Furnace Stave Shared Inlet Pipe Weld Reduction
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Solution Overview
Problem
Conventional cooling staves for blast furnaces require numerous weld connections for coolant distribution, which are critical for fluid tightness but also prone to mechanical and thermal stress, increasing complexity and potential leaks.
Innovation Solution
The design reduces the number of weld connections by allowing two internal channels to share a common inlet or outlet pipe, with options for these channels to be either overlapping or non-overlapping in fluid communication, thereby simplifying the coolant distribution system and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If each internal channel has its own separate inlet and outlet pipes, then the coolant distribution is more reliable and complete, but the number of weld connections increases significantly
Solution Approach 1:
The patent combines multiple inlet channels into a single common inlet pipe and multiple outlet channels into a single common outlet pipe. This merging approach reduces the total number of weld connections from potentially dozens (if each channel had separate pipes) to just a few critical connections, while still ensuring all channels receive coolant through the shared piping system.
Solution Approach 2:
The common inlet pipe serves multiple internal channels simultaneously, making it a multi-functional component. This universal piping approach allows a single pipe structure to perform the cooling function for multiple channels, reducing overall system complexity and the number of required weld connections.
2Reliability
If multiple separate pipes are used for each internal channel, then fluid tightness can be ensured at each connection, but the mechanical and thermal stress on weld connections increases
Solution Approach 1:
By merging multiple pipe connections into fewer common inlet and outlet pipes, the patent reduces the total number of weld joints that are subject to mechanical and thermal stress. Fewer weld connections mean less cumulative stress and lower probability of failure across the system.
3Reliability
If each internal channel has dedicated piping, then the cooling system is more reliable, but the material usage and manufacturing complexity increase
Solution Approach 1:
The patent combines multiple piping systems into unified common inlet and outlet structures, significantly reducing the total amount of material required and simplifying the manufacturing process. This merging approach reduces both material consumption and manufacturing complexity while preserving the essential cooling function.
Solution Approach 2:
The common inlet and outlet pipes are designed as multi-functional components that serve multiple internal channels. This universal design reduces the overall number of parts that need to be manufactured and assembled, thereby simplifying the manufacturing process and reducing material usage.
4Device complexity
If the inlet channels of two internal channels are overlapping or in fluid communication, then the structure is simplified, but the coolant distribution control becomes more complex
Solution Approach 1:
The patent allows inlet channels to overlap or be in fluid communication, merging their functions into a shared flow path. This structural merging simplifies the overall geometry and reduces the number of separate components, making the structure easier to manufacture and assemble.
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
This design enhances the structural integrity and reduces material requirements while maintaining effective cooling efficiency, minimizing the risk of leaks and mechanical stress on weld connections.
Implementation Method 1
Coolant, such as, for example, water at an elevated pressure is pumped through the pipes and/or passages in order to cool the stave. The cooled stave thus cools the refractory bricks disposed within slots or channels defined by the stave.
Data Source
AI summary
A furnace stave comprising a plurality of internal channels or conduits for circulating cooling fluid through the stave; an inlet and an outlet channel associated with each internal channel; wherein the inlet channels of two internal channels are fed by the same inlet pipe or conduit. In another preferred aspect, the inlet channels of two internal channels fed by the same inlet pipe or conduit may or may not be overlapping or in fluid communication with each other.