Modular Heat Protection Tiles for Metallurgical Reactor Charging
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Solution Overview
Problem
Maintenance of heat protection shields in metallurgical reactor charging installations is complicated and time-consuming due to high temperatures and temperature gradients, requiring shutdown for repairs and posing safety risks.
Innovation Solution
A heat protection assembly comprising heat-resistant refractory tiles with gaps for thermal expansion, supported by a thermal-resistant structure, and modular panels with detachable connections for easy inspection and replacement, incorporating a heat insulation layer and coolant channels for enhanced protection and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a monolithic refractory layer is used for heat protection, then the shielding capacity is high, but the thermal stress causes cracking and reduced reliability
Solution Approach 1:
The heat protection shield is divided into multiple individual tiles arranged in a matrix pattern, with each tile separated by expansion joints. This segmentation allows each tile to expand and contract independently under thermal stress, preventing the cracking that occurs in monolithic structures while maintaining overall heat protection capability.
2Object-affected harmful factors
If the heat protection shield is designed as a single rigid structure, then the heat protection is effective, but maintenance and repair are complicated and time-consuming
Solution Approach 1:
The shield is segmented into modular tiles that can be individually accessed, removed, and replaced. This modularity allows maintenance personnel to work on specific damaged areas without needing to dismantle the entire shield structure, significantly improving ease of repair and reducing downtime.
Solution Approach 2:
The tiles are designed with detachable connections through expansion joints, allowing the structure to transition from a rigid monolithic form to a flexible modular configuration during maintenance. This dynamic capability enables easy assembly and disassembly of individual tiles for repair operations.
3Reliability
If gaps are provided between tiles for thermal expansion, then the reliability under thermal stress improves, but the heat convection through gaps increases heat loss
Solution Approach 1:
The expansion joints are designed with specific local characteristics - narrow gaps filled with heat-resistant insulation material. This local quality modification allows the joints to accommodate thermal expansion while minimizing heat convection losses, balancing reliability with energy efficiency.
4Ease of repair
If the heat protection shield requires shutdown for repair, then the refractory layer can be properly maintained, but the productivity is reduced
Solution Approach 1:
The modular tile design enables hot-side maintenance where individual tiles can be replaced without shutting down the entire system. This segmentation allows maintenance operations to be performed on isolated sections while the rest of the system remains operational, maintaining productivity while ensuring proper maintenance.
Solution Approach 2:
The detachable connection design allows tiles to be pre-assembled and quickly installed, enabling rapid replacement during maintenance operations. This preliminary preparation of modular components reduces the time required for repairs and minimizes operational downtime.
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 extends the lifetime of heat protection shields by allowing thermal expansion, reducing maintenance complexity, and ensuring safety through modular design and easy access for repairs, minimizing downtime and risk to personnel.
Implementation Method 1
A gap may be provided between adjacent tiles. The gap allows for a thermal expansion of the individual tiles. The thermal stress within an individual tile is therefore relatively small compared to the stress in a monolithic refractory layer.
Implementation Method 2
Each tile is heat-protective in that it is heat-resistant, in particular fire-resistant... Each tile normally comprises a refractory material. Heat resistance may be desired up to about 1200° C.
Data Source
AI summary
The invention relates to a heat protection assembly (2, 30) for a charging installation (1) of a metallurgical reactor. In order to increase the lifetime of a heat protection shield in a charging installation of a metallurgical reactor, the assembly (2, 30) comprises a plurality of heat protection tiles (31.1, 31.2, 31.3, 31.4) disposed adjacent to each other along a surface The assembly further comprises a plurality of heat protection panels (10, 110), each panel (10, 110) comprising a common base plate (11, 111) to which a plurality of tiles (31.1, 31.2, 31.3, 31.4) are connected, which heat protection panels (10, 110) are configured to be mounted on the charging installation (1) adjacent to each other.