Insulating Cooling Device for Thermal Cracking Furnace
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Solution Overview
Problem
Conventional thermal cracking furnaces take an excessively long time to cool down after the pyrolysis process, leading to reduced product yield rates and safety hazards due to self-combustion and flying dust during manual cooling attempts.
Innovation Solution
An insulating and cooling device with adiabatic covers and strategically positioned cooling openings that allow for rapid air flow to cool the furnace, utilizing a combination of natural and forced air flow to expedite the cooling process, and featuring a design that minimizes turbulence and maximizes cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the outer furnace is used to maintain temperature during pyrolysis, then the pyrolysis process can be sustained, but the cooling time becomes excessively long (6-8 hours or even 24 hours)
Solution Approach 1:
The cooling system is segmented into multiple independent cooling zones with separate cooling openings distributed around the furnace body. This allows different regions to cool simultaneously through multiple air flow paths, dramatically reducing total cooling time compared to a single centralized cooling approach.
Solution Approach 2:
The cooling openings are positioned in three-dimensional space around the furnace, creating multi-directional air flow paths. Air enters through cooling openings at different heights and locations, flowing through the furnace wall thickness in radial and axial directions, maximizing heat dissipation surface area and cooling efficiency.
2Speed
If the inner furnace cover is opened to cool down the furnace, then cooling speed increases, but carbon black self-combustion and flying dust occur causing safety hazards and environmental pollution
Solution Approach 1:
The cooling openings serve as intermediary channels that allow controlled air intake for cooling without direct exposure of the furnace interior to the external environment. Air flows through designated passages in the furnace wall, providing cooling while preventing direct contact between oxygen and carbon black, thus avoiding self-combustion and dust emission.
Solution Approach 2:
The furnace maintains a controlled atmosphere during cooling by limiting oxygen ingress through the cooling openings. The air flow is directed through paths that minimize oxygen concentration at the carbon black collection zone, creating a relatively inert environment that prevents combustion while still allowing heat dissipation.
3Reliability
If conventional cooling methods are used, then the furnace cools down naturally, but the cooling time is too long which seriously influences product yield rate
Solution Approach 1:
The cooling system enables continuous and sustained heat dissipation through multiple cooling openings positioned throughout the furnace. Air flow is maintained continuously through the furnace wall thickness, preventing heat accumulation and maintaining a steady cooling rate, which significantly reduces total cooling time compared to intermittent or passive cooling methods.
Solution Approach 2:
The cooling system utilizes pneumatic principles by introducing ambient air through cooling openings to create forced convection current through the furnace wall. The air flow dynamics are harnessed to maximize heat transfer efficiency, with air entering at cooler regions and exiting at hotter regions, creating a natural but accelerated cooling cycle.
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
Significantly reduces the cooling time of the thermal cracking furnace, enhancing product yield rates and worker safety by achieving rapid and uniform cooling of the furnace, thereby allowing quicker recycling of by-products like carbon black.
Implementation Method 1
a first adiabatic cover and a second adiabatic cover covering the first cooling opening and the second cooling opening during the pyrolysis process to provide insulating function
Implementation Method 2
the outside air flows into the insulating and cooling device from one of the cooling openings and further flows through the surface of the thermal cracking furnace, and finally flows out from the other cooling opening to achieve more rapid cooling
Data Source
AI summary
An insulating and cooling cracking device includes a thermal cracking furnace accommodated therein. The insulating and cooling device has at least one cooling opening set on its side wall and at least one adiabatic cover. When the thermal cracking device is in heating, the adiabatic cover is closed. When the pyrolysis process is completed, the adiabatic cover is opened to allow the air to flow into one cooling opening. The air further flows through the surface of the thermal cracking furnace, and flows out from another cooling opening to achieve the advantage of more rapid cooling.