Continuous Casting Cooling Block for Suspension Smelting Furnace
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Solution Overview
Problem
The high cost and quality issues associated with sand-cast copper cooling blocks in suspension smelting furnaces, which consume excessive copper and are prone to corrosion, leading to installation complexities and material inefficiencies.
Innovation Solution
A continuous casting method is used to manufacture a cooling block that is attached to the arch of the reaction shaft and the wall of the annular reaction gas channel, reducing material consumption and enhancing corrosion resistance, with features like drilled channels for cooling fluid circulation and openings for accessory installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sand casting method is used to manufacture cooling block, then manufacturing flexibility is improved, but manufacturing precision and quality are worsened
Solution Approach 1:
The patent replaces the sand casting process with a continuous casting process, substituting a mechanical/form-based manufacturing system with a more controlled metallurgical process. This continuous casting method produces a cooling block with superior structural integrity and dimensional precision while maintaining manufacturing efficiency through continuous production.
2Ease of manufacture
If sand casting method is used to manufacture cooling block, then manufacturing simplicity is improved, but material consumption is worsened
Solution Approach 1:
The patent changes the manufacturing parameters from batch sand casting to continuous casting, which fundamentally alters the material utilization efficiency. The continuous process allows for precise control of copper flow and solidification, minimizing waste and reducing overall copper consumption while maintaining the required cooling block dimensions and properties.
3Ease of manufacture
If sand cast cooling block is used, then manufacturing cost is reduced, but corrosion resistance is worsened
Solution Approach 1:
The patent replaces the sand casting manufacturing system with a continuous casting system, which produces a cooling block with superior metallurgical quality. The continuous casting process creates a more uniform microstructure and eliminates sand inclusions, thereby significantly improving corrosion resistance and overall reliability of the cooling block in the smelting furnace environment.
4Reliability
If continuous casting method is used to manufacture cooling block, then corrosion resistance is improved, but manufacturing complexity is worsened
Solution Approach 1:
The patent segments the manufacturing process into standardized continuous casting operations that can be continuously produced. By breaking down the cooling block production into a systematic continuous process with defined stages (molten copper preparation, continuous casting, cooling, and extraction), the complexity is managed through process standardization rather than increasing overall manufacturing 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
This approach significantly reduces raw material usage, simplifies installation, and provides improved protection against corrosion, making the process more efficient and cost-effective compared to traditional sand-casting methods.
Implementation Method 1
a cooling block (10), which surrounds the annular reaction gas channel (8)... The continuously-cast cooling block provides improved protection against corrosions
Implementation Method 2
drilled channels for cooling fluid circulation
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a suspension smelting furnace comprising a reaction shaft (1), an uptake shaft (2), and a lower furnace (3), as well as a concentrate burner (4) for feeding reaction gas and fine solids into the reaction shaft (1) of the suspension smelting furnace. The concentrate burner (4) comprises a fine solids discharge channel (5) that is radially limited by the wall (6) of the solids discharge channel, a fine solids dispersion device (7) in the fine solids discharge channel (5), an annular reaction gas channel (8) that surrounds the fine solids discharge channel (5) and is radially limited by the wall (9) of the annular reaction gas channel (8), and a cooling block (10) that surrounds the annular reaction gas channel (8). The cooling block (10) is a component that is manufactured by a continuous casting method. The cooling block (10) is attached to the arch (11) of the reaction shaft (1) and the wall (9) of the annular reaction gas channel (8), so that the discharge orifice (12) of the annular reaction gas channel (8) is formed between a structure (13), which is jointly formed by the cooling block (10) and the wall (9) of the annular reaction gas channel (8), and the wall (6) of the solids discharge channel. The invention also relates to a concentrate burner (4) for feeding reaction gas and fine solids into the reaction shaft (1) of a suspension smelting furnace.