Collapsible Monorail for Shaft Furnace Stave Replacement
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Solution Overview
Problem
Current methods for maintaining stave linings in shaft furnaces are inefficient, requiring extensive downtime and complex preparations due to the need for multiple openings and full furnace emptying, which limits the number of staves that can be replaced simultaneously and increases maintenance duration.
Innovation Solution
A collapsible circular monorail system divided into arc portions with rotatable connections, allowing the monorail to be folded and inserted through existing maintenance openings, enabling efficient stave replacement without requiring additional openings or significant modifications to the furnace, and supporting multiple stave positioning hoists for simultaneous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a circular monorail is used to support stave positioning hoists, then multiple staves can be replaced simultaneously, but the installation complexity increases and requires full furnace emptying
Solution Approach 1:
The circular monorail is divided into multiple arc-shaped segments that can be independently assembled. Each segment contains mounting positions for stave positioning hoists, allowing the monorail to be constructed in sections rather than as a single complex unit. This segmentation reduces installation complexity while maintaining the capability to support multiple staves simultaneously.
Solution Approach 2:
The monorail system incorporates movable and adjustable components that allow it to be configured and reconfigured during installation and operation. The arc segments can be positioned and secured at different locations, providing flexibility in installation without requiring complete furnace emptying, thus reducing installation complexity while maintaining productivity.
2Ease of operation
If multiple openings are created in the furnace wall for cable manipulation, then staves can be manipulated independently, but the device complexity and preparation time increase
Solution Approach 1:
The monorail system is designed as a universal structure that can accommodate multiple stave positioning hoists along its length. A single opening is sufficient to install the entire monorail assembly, which then provides multiple independent manipulation points for staves. This multi-functional design reduces the number of openings required while maintaining independent stave manipulation capability.
Solution Approach 2:
Multiple stave positioning functions are merged into a single integrated monorail structure. Instead of requiring separate cable manipulation systems through multiple openings, the monorail combines multiple hoist mounting positions into one unified installation that accesses the furnace through a single opening, thereby reducing device complexity while preserving operational independence.
3Reliability
If the furnace is fully emptied and restarted after maintenance, then complete relining can be performed, but the downtime and loss of productivity increase
Solution Approach 1:
The monorail system is pre-assembled with stave positioning hoists mounted at appropriate locations before insertion into the furnace. This preliminary preparation allows maintenance personnel to quickly install the support structure without requiring full furnace emptying, thereby reducing downtime while ensuring proper stave positioning for complete relining quality.
Solution Approach 2:
The monorail system enables continuous maintenance operations without requiring complete furnace shutdown and emptying. The system can be installed through existing openings while the furnace remains partially operational, allowing maintenance work to proceed without interrupting overall furnace productivity, thus maintaining both relining quality and operational continuity.
Data Source
AI summary
A device for mounting and/or dismantling staves on/from an inner wall of a shaft furnace, the device including a circular monorail for supporting at least one stave positioning hoist, where the monorail is divided into at least four separate arc portions, where each arc portion is connected to a neighboring arc portion by means of a rotatable connection, the arc portions are moveable between an unfolded position, in which the arc portions form a circular monorail, and a folded position, in which the overall size of the monorail is, in one direction, reduced.