 22.1 ) which are adapted for connecting the valve element (21 ) to the coupler element (22) in different orientations relative to the coupler element (22), each orientation corresponding to one configuration.

4. The material gate according to any of claims 1 to 3, wherein the valve element (21 ) is detachably connected to the coupler element (22).

5. The material gate according to any of claims 1 to 4, wherein the valve element (21 ) comprises a plurality of equally shaped valve-element edges (21.2-21.5) which are pairwise offset from each other by a rotation angle (a) with respect to a configuration axis (B).

6. The material gate according to any of claims 1 to 5, wherein all valve-element edges (21 .2-21 .5) are offset from a connection portion (21 .6) of the valve element (21 ) which is connected to the coupler element (22).

7. The material gate according to any of claims 1 to 6, wherein the valve assembly(20) comprises rotation-support means (27) which connect the valve element (21) to the coupler element (22) while enabling a rotation of the valve element (21 ) relative to the coupler element (22) about the configuration axis (B).

8. The material gate according to any of claims 1 to 7, wherein the valve element(21 ) and the coupler element (22) are connected by a plurality of connector elements (25, 26), the rotation-support means (27) comprise a central connector element (25) disposed on the configuration axis (B), and at least one off-center connector element (26) is disposed offset from the configuration axis (B) to prevent rotation about the configuration axis (B).

9. The material gate according to any of claims 1 to 8, wherein the valve element (21 ) is adapted to be connected to the coupler element (22) in a total of two to eight, preferably three to six, more preferably four different configurations.

10. The material gate according to any of claims 1 to 9, wherein the valve assembly(20) is pivotable relative to the housing (2) about a valve-pivot axis (P).

11. The material gate according to any of claims 1 to 10, wherein the valve element(21 ) has an arcuate inner surface (21.1), which is preferably spherical and / or centered about a center point (C) on the valve-pivot axis (P).

12. The material gate according to any of claims 1 to 11 , wherein the housing (2) comprises a main body (3) defining a housing cavity (3.4), wherein the funnel (7) is connected to the main body (3), and the funnel (7) and the valve assembly (20) are at least partially disposed inside the housing cavity (3.4).

13. The material gate according to any of claims 1 to 12, wherein the main body (3) comprises an access opening (3.5) communicating with the housing cavity (3.4), a closure element (4) is connected to the main body (3) to close the access opening (3.5) in an access-closed position, and the coupler element (22) is connected to the closure element (4) to be pivotable about the valve-pivot axis (P).

14. The material gate according to any of claims 1 to 13, wherein the closure element (4) is removable from the access opening (3.5), whereby that the valve assembly (20) is at least partially moved through the access opening (3.5) out of the housing (2).

15. An industrial plant (50), comprising the material gate (1 ) according to any of claims 1 to 14.

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