Baffle Plate in Fluidized Bed Cooler for Urea Granules

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Solution Overview

Problem

Fluid bed coolers for urea-containing granules often experience granule accumulation under the perforated plate, leading to costly shutdowns and production losses due to the need for frequent cleaning.

Innovation Solution

A fluid bed cooler design featuring a baffle plate and distributor plate between the product inlet and perforated plate, which slows down granule entry and distributes them evenly, reducing accumulation by up to 90% and minimizing deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If granules are transferred directly to the cooler without additional components, then the cooling process is simple and fast, but granule accumulation occurs under the perforated plate requiring frequent shutdowns

Engineering Contradiction:

Improvecontinuous operation timeVSAvoidoperational stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A baffle plate is introduced as an intermediary component between the product inlet and the perforated plate. This baffle plate serves as a mediator that slows down the granule flow and prevents direct impact on the perforated plate, thereby preventing accumulation while maintaining continuous operation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The baffle plate performs preliminary action by reducing granule velocity and kinetic energy before they reach the perforated plate. This preliminary slowing down prevents the accumulation problem from occurring in the first place, eliminating the need for shutdowns

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the cooler operates continuously without cleaning, then production is maintained, but granule accumulation increases leading to operational issues

Engineering Contradiction:

Improveproduction continuityVSAvoidgranule accumulation

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The baffle plate converts the harmful kinetic energy of incoming granules into a beneficial slowing effect. By positioning the baffle plate strategically, the granule flow is redirected and slowed down, transforming the potential accumulation problem into a controlled flow pattern that prevents harmful deposits

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If cleaning operations are performed frequently to remove granule accumulations, then equipment performance is maintained, but production downtime and costs increase

Engineering Contradiction:

Improvecooler performanceVSAvoidshutdown time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The baffle plate performs preliminary action by preventing granule accumulation from occurring in the first place. By slowing down granule flow before it reaches the perforated plate, the design eliminates the need for frequent cleaning shutdowns, maintaining continuous production

Inventive Principle:

Principle #10Preliminary action

4Speed

If granules enter the cooling chamber at high speed, then the cooling process is efficient, but granule deformation occurs and accumulation increases

Engineering Contradiction:

Improvegranule flow speedVSAvoidgranule integrity

Core Design Contradiction:

SpeedVSShape

Solution Approach 1:

The baffle plate acts as an intermediary that decelerates granule flow before they enter the cooling chamber. This mediator component reduces the kinetic energy of granules, preventing deformation while maintaining sufficient flow speed for effective cooling

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The baffle plate provides beforehand cushioning by absorbing and dissipating the kinetic energy of incoming granules. This prior cushioning effect prevents granule deformation and reduces impact forces that could cause accumulation, while still allowing efficient cooling to proceed

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 baffle and distributor plates effectively reduce granule lumps and kinetic energy, enhancing the uniformity of granule transfer and extending cooler operation time, while reducing downtime and cleaning costs.

Implementation Method 1

The baffle plate allows the speed of the granule particles entering the cooling chamber via the product inlet opening to be slowed down without causing significant deformation of the granule particles

Methodology Applied

Scientific EffectKinetic energy reduction:

Implementation Method 2

The granules are cooled, for example, by an air or (inert) gas stream, via a perforated plate and a cooling medium inlet located beneath it

Methodology Applied

Scientific EffectHeat transfer:

Implementation Method 3

The particles obtained in the fluidized bed granulator have a higher temperature, often in the range of 90-100°C, due to the process

Methodology Applied

Scientific EffectHeat generation:

Data Source

PatentEP3508465B1Internal baffles in fluidised bed cooler

Publication Date: 2023.11.29 THYSSENKRUPP FERTILIZER TECH GMBH

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AI summary

The invention comprises a fluidized bed cooler for cooling a urea-containing granulate, comprising at least a cooler chamber (1) with a product inlet opening (2), a product outlet opening (3), a perforated plate (4) arranged in the cooler chamber (1) and at least one cooling medium inlet opening (7) arranged below the perforated plate (4), characterized in that the product inlet opening (2) is arranged above the perforated plate (4) and a baffle plate (5) is arranged between the product inlet opening (2) and the perforated plate (4).