Shaft Furnace Cooling Box Form-Fit Partition Design

Solution Overview

Problem

The existing manufacturing methods for cooling boxes in shaft furnaces are costly and time-consuming, particularly due to the need for complex processes like sand casting and explosion welding, which increase the overall cost and reduce efficiency.

Innovation Solution

A cooling box design featuring an elongated hollow body with a form-fit connection for partition plates, eliminating the need for welding and allowing machining from a single block of material, with a cover plate providing sealing and pressure to secure the partition plates, reducing manufacturing time and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If sand casting technique is used to manufacture cooling box, then complicated shapes of cooling circuit can be built inside the cooling box, but the manufacturing process becomes long and complex including preparation of mould, drilling evacuation holes, and closing holes

Engineering Contradiction:

Improvecooling circuit shape complexityVSAvoidmanufacturing process time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The cooling circuit channels are pre-formed as integral parts of the cooling box body during the initial manufacturing process, eliminating the need for subsequent drilling and closing operations. The body is designed with predetermined cavities and passages that serve as the cooling circuit, so no additional steps are required to create the circuit paths.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cooling box body and the cooling circuit are merged into a single integrated component. Instead of creating the cooling circuit as a separate element that needs to be installed later, the circuit channels are formed directly within the body structure itself, combining the housing and the fluid passage functions into one piece.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If explosion welding technique is used to connect cooling circuit to walls, then the cooling circuit can be integrated in cooling box body, but the manufacturing process becomes complex and expensive

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing complexity and cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The cooling box body and the cooling circuit are merged into a single integrated component. Instead of creating the cooling circuit as a separate element that needs to be installed later, the circuit channels are formed directly within the body structure itself, combining the housing and the fluid passage functions into one piece.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The complex explosion welding process is extracted and replaced by a simpler integration method. The cooling circuit is designed to be inherently part of the body structure, eliminating the need for separate connection processes and reducing manufacturing complexity while maintaining structural integrity.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If cooling boxes are welded to furnace wall, then gas tight sealing is ensured, but manufacturing cost increases due to large number of cooling boxes and their replacement

Engineering Contradiction:

Improvegas tight sealingVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The cooling box body and the cooling circuit are merged into a single integrated component. Instead of creating the cooling circuit as a separate element that needs to be installed later, the circuit channels are formed directly within the body structure itself, combining the housing and the fluid passage functions into one piece.

Inventive Principle:

Principle #5Merging (Combining)

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 reduces manufacturing costs and time by eliminating the need for welding and complex processes, while maintaining robustness and efficiency in coolant fluid circulation, enhancing the overall performance and longevity of the cooling box.

Implementation Method 1

coolant fluid, like for example water, circulates... travels along the cooling path gaining heat from the furnace and leaves the cooling box

Methodology Applied

Scientific EffectHeat dissipation: Convection

Implementation Method 2

coolant fluid... travels along the cooling path gaining heat from the furnace

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS11535904B2Cooling box for a shaft furnace

Publication Date: 2022.12.27 PAUL WURTH SA

AI summary

A cooling box for a metallurgical furnace including an elongated hollow body extending from a front end, to an opposite rear end, the rear end being, in use, connected to a wall of the furnace; the body includes an inner chamber having a cooling circuit configured to receive a flow of coolant fluid therein between at least one inlet and at least one outlet; the cooling box further including at least one partition plate fitted in the inner chamber through a form-fit connection to form the cooling circuit.