Granular Iron Cooling Flow Layout to Prevent Coalescence
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Solution Overview
Problem
Existing methods for cooling granular iron from molten iron are inefficient, leading to mutual coalescence and difficulty in conveyance due to stagnation regions and high water temperatures, which can cause steam explosions and hinder efficient production.
Innovation Solution
A granular iron manufacturing apparatus with a water-flow controlling container and cooling water pipe group that generates counterflows inside the cooling water tank, including an inclined partition cylindrical body and duct cylindrical body, to enhance cooling efficiency and prevent coalescence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If granular iron is cooled in a conventional cooling water tank, then cooling is achieved, but stagnation regions form and cooling efficiency decreases leading to coalescence
Solution Approach 1:
The cooling water tank is divided into multiple cooling zones with separate water supply and discharge points. The tank is segmented into a first cooling water supply region, first discharge region, second cooling water supply region, and second discharge region, allowing independent control of cooling water flow in different areas to eliminate stagnation regions and ensure uniform cooling throughout the granular iron mass.
Solution Approach 2:
The patent introduces vertical stratification of cooling zones by positioning cooling water supply and discharge regions at different heights and locations within the tank. This multi-dimensional arrangement of cooling water flow paths ensures comprehensive coverage and prevents stagnation by creating coordinated circulation patterns in both horizontal and vertical dimensions.
2Power
If cooling water temperature is increased to improve heat transfer, then cooling capacity increases, but vapor film formation increases leading to film boiling and reduced cooling efficiency
Solution Approach 1:
The cooling water system is segmented into multiple zones with independent temperature control. By dividing the tank into different cooling regions with separate supply and discharge systems, each zone can maintain optimal temperature ranges to prevent localized vapor film formation while achieving high overall cooling capacity.
Solution Approach 2:
The patent implements continuous cooling water circulation through coordinated supply and discharge systems in multiple zones. This continuous flow prevents temperature stagnation and maintains stable cooling conditions, avoiding the intermittent heating that could lead to vapor film formation and film boiling.
3Area of stationary object
If a large cooling water tank is used to accommodate spreading liquid drops, then installation space increases, but cooling efficiency decreases due to larger volume and potential stagnation
Solution Approach 1:
The large cooling water tank is segmented into multiple functional zones with dedicated cooling water supply and discharge regions. This segmentation allows efficient utilization of the large volume by creating multiple active cooling circuits, preventing stagnation regions, and maintaining high cooling efficiency throughout the entire tank volume.
Solution Approach 2:
The patent maximizes the utilization of three-dimensional space within the large tank by strategically positioning cooling water supply and discharge regions at different heights and locations. This spatial optimization ensures comprehensive cooling coverage throughout the entire tank volume, converting the potential disadvantage of large volume into an advantage for enhanced cooling capacity.
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 apparatus effectively suppresses mutual coalescence of granular iron, enabling stable production and efficient conveyance by maintaining uniform cooling and reducing the risk of steam explosions.
Implementation Method 1
the cooling water pipe group includes an upper-level cooling water pipe group and a middle-level cooling water pipe group that are connected to the partition cylindrical body and a lower-level cooling water pipe group connected to the duct cylindrical body, the upper-level cooling water pipe group is connected to an upper level, of an inclined surface, including an upper end of the partition cylindrical body and generates, with cooling water supplied from the upper-level cooling water pipe group, a cooling-water flow from an upper side to the lower side along an inclined surface
Implementation Method 2
a cooling water pipe group configured to supply cooling water into the water-flow controlling container... the cooling water pipe group includes an upper-level cooling water pipe group and a middle-level cooling water pipe group that are connected to the partition cylindrical body and a lower-level cooling water pipe group connected to the duct cylindrical body
Implementation Method 3
generates, with cooling water supplied from the upper-level cooling water pipe group, a cooling-water flow from an upper side to the lower side along an inclined surface
Implementation Method 4
the middle-level cooling water pipe group is connected horizontally to a middle level of an inclined surface of the partition cylindrical body toward a cylindrical core of the partition cylindrical body and generates, with cooling water supplied from the middle-level cooling water pipe group, a first circulating flow including flows moving toward the cylindrical core of the partition cylindrical body, merging at the cylindrical core, and moving upward
Implementation Method 5
the lower-level cooling water pipe group is connected to a side surface of the duct cylindrical body and generates, with cooling water supplied from the lower-level cooling water pipe group and drainage water from the partition cylindrical body, a second circulating flow circulating inside the duct cylindrical body
Implementation Method 6
The film boiling has a low cooling capacity and, for example, has a heat transfer coefficient as small as several hundredths of that of nucleate boiling in which no vapor film is formed. Thus, when the film boiling lasts long, the granular iron is failed to be cooled sufficiently
Data Source
AI summary
A granular iron manufacturing apparatus including: a granulation device configured to break up molten iron into a liquid drop; a cooling water tank configured to cool the liquid drop by causing the liquid drop to fall into cooling water, a water-flow controlling container that is provided inside the cooling water tank and whose upper and lower ends are open; and a cooling water pipe group configured to supply the cooling water into the water-flow controlling container.