Granular Material Control Device for Carrier Line Density
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Solution Overview
Problem
Existing granular material supply systems face challenges in maintaining accurate and timely control of granular material flow rates over long carrier lines, leading to delays and fluctuations in material density, which affect the efficiency and stability of metallurgical reactions, resulting in environmental and economic losses.
Innovation Solution
A control device and method that adjust the density and flow rate of granular material in the carrier line by using a density control unit and flow rate control unit, respectively, to maintain a set value and command flow rate, utilizing sensors to monitor and adjust the carrier gas and granular material flow rates through proportional-integral control, ensuring consistent delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the carrier gas flow rate is reduced to improve efficiency, then energy consumption is reduced, but the granular material settles at the bottom of the carrier line causing blockage
Solution Approach 1:
The patent changes the physical state parameters of the granular material by controlling the carrier gas flow rate to maintain particle velocity between 5-10 m/s, preventing settlement while reducing energy consumption compared to higher flow rates
Solution Approach 2:
The patent implements feedback control by measuring the actual granular material flow rate and comparing it with the target value, then adjusting the carrier gas flow rate accordingly to maintain optimal particle velocity and prevent blockage
2Reliability
If the carrier gas flow rate is increased to maintain particle velocity and prevent blockage, then reliability is improved, but energy consumption increases
Solution Approach 1:
The patent optimizes the carrier gas flow rate parameter to maintain particle velocity within the optimal range of 5-10 m/s, achieving the minimum necessary flow rate to prevent blockage while minimizing energy consumption
Solution Approach 2:
The patent uses feedback control to continuously monitor and adjust the carrier gas flow rate based on actual granular material flow rate measurements, ensuring optimal energy efficiency while maintaining reliable operation
3Productivity
If the flow rate of granular material is increased to improve productivity, then output is improved, but density fluctuations and delays occur in long carrier lines
Solution Approach 1:
The patent implements feedback control by measuring the actual granular material flow rate and density in the carrier line, then adjusting the carrier gas flow rate to maintain consistent density and prevent fluctuations over long distances
Solution Approach 2:
The patent performs preliminary adjustment of the carrier gas flow rate before granular material accumulation or density fluctuations occur, preventing delays and maintaining stable density throughout the carrier line
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 solution enables precise control of granular material flow rates and densities, reducing delays and fluctuations, thereby improving the stability and efficiency of metallurgical reactions and minimizing environmental and economic losses.
Implementation Method 1
a high-pressure loss aerator 3 for fluidizing the internal granular material is attached to a lower portion of the blow tank 2. When an aeration gas is supplied to the aerator 3 via an aeration line 6, the granular material in the blow tank 2 is fluidized and cut out (flown out) to a cutout line 9 due to the differential pressure between the blow tank 2 and a carrier line 7
Implementation Method 2
the granular material in the blow tank 2 is supplied to the carrier line 7 through the cutout line 9 and supplied to the supply destination facility 10 by a carrier gas flowing through the carrier line 7
Data Source
AI summary
In a granular material supply system including a tank that stores granular material, a carrier line through which the granular material flowing out of the tank is carried to a carrier destination, and a cutout line that connects the tank and the carrier line and through which the granular material flowing out of the tank is supplied to the carrier line, a control device includes a density control unit configured to control a density of the granular material on a downstream side of a junction of the cutout line and the carrier line to a set value predetermined and a flow rate control unit configured to control a flow rate of the granular material to be supplied to the carrier destination through the carrier line to a command value instructed by the carrier destination.