Modular Cooling Panels for Metallurgical Reactor Charging Installation
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Solution Overview
Problem
The maintenance of heat protection shields and refractory layers in metallurgical reactor charging installations is complicated and time-consuming due to high temperatures and temperature gradients, especially when the cooling circuit and refractory material deteriorate over time.
Innovation Solution
A modular cooling assembly with detachable cooling panels and integrated heat protection elements, including refractory tiles with a support structure and thermal expansion gaps, facilitates easy inspection, maintenance, and replacement, while a meandering coolant channel design with parallel connections minimizes pressure drop and enhances cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heat protection shield with cooling circuit is used in charging installation, then protection against high temperatures is improved, but maintenance complexity increases due to severe operating conditions and deterioration over time
Solution Approach 1:
The heat protection shield is divided into multiple separate cooling panels that can be individually removed and replaced. Each panel is a self-contained module with its own cooling circuit, allowing maintenance to be performed on a panel-by-panel basis rather than requiring complete system shutdown and complex disassembly of an integrated shield structure.
Solution Approach 2:
The cooling panels are designed with detachable connections that enable dynamic reconfiguration and easy removal. The panels can be quickly detached from the charging installation using simple connection mechanisms, allowing rapid replacement of deteriorated panels without affecting the entire heat protection system.
2Ease of repair
If cooling panels are made modular with detachable connections, then ease of maintenance is improved, but device complexity increases due to multiple separate components
Solution Approach 1:
All cooling panels are designed as identical or substantially similar modules with standardized detachable connections and uniform dimensions. This universality allows any panel to be replaced by any other panel, simplifying inventory management and maintenance procedures while reducing the variety of components that need to be handled during maintenance operations.
Solution Approach 2:
The modular cooling panels are designed as replaceable units that can be easily manufactured and replaced when deteriorated. The standardized design allows for economical production and rapid replacement, treating each panel as a consumable component rather than a permanent fixture, thereby reducing the overall complexity of maintaining the system.
3Reliability
If refractory material is applied as heat protection layer, then thermal protection is improved, but maintenance time increases due to complicated removal and replacement procedures under high temperatures
Solution Approach 1:
The refractory heat protection layer is applied as integrated modules on each separate cooling panel rather than as a continuous layer on the entire shield. This segmentation allows individual panels with their refractory layers to be removed and replaced independently, dramatically reducing maintenance time compared to removing and reapplying refractory material across the entire heat protection surface.
Solution Approach 2:
The refractory heat protection layer is pre-applied to each cooling panel during manufacturing before installation. This preliminary action ensures that thermal protection is already in place when panels are installed, eliminating the need for time-consuming on-site refractory application and curing processes during maintenance operations.
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 configuration allows for efficient and safe maintenance of the heat protection and cooling systems, reducing downtime and improving operational safety by enabling easy replacement of panels and refractory materials without exposing workers to hazardous conditions.
Implementation Method 1
a cooling assembly (4) disposed for cooling a reactor side of the charging installation (1)... each cooling panel (10) comprising at least one coolant channel (12)
Implementation Method 2
The coolant channels may be formed by normal tube-like pipes as known in the art... The channel may be formed along with the base plate in a primary forming process like casting or it may be machined into the pre-manufactured base plate
Implementation Method 3
a heat protection layer of refractory material, which is disposed on the underside of the cooling circuit... While a charging installation of the abovementioned application generally works well, maintenance of the heat protection shield is often complicated and time-consuming
Implementation Method 4
refractory tiles with a support structure and thermal expansion gaps
Data Source
AI summary
The invention relates to a charging installation (1) of a metallurgical reactor, with a cooling assembly (4) disposed for cooling a reactor side of the charging installation (1). In order to facilitate the installation and maintenance of a heat protection shield in a charging installation of a metallurgical reactor, the cooling assembly (4) comprises a plurality of cooling panels (10), each cooling panel (10) comprising at least one coolant channel (12). The channel (12) is formed as a groove in the base plate (11), which groove is covered by a cover plate (13) mounted on the base plate (11).