Hot Blast Control Valve Plug Member Alignment
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Solution Overview
Problem
Existing hot blast control valves for blast furnaces face issues with obstruction, high maintenance costs, and frequent replacement due to exposure to extreme temperatures and aggressive gases, leading to reliability and durability concerns.
Innovation Solution
A hot blast control valve with a metallic valve housing and a refractory-lined gas channel, featuring a valve member with a cylindrical and hemispherical body portion that allows free flow in the open position, reducing pressure drop and leakage, and a clamping mechanism with heat-resistant materials and cooling channels for efficient operation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a butterfly valve with a centrally arranged rotation axis is used, then the control member can be rotated between open and closed positions, but the control member remains an obstruction in the path of hot blast even in the fully open position, causing pressure drop
Solution Approach 1:
Instead of rotating a control member within a fixed conduit path (butterfly valve approach), the invention inverts the approach by using a plug member that rotates to align its through-passage with the gas channel. When open, the through-passage creates a direct aligned flow path from inlet to outlet, eliminating the obstruction effect and associated pressure drop.
Solution Approach 2:
The invention changes the flow path geometry from a lateral flow pattern (butterfly valve where flow goes around the control member) to an axial aligned flow pattern (plug valve where flow passes straight through the through-passage). This dimensional change in flow path arrangement eliminates the obstruction effect.
2Temperature
If cooling channels are provided for the control member to prevent damage from high temperatures, then the control member can be cooled, but the cooling is often not sufficient and the control member still needs frequent replacement
Solution Approach 1:
The invention extracts the control member (plug member) from the hot gas environment by designing it with a through-passage that allows hot blast to flow through the center, reducing direct thermal exposure. The plug member can be removed and replaced independently without removing the entire valve body, enabling quick maintenance and replacement of the heat-exposed component.
Solution Approach 2:
The valve is segmented into separable components: the valve body (with cooling channels) and the plug member (with through-passage). This segmentation allows the plug member, which is directly exposed to hot gas, to be independently replaced without replacing the entire valve, improving reliability and reducing maintenance costs.
3Ease of operation
If the control member is designed to block the path of hot blast in the closed position, then flow control is achieved, but the control member forms an obstacle in the path of hot blast even when open
Solution Approach 1:
Instead of using a disc that rotates to partially block flow, the invention uses a plug member with a through-passage that rotates to either align with (open position, maximum flow) or block (closed position, zero flow) the gas channel. This inversion of the control mechanism eliminates partial obstruction in the open position.
4Ease of operation
If a butterfly valve is used for hot blast control, then flow control is possible, but replacement of the control member requires complete valve uninstallation, leading to considerable maintenance time and cost
Solution Approach 1:
The valve is designed with separable components where the plug member can be independently removed from the valve body. The plug member is connected via a shaft that can be disconnected, allowing the plug member to be replaced without uninstalling the entire valve from the conduit, significantly reducing maintenance time and cost.
Solution Approach 2:
The valve design incorporates preliminary considerations for maintenance by providing accessible connection points and a modular structure. The plug member and shaft are designed to be easily disconnected and reconnected, preparing the system for quick maintenance operations without requiring complete valve removal.
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 provides a hot blast control valve that minimizes pressure drop and leakage, reduces maintenance costs, and allows for easy replacement without disassembling the valve, enhancing the control and durability of the hot blast flow.
Implementation Method 1
cooling channels are provided for cooling the disc-shaped control member
Data Source
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AI summary
The present invention proposes a hot blast control valve (10) for a metallurgical installation, in particular for controlling the flow of hot blast of a blast furnace. The hot blast control valve (10) comprises a metallic valve housing (12) with a refractory lining (20) in which a gas channel (22) is defined; and a valve member (24) rotatably arranged in the gas channel (22) so as to be able of varying a free passage in the gas channel (22) by rotation of the valve member (24) about a rotation axis (26) between an open position and a closed position. The valve member (24) has an envelope with rotational symmetry about the rotation axis (26) and has a through passage (28) arranged in the valve member (24) in a direction transversely to the rotation axis (26) of the valve member (24). The through passage (28) has a cross- section substantially identical to that of the gas passage (22). Furthermore, the through passage (28) is arranged in the valve member (24) so as to be aligned with the gas channel (22) when the valve member (24) is in its open position.