Copper Cooling Plate with Ceramic Inserts for Blast Furnace Wear
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Solution Overview
Problem
Copper cooling plates in blast furnaces experience early erosion due to lack of wear resistance, and previous solutions like steel inserts are not adequately cooled and can be washed out by gases.
Innovation Solution
Incorporating wear-resistant ceramic inserts into the ribs and multilayer protrusions made of high thermal conductivity materials with ceramic layers to enhance wear resistance and protect against erosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If copper cooling plates are used to provide good thermal conductivity, then heat transfer efficiency is improved, but wear resistance deteriorates causing early erosion
Solution Approach 1:
The patent applies composite materials by combining copper body with ceramic inserts (such as silicon carbide) in the ribs. The copper provides thermal conductivity while the ceramic inserts provide wear resistance, creating a composite structure that resolves the contradiction between thermal performance and wear resistance.
Solution Approach 2:
The patent applies local quality by introducing wear-resistant ceramic inserts only in specific locations (the ribs) where wear occurs, rather than making the entire cooling plate from wear-resistant material. This allows the copper body to maintain its thermal conductivity while protected areas gain wear resistance.
2Reliability
If steel pieces are introduced in grooves to protect ribs from erosion, then wear resistance is improved, but the steel pieces are not properly cooled and can be washed out by gas
Solution Approach 1:
The patent uses ceramic inserts as an intermediary material that combines the benefits of wear resistance with improved cooling performance. The ceramic material serves as a mediator between the copper body and the harsh gas environment, providing protection while being compatible with the thermal conditions.
Solution Approach 2:
The patent changes the material parameter from steel to ceramic for the protective inserts. This parameter change transforms the material properties to match the operating conditions better, as ceramic materials can withstand the thermal and chemical environment of blast furnaces more effectively than steel.
3Reliability
If ribs are made harder to resist erosion, then wear resistance is improved, but thermal conductivity may deteriorate
Solution Approach 1:
The patent uses composite materials with copper providing thermal conductivity and ceramic inserts providing wear resistance. This composite approach allows different regions of the rib to have different properties, maintaining overall thermal performance while providing localized wear protection.
Solution Approach 2:
The patent applies local quality by making only the surface or specific regions of the ribs wear-resistant through ceramic inserts, while the bulk copper body maintains its high thermal conductivity. This localized approach minimizes the impact on overall thermal performance.
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 solution significantly increases the wear resistance of copper cooling plates, preventing early erosion and ensuring durability by distributing thermal loads and pressure effectively.
Implementation Method 1
at least one of its ribs comprises at least one housing located between its first extremities and comprising at least one insert made of a wear resistant ceramic that increases locally the wear resistance of this rib
Implementation Method 2
a first layer made of a material having a high thermal conductivity, and a second layer made of the wear resistant material and set on top of the first layer
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to a cooling plate (1) for use in a blast furnace. This cooling plate (1) comprises a copper body (2) having an inner face (3) comprising ribs (4-1, 4-2) parallel therebetween, having first extremities(6) opposite therebetween and separated by grooves (5)having second extremities(7)opposite therebetween. At least one of these ribs (4-1)comprises at least one housing (8) located between its first extremities(6) and comprising at least one insert (9) made of a wear resistant material that increases locally the wear resistance of this rib (4-1).