Metal Disk Slag Granulator with Terracing and Cooling
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Solution Overview
Problem
Conventional refractory ceramic disks used in dry slag granulation become inadequate at high slag flow rates, leading to wear and inability to cope with increased flow, especially in blast furnace applications.
Innovation Solution
A metal rotary atomizing granulator with a rotatable disk featuring terracing on the slag-receiving surface and a cooling system for coolant application on the underside, forming a protective layer of solidified slag to prevent wear and thermal shock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional refractory ceramic disks are used for slag granulation, then the disk structure is simple and easy to manufacture, but the disk becomes inadequate at high slag flow rates, leading to rapid wear and inability to cope with increased flow
Solution Approach 1:
The invention uses a composite structure consisting of a metal disk base with a layer of solidified slag formed on its surface. The metal disk provides structural strength and thermal conductivity, while the solidified slag layer provides wear resistance and thermal protection. This composite material approach allows the disk to handle high slag flow rates while maintaining durability and resistance to wear.
Solution Approach 2:
The invention changes the physical and chemical parameters of the disk by forming a layer of solidified slag on the metal surface. This layer alters the surface properties to provide better wear resistance and thermal shock resistance, enabling the disk to operate reliably at high slag flow rates that would otherwise cause rapid degradation of conventional ceramic disks.
2Productivity
If the diameter of the flat disk is increased to cope with higher flow rates, then the disk area increases to handle more slag, but the flat refractory disk becomes inadequate and edges rapidly become worn
Solution Approach 1:
The composite structure of metal disk with solidified slag coating provides both the structural integrity needed for large diameter disks and the wear resistance required for extended service life. The metal base allows the disk to be made larger to handle higher flow rates, while the slag layer protects the edges and surface from rapid wear.
Solution Approach 2:
The solidified slag layer provides localized protection where it is most needed - on the surface and edges of the disk that directly contact the molten slag. This local quality enhancement allows the disk to maintain its shape and resist wear at critical areas while handling high flow rates.
3Temperature
If refractory ceramic material is used for the disk, then the disk can withstand high temperatures, but the material is prone to rapid wear at the edges and gets ground down to a flat disk shape
Solution Approach 1:
The metal disk with solidified slag coating combines the thermal resistance needed for high-temperature operation with the shape maintenance capabilities of a reinforced structure. The metal base provides thermal conductivity and structural support, while the slag layer protects the surface and edges from erosion, preventing the disk from being ground down.
4Strength
If a metal disk is used instead of refractory ceramic, then the disk has better thermal conductivity and structural strength, but the metal becomes vulnerable to thermal shock and wear from high temperature slag
Solution Approach 1:
The composite structure addresses this contradiction by combining metal with solidified slag. The metal provides structural strength and thermal conductivity, while the slag layer acts as a protective barrier against thermal shock and wear from the high-temperature molten slag, allowing the metal disk to withstand both mechanical and thermal stresses.
Solution Approach 2:
The solidified slag layer serves as an intermediary between the metal disk and the molten slag. This intermediate layer absorbs and distributes the thermal shock and mechanical wear, protecting the metal substrate from direct exposure to the harmful effects of the high-temperature slag.
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 enables operation at higher slag flow rates by protecting the metal disk from thermal shock and wear, extending its service life and maintaining the shape of the disk, thus addressing the limitations of conventional ceramic disks.
Implementation Method 1
the disk comprises a metal; wherein the granulator further comprises a cooling system for supplying a coolant to the disk
Implementation Method 2
the cooling system comprises coolant sprays directed at the second surface of the disk remote from the first surface
Implementation Method 3
a layer of solidified slag formed on the first surface
Implementation Method 4
the terracing in order to provide protection for the metal dish from the impact of the high temperature slag
Data Source
Figure 1A~1B
Figure 2~4
Figure 5~6
AI summary
A dry slag rotary atomising granulator comprises a rotatable disk (2) mounted on a support (3) for rotation about an axis of rotation (6). The disk comprises a metal and the granulator further comprises a cooling system (13, 14, 15) for supplying a coolant to the disk. The disk comprises a first surface (23) to receive slag and a second surface (18) remote from the slag receiving first surface for receiving coolant. The disk further comprises terracing (24) on the first surface and a layer (22) of solidified slag formed on the first surface.