Furnace Shell Insulation Using Folded Fiber Mats and Beams
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Solution Overview
Problem
The existing methods for installing heat insulating blocks on furnace shells, such as stack lining and modular methods, face issues with poor precision, high costs, and time-consuming processes, particularly due to inadequate support of inorganic fiber mats and the need for metal fixtures.
Innovation Solution
A method involving the use of a folded inorganic fiber aggregate mat with beams inserted into folds to create a heat insulating block, where the beams are fixed to the furnace shell separately, allowing for improved support and reduced manufacturing time and costs, with beams of different lengths enhancing workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the stack lining method is used to install heat insulating blocks, then construction speed is fast and manufacturing costs are low, but the inorganic fiber mats cannot be sufficiently supported causing them to fall off or create gaps, and construction precision becomes poor
Solution Approach 1:
The support structure is segmented into multiple beams distributed across the heat insulating block, with each beam providing localized support at fold positions. This segmentation allows the mat to be supported at multiple discrete points rather than requiring a continuous support structure, maintaining construction speed while improving precision and preventing gaps.
Solution Approach 2:
The beams are prepared in advance with predetermined positions and lengths, and the fold positions of the mat are predetermined during manufacturing. This preliminary preparation eliminates the need for on-site measurement and adjustment, maintaining fast construction speed while ensuring precise alignment and positioning of support points.
2Reliability
If the modular method is used to install heat insulating blocks, then the inorganic fiber mats can be firmly fixed to the furnace wall, but time and costs are required for making heat insulating blocks with metal fixtures
Solution Approach 1:
The fixture is segmented into multiple independent beams rather than using a single integrated metal fixture. Each beam can be independently inserted into folds of the mat, simplifying the manufacturing process and reducing time while maintaining reliable support through distributed attachment points.
Solution Approach 2:
Instead of using a uniform metal fixture across the entire block, the invention uses localized beams positioned only at critical fold points of the mat. This local quality approach provides sufficient support reliability where needed while minimizing material usage and manufacturing complexity.
3Ease of operation
If beams are inserted into folds of the heat insulating block, then the heat insulating block can be firmly fixed to the furnace shell with good workability, but the structure becomes more complex
Solution Approach 1:
Instead of inserting the mat into a pre-formed fixture structure, the invention inverts the approach by inserting beams into predetermined folds of the mat. This inversion simplifies the assembly process and improves workability while the predetermined fold positions keep the overall structure relatively simple.
Data Source
AI summary
Provided is a method of installing a heat insulating block on a furnace shell which enables a heat insulating block to be firmly fixed to a furnace wall but does not require much time and costs for making the heat insulating block, and which further offers good workability at a site. The method of installing a heat insulating block on a furnace shell includes: inserting a beam of a fixture into a fold of an inorganic fiber aggregate mat that is folded up to form a heat insulating block; and fixing the fixture and a furnace shell to each other.