Gas Distributor for Heating Apparatus with Stepped Conical Zone
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gas distributors in preheaters for smelting processes suffer from uneven heating gas distribution due to particle segregation, leading to non-uniform heating flows and are prone to blockages, and the use of a single large vessel compromises plug flow and system availability.
Innovation Solution
A gas distribution arrangement featuring a stepped conical lower zone with overlapping rings and a cylindrical intermediate zone, along with a tapering upper zone, ensures uniform gas distribution and maintains plug flow by minimizing friction and interference, using multiple smaller vessels connected by feed conduits to prevent overheating and improve operability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single large preheating vessel is used, then the heating capacity is increased, but the plug flow characteristics are compromised and system availability is reduced
Solution Approach 1:
The single large preheating vessel is divided into multiple smaller vessels (first vessel, second vessel, etc.), each equipped with its own gas distributor. This segmentation maintains plug flow characteristics in each smaller vessel while providing redundancy - if one vessel requires maintenance, others can continue operating, thus improving system availability while maintaining heating capacity.
2Device complexity
If conventional gas distributors are used, then the gas distribution structure is simple, but uneven gas distribution and blockages occur due to particle segregation
Solution Approach 1:
The gas distributor introduces gas through multiple levels (upper level and lower level gas outlets) rather than a single plane, and uses inclined surfaces to redirect gas flow. This dimensional approach ensures gas is distributed uniformly across the entire cross-section of the solid material bed, overcoming the limitations of conventional single-level distributors while maintaining structural simplicity.
3Device complexity
If the gas distributor aperture orientation is conventional, then the structure is simple, but the apertures are prone to blockages by solids
Solution Approach 1:
Instead of having gas outlets facing upward or horizontally where solids can easily enter and block them, the gas distributor uses inclined surfaces that direct gas flow at angles away from the vertical solid material stream. This inversion of the conventional aperture orientation prevents solids from blocking the gas outlets while maintaining structural simplicity.
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 solution achieves more uniform heating, reduces downtime, and enhances system availability by ensuring consistent material flow and temperature control, while minimizing capital investment and operational risks.
Implementation Method 1
a gas distribution arrangement, suitable for use in a heating apparatus for heating solid material
Implementation Method 2
shaft type counter flow gas / solid heat exchange is the most efficient means for the exchange of heat from or to a continuous free flowing solid stream
Implementation Method 3
smelting furnace off gas containing certain calorific compounds can be combusted and added to recirculating inert gasses in order to provide the heat transfer medium
Data Source
Figure 1
Figure 2~4
Figure 3
AI summary
This invention relates to a heating apparatus and to a gas distributor for use in the heating apparatus. More particularly but not exclusively, the invention relates to a pre-heater for heating material prior to being conveyed to a smelting process, and to a heating gas distributor used in such heating apparatus. The heating gas distributor comprises an enclosure having a gas inlet arrangement and a gas outlet arrangement. The enclosure includes an operatively upper zone and an operatively lower zone, with the gas outlet arrangement provided in the operatively lower zone. The operatively lower zone is of a downwardly tapering configuration.