Corrugated Insulation Brick Thermal Lining for Ladle Vessels
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Solution Overview
Problem
Vessels used to transport high-temperature materials, such as molten metal, experience creep deformation due to inefficient thermal insulation, leading to potential failure and safety hazards, with existing solutions like ceramic insulation boards suffering from shrinkage, abrasion, and frequent relining needs.
Innovation Solution
The use of insulation bricks with corrugations on their outer side walls creates air pockets that enhance thermal insulation, allowing for a thinner brick design and potentially eliminating the need for additional insulation, thereby reducing heat transfer to the vessel shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If ceramic insulation boards are used to improve thermal efficiency, then thermal insulation is improved, but the boards shrink and abrade leading to loss of compression and gaps that reduce thermal efficiency
Solution Approach 1:
The patent uses porous firebrick material with controlled porosity to provide thermal insulation while maintaining structural stability. The porous structure provides insulation without the shrinkage and abrasion problems of ceramic insulation boards, while the refractory nature of the firebrick ensures durability under high temperature conditions.
Solution Approach 2:
The patent employs a composite lining system combining firebrick with refractory concrete or mortar to create a durable, stable structure. This composite approach allows the firebrick to provide insulation while the refractory concrete fills gaps and maintains compression, preventing the gap formation that occurs with ceramic boards alone.
2Loss of energy
If typical insulation bricks are used to line a ladle, then thermal insulation is provided, but the lining process is time consuming and expensive
Solution Approach 1:
The lining is divided into modular firebrick units with standardized dimensions and configurations. These segmented bricks can be pre-manufactured and quickly installed in a systematic pattern, reducing the time and complexity of the lining process compared to custom-shaped insulation bricks.
Solution Approach 2:
The patent optimizes the dimensions, shape, and thermal properties of the firebricks to achieve the required insulation performance with a thinner, more efficient lining. By changing the parameters of the brick design (such as incorporating air spaces or optimized thickness), the insulation effectiveness is improved while reducing material quantity and installation time.
3Quantity of substance
If the brick thickness is reduced to use less material, then material usage is reduced, but thermal insulation effectiveness decreases
Solution Approach 1:
The patent incorporates air spaces or voids within the brick structure, adding a dimensional element that provides thermal insulation without increasing the overall brick thickness. This internal structuring allows thinner bricks to achieve the same insulation effectiveness as thicker solid bricks, reducing material usage while maintaining thermal performance.
Solution Approach 2:
The firebricks are designed with controlled porosity or internal cellular structures that provide thermal insulation pathways. This allows the bricks to be thinner while maintaining insulation effectiveness, as the porous structure traps air and reduces heat transfer without requiring increased thickness.
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 corrugated insulation bricks provide improved thermal efficiency, reduce material usage, and minimize the need for additional insulation, leading to increased durability and reduced maintenance costs while preventing vessel deformation and failure.
Implementation Method 1
These corrugations provide air pockets between the bricks and the shell, which increase the thermal insulation provided by the bricks
Data Source
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AI summary
Presented are an insulation brick and the method of using an insulation brick to create a thermal lining. A set of corrugations are formed into a sidewall of the brick to increase the thermal insulation. A first end of the insulation brick has a convex portion while the second end of the insulation brick has a concave portion. This allows a first insulation brick to mate with another brick in an end to end configuration.