Back-ventilated fire-resistant wall with vertical grooves
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Solution Overview
Problem
Conventional rear-ventilated refractory walls face challenges in effectively protecting boiler walls from corrosion while maintaining optimal heat transfer and minimizing gas pump capacity, as they often require high air volumes and pressure, leading to inefficient heat dissipation and increased energy consumption.
Innovation Solution
A rear-ventilated refractory wall system with gas supply means that distribute inert gas through continuous vertical grooves between the boiler wall and protective cladding, reducing the gap distance to a few millimeters, allowing for smaller gas volumes and lower pressure drops, enhancing heat transfer, and incorporating turbulence elements to improve gas flow distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rear-ventilated refractory walls use high air volumes and pressure to prevent flue gas penetration, then corrosion protection of the boiler wall is improved, but heat transfer efficiency deteriorates and energy consumption increases
Solution Approach 1:
The patent changes the key parameters of the protective gas system by reducing the gas volume flow rate and pressure differential from conventional high values to optimized lower values. This is achieved by improving the gas distribution system through vertical grooves in the refractory plates, which allow efficient gas distribution at lower flow rates, thereby reducing energy consumption while maintaining adequate corrosion protection
Solution Approach 2:
The patent employs pneumatic principles by using a protective gas (typically air) supplied through the boiler wall via vertical grooves in the refractory plates. The gas flows through the intermediate space between the boiler wall and protective cladding, creating a pressure differential that prevents flue gas penetration while enabling heat transfer. The system optimizes the pneumatic flow to achieve the desired protection with minimal energy input
2Reliability
If conventional rear-ventilated refractory walls use high air volumes to prevent flue gas penetration, then corrosion protection is improved, but heat transfer between protective cladding and boiler wall deteriorates
Solution Approach 1:
The patent optimizes the gas flow parameters (volume and pressure) to achieve the minimum necessary for corrosion protection while minimizing the insulating effect on heat transfer. By using vertical grooves for efficient gas distribution, the system maintains lower gas volumes that reduce the thermal insulation barrier, thereby improving heat transfer efficiency while still providing adequate protection against flue gases
3Reliability
If conventional rear-ventilated refractory walls use high pump capacity to maintain protective gas pressure, then flue gas prevention is improved, but energy consumption increases
Solution Approach 1:
The patent significantly reduces the required pump capacity by optimizing the protective gas system parameters. The vertical groove distribution system enables effective gas distribution at much lower flow rates and pressure differentials compared to conventional systems, thereby reducing the pump energy consumption while maintaining reliable prevention of flue gas penetration
Solution Approach 2:
The patent uses pneumatic flow through vertical grooves in the refractory plates to distribute protective gas efficiently. This pneumatic system achieves effective gas distribution with minimal pressure drop and flow rate requirements, significantly reducing the energy consumption of the pump while maintaining adequate protection against flue gases
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
This design effectively prevents corrosive flue gases from reaching the boiler wall, reduces energy consumption by minimizing gas volume and pressure requirements, and enhances heat transfer between the protective cladding and boiler wall, ensuring reliable corrosion protection and efficient energy use.
Implementation Method 1
The gas or the air is under a slight overpressure compared to the combustion chamber, which prevents the flue gases from penetrating the combustion chamber into the space between the walls
Implementation Method 2
the heat transfer between the protective casing and the pipe wall is significantly increased
Implementation Method 3
the heat transfer between the protective casing and the pipe wall is significantly increased
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A fire-resistant wall intended in particular for use in a combustion furnace comprises a tube wall (1), composed of tubes (11) connected by webs (12), and, placed in front at a distance from the tube wall, a fire-resistant protective cladding (2) composed of a plurality of fire-resistant panels (21) which are arranged next to and above one another and which are fastened to the webs (12) of the tube wall via in each case at least one panel holder (22). The panels (21) are provided with continuous open grooves (21a) into which the panel holders (22) engage. In the tube wall (1) are provided inlet openings (31) via which air can be introduced into the gap (3) between the tube wall (1) and the protective cladding (2). Also provided are outlet openings through which air can be removed from the wall. The air supply openings (31) are arranged in the region of the open grooves (21a) of the panels (21), with the result that the supplied air flows directly into the grooves and is distributed through these grooves over the entire wall. By incorporating the grooves (21a) into the air distribution system within the wall, the gap width (d) between the tube wall (1) and the protective cladding (2) can be reduced to £ 5 mm, thereby considerably improving the heat transfer. It is possible at the same time to manage with relatively small air volumes and the pressure loss is considerably reduced, making it possible to achieve considerable energy savings.