Air-Cooled Grate Block with S-Shaped Cooling Ducts
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Solution Overview
Problem
Existing incineration grates face high production and process engineering costs due to the use of water-cooled grate blocks, which are necessary for efficiently cooling residues with high calorific values, while air-cooled blocks lack sufficient cooling efficiency and wear resistance.
Innovation Solution
A grate block design featuring a cast body with an S-shaped cooling duct system using air as the cooling medium, allowing for efficient cooling of high-calorific residues without water cooling, and incorporating a rib for stability and varying cross-sectional areas for differentiated cooling, enabling long service life comparable to water-cooled blocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water-cooled grate blocks are used, then cooling efficiency is improved, but production cost and process engineering effort increase
Solution Approach 1:
The patent replaces the water-cooling system (mechanical/chemical system requiring water circulation infrastructure) with an air-cooling system. The cooling channels are designed to allow air flow directly through the grate block structure, eliminating the need for water supply and drainage systems while maintaining effective cooling of the combustion grate.
Solution Approach 2:
The patent changes the cooling medium parameter from water to air. By optimizing the cooling channel geometry and air flow patterns, the system achieves sufficient cooling efficiency using air instead of water, thereby reducing production costs and simplifying the overall system while maintaining temperature control capabilities.
2Ease of manufacture
If air-cooled grate blocks are used, then production cost is reduced, but cooling efficiency and wear resistance decrease
Solution Approach 1:
The cooling function is segmented into multiple channels distributed throughout the grate block structure. The cooling channels are strategically positioned to cool different zones of the grate block, ensuring comprehensive cooling coverage. This segmentation allows air to effectively remove heat from multiple locations simultaneously, improving overall cooling efficiency despite using air instead of water.
Solution Approach 2:
The cooling approach transitions from surface-level cooling to volumetric cooling by incorporating cooling channels within the three-dimensional structure of the grate blocks. This internal cooling architecture allows air to penetrate and cool the entire volume of the grate blocks, significantly improving cooling efficiency and wear resistance compared to external cooling methods.
3Temperature
If cooling channels are added to grate blocks, then cooling efficiency is improved, but structural complexity increases
Solution Approach 1:
The cooling channels are merged with the structural elements of the grate blocks. The channels are integrated into the existing block geometry, utilizing the same material and manufacturing processes. This merging approach allows the cooling function to be achieved without adding separate complex cooling components, thereby improving cooling efficiency while minimizing increases in structural complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The grate block achieves excellent cooling efficiency and long service life by utilizing air cooling for residues with high calorific values, eliminating the need for preheated primary air and optimizing cooling medium flow rates, thus reducing production and maintenance costs.
Implementation Method 1
a first cooling channel section (40) runs through the upper wall (10) and the front wall (20) to an outlet opening (45) arranged in the front wall (20). A cooling duct wall (55) extends from the inlet opening (50) and forms a second cooling channel section (60) which is flow-connected to the first cooling channel section (40) at the wall inlet (35)
Data Source
Figure 1
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AI summary
The air-cooled grate block (1) has a block body (5) embodied as a cast part, which has an upper wall (10) and a front wall (20). The upper wall forms a bearing surface (15), and a base (25) is pre-formed in the front wall. A cooling channel (40) is connected with another cooling channel (60). Another cooling channel is formed at a wall inlet (35) by one of an inlet opening (50) arranged adjacent to the base. The front wall and a cooling channel wall (55) are spaced from the upper wall. An independent claim is included for a grate with multiple grate block rows.