Crushed Sand Coated Cleaning Ball for Condenser Tube Maintenance
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Solution Overview
Problem
Existing cleaning balls used in condenser cleaning equipment discharge synthetic resin chips into the ocean, causing environmental pollution and violating marine conservation policies, despite their effectiveness in maintaining heat transfer tube cleanliness.
Innovation Solution
A cleaning ball with a skin layer of crushed sand, specifically sandstone containing granite particles, bonded to a sponge rubber sphere, which is designed to deform and clean heat transfer tubes without polluting the marine environment, using a method that includes pre-processing the surface, applying an adhesive, and drying the crushed sand coating to form a concave and convex shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a cleaning ball with synthetic resin chips is used to clean heat transfer tubes, then the cleaning effectiveness and scale-scraping ability are improved, but the cleaning ball discharges synthetic resin particles into the ocean causing environmental pollution
Solution Approach 1:
The invention changes the material parameter of the outer sheath from synthetic resin chips to crushed sand particles. This parameter substitution maintains the mechanical cleaning function while eliminating the environmental pollution problem, as crushed sand is biodegradable and harmless to the marine environment.
Solution Approach 2:
The invention uses a composite structure consisting of a sponge rubber ball core combined with a crushed sand outer sheath. This composite material approach combines the deformability and cleaning action of the sponge rubber with the abrasive cleaning capability of crushed sand, achieving effective cleaning without environmental harm.
2Strength
If the outer sheath is made of crushed synthetic resin to enhance wear resistance, then the cleaning ball's durability and scale-scraping effect are improved, but the synthetic resin particles are discharged into the ocean over time
Solution Approach 1:
The invention substitutes the material parameter from synthetic resin to crushed sand for the outer sheath. This change maintains the wear resistance and scale-scraping functionality while transforming the discharged particles from harmful synthetic resin to biodegradable natural sand, eliminating the substance loss problem.
3Reliability
If a coating is formed on the brass tube inner surface by iron ion implantation to resist corrosion, then the corrosion resistance is improved, but fouling on the inner surface is facilitated causing deterioration in heat transfer performance
Solution Approach 1:
The invention extracts and removes the fouling substance accumulated on the coated surface by using the mechanical action of the cleaning ball. The cleaning ball physically removes the fouling that forms on the corrosion-resistant coating, thereby maintaining heat transfer performance while preserving the corrosion protection.
Solution Approach 2:
The cleaning ball equipment provides continuous cleaning action to prevent fouling accumulation on the coated surface. By continuously removing fouling, the system maintains both the corrosion resistance provided by the coating and the heat transfer performance, creating a continuous protective effect.
4Productivity
If cleaning ball equipment is used to prevent fouling and maintain heat transfer performance, then the heat transfer efficiency is improved, but the cleaning ball materials must be selected to avoid environmental pollution
Solution Approach 1:
The invention changes the material parameter of the cleaning ball from synthetic resin-based outer sheath to crushed sand outer sheath. This parameter change enables the cleaning ball to maintain its cleaning function for preserving heat transfer efficiency while eliminating the environmental pollution issue, as crushed sand is naturally biodegradable.
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 cleaning ball efficiently cleans condenser heat transfer tubes while minimizing environmental impact, as the biodegradable materials reduce pollution risks even if discharged into the ocean, maintaining effective heat transfer and corrosion resistance.
Implementation Method 1
a skin layer containing crushed sand (10) bonded to a surface of the sponge rubber sphere (30)... configured to deform corresponding to deformation of the sponge rubber ball
Implementation Method 2
a skin layer including crushed sand bonded to a surface of the sponge rubber sphere
Data Source
AI summary
A cleaning ball with a naturally derived material bonded to a surface of the cleaning ball for a condenser in a power plant is capable of performing efficient cleaning, and even if the material bonded to the surface of the ball is discharged to the ocean, the material does not cause damages to a marine environment. The cleaning ball includes a sponge rubber ball configured to deform and clean a heat transfer tube of the condenser; and a skin layer including crushed sand bonded to a surface of the sponge rubber ball. The crushed sand comprises sandstone containing granite particles, and the crushed sand has a particle size between 0.05 mm and 2.00 mm, and the skin layer is formed in concave and convex shapes on a non-deformed shape of the sponge rubber ball, and is configured to deform corresponding to deformation of the sponge rubber ball.