Single-Piece Cast Iron Boiler Chamber Mold for Faster Assembly
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Solution Overview
Problem
The manufacturing of circulating fluidized bed boiler combustion chambers is laborious, time-consuming, and requires extensive experience due to separate assembly of components like primary stage air nozzles, ash removal, biomass and lignite feed, secondary stage air, burner, and burner cooling air inlets, which complicates production and increases reliance on imports.
Innovation Solution
A single-piece refractory cast iron combustion chamber mold is designed with bolted connections for sheet metals, incorporating thermal insulation and refractory material, allowing simultaneous assembly of these components into a compact, efficient structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate assembly of components (primary stage air nozzles, ash removal, biomass feed, etc.) is used in combustion chamber manufacturing, then each component can be individually optimized, but the manufacturing process becomes laborious, time-consuming, and requires extensive experience
Solution Approach 1:
The patent merges multiple separate combustion chamber components (primary stage air nozzles, ash removal, biomass feed, secondary stage air, burner, and burner cooling air inlets) into a single integrated combustion chamber structure. This consolidation eliminates the need for separate assembly of individual components, thereby reducing manufacturing labor and time while maintaining the functional optimization of each component through precise design integration.
2Adaptability or versatility
If separate assembly of combustion chamber components is used, then individual component design is flexible, but the overall manufacturing process becomes complex and experience-dependent
Solution Approach 1:
The invention integrates multiple combustion chamber functions into a single monolithic structure, combining primary stage air nozzles, ash removal, biomass feed, secondary stage air, burner, and burner cooling air inlets into one unified component. This merging simplifies the assembly process by eliminating multiple separate installations while preserving design flexibility through integrated optimization of all components within the single structure.
3Ease of manufacture
If traditional separate manufacturing method is used, then each component can be manufactured with standard procedures, but the overall production time and labor requirements increase significantly
Solution Approach 1:
The patent combines multiple combustion chamber components into a single integrated unit that can be manufactured as one piece using standard refractory casting procedures. This approach maintains the ease of using established manufacturing methods while dramatically reducing the total production time by eliminating the sequential assembly of multiple separate components.
4Ease of operation
If separate assembly of combustion chamber components is used, then installation can be modular, but the manufacturing process becomes laborious and requires extensive experience
Solution Approach 1:
The invention integrates all combustion chamber components (primary stage air nozzles, ash removal, biomass feed, secondary stage air, burner, and burner cooling air inlets) into a single monolithic structure. This integration simplifies the manufacturing process by eliminating complex assembly procedures while maintaining installation ease through the modular nature of the complete unit, which can be installed as one piece without requiring extensive experience in assembling multiple separate components.
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
Facilitates easy adaptation to different capacities, reduces manufacturing time and labor, minimizes defects, and achieves high insulation performance, thereby enhancing production efficiency and reducing dependence on experience.
Implementation Method 1
a thermal insulation layer placed on the outward facing surfaces of the anchoring metals
Data Source
Figure 1
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AI summary
The invention relates to a compact (one-piece) refractory cast iron combustion chamber mold for a circulating fluidized bed boiler for the combustion and/or gasification of biomass, waste, lignite and mixtures thereof, and a method of obtaining a combustion chamber with this mold.