Rotary Furnace Cooling Modules with Pulsed Jets
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Solution Overview
Problem
Current cooling systems for rotary furnaces are complex, noisy, and energy-intensive, failing to provide effective localized cooling and detecting or managing high-temperature hot spots efficiently.
Innovation Solution
A cooling system comprising pulsed fan-shaped cooling fluid jets applied via modular nozzles with actuatable valves and heat sensors, controlled by a system unit to maintain setpoint temperatures, allowing for localized and efficient cooling with reduced energy consumption and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fan cooling systems are used to cool the furnace shell, then the furnace shell temperature is controlled, but the system becomes complex, noisy, and energy-intensive
Solution Approach 1:
The cooling system is divided into multiple independent cooling modules, each responsible for a specific section of the furnace shell. Each module can be controlled independently, reducing overall system complexity while maintaining effective temperature control across the entire furnace shell surface.
Solution Approach 2:
The patent implements localized cooling by directing cooling fluid jets to specific hot spots or high-temperature sections of the furnace shell rather than cooling the entire surface uniformly. This allows precise temperature control where needed while reducing energy consumption and system complexity.
2Temperature
If fan cooling systems are used to cool the furnace shell, then the furnace shell temperature is controlled, but the system produces high noise levels
Solution Approach 1:
The patent replaces the mechanical fan-based cooling system with a fluid jet-based cooling system. Instead of using rotating fans that generate significant noise, the system uses controlled jets of cooling fluid directed at the furnace shell, dramatically reducing noise pollution while maintaining effective cooling.
3Temperature
If fan cooling systems are used to cool the furnace shell, then the furnace shell temperature is controlled, but the power consumption increases
Solution Approach 1:
The cooling system applies cooling fluid jets only to specific sections of the furnace shell that require cooling, rather than cooling the entire surface. This partial action approach reduces energy consumption while maintaining effective temperature control where it is most needed.
Solution Approach 2:
The cooling system operates in periodic cycles, activating cooling modules only when and where high temperatures are detected. This intermittent operation based on thermal feedback significantly reduces power consumption compared to continuous cooling of the entire furnace shell.
4Temperature
If conventional cooling systems are used, then general cooling is provided, but localized hot spots cannot be detected or cooled individually
Solution Approach 1:
The furnace shell cooling system is segmented into multiple independent cooling modules, each capable of being controlled individually. This segmentation enables the system to detect and respond to localized hot spots by activating only the specific modules needed, providing both overall cooling and localized temperature control.
Solution Approach 2:
The cooling system incorporates temperature sensors that continuously monitor the furnace shell surface temperature and provide feedback to the control system. This feedback mechanism enables the system to detect localized hot spots and automatically adjust the cooling fluid jet delivery to those specific areas, achieving adaptive localized cooling control.
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 system achieves low-noise, energy-efficient, and precise localized cooling, preventing mechanical stresses and damage to the furnace shell while maintaining operational stability.
Implementation Method 1
applying cooling fluid from the outside onto the furnace shell in an impact area
Implementation Method 2
applying cooling fluid from the outside onto the furnace shell
Implementation Method 3
first heat sensor which serves to measure a first local temperature of the furnace shell
Data Source
AI summary
The invention relates to a cooling system (3) for rotary furnaces (1), and also to a method for operating such a cooling system (3). The cooling system (3) comprises for this purpose an arrangement of one or more cooling modules (31, 31′, 31″), which are arranged in the portion (21) to be cooled of the furnace shell (2), at least along the axis of rotation (R) of the furnace shell (2), wherein each cooling module (31) comprises an activatable switching valve (311) and a fan nozzle (312) for issuing a pulsed fan-shaped cooling liquid jet (4) and, when there are a number of cooling modules, the neighbouring cooling modules (31, 31′, 31″) are arranged in relation to one another at a distance (A1) parallel to the axis of rotation (R) of the furnace shell (2). Each cooling module (31, 31′, 31″) comprises at least one first heat sensor (313), connected to a cooling system control (32), for measuring a first local temperature (T1) of the furnace shell (2) ahead of the area of impingement (41) as seen in the direction of rotation (DR) of the furnace shell (2).