One-Piece Refractory Cast Iron Mold for Rapid Boiler Chamber Production
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Solution Overview
Problem
Manufacturing combustion chambers for circulating fluidized bed boilers is laborious, time-consuming, and requires extensive experience, especially when producing components like primary stage air nozzles, ash removal, biomass and lignite feed, secondary stage air, burner and burner cooling air inlets, and seal pot returns, which are currently manufactured separately and with difficulty using steel and refractory materials.
Innovation Solution
A one-piece refractory cast iron combustion chamber mold is designed with inner and outer sheet metals connected by bolts, incorporating anchoring metals and insulation, allowing simultaneous production of these components as a single unit, with a method involving pouring and baking refractory material between insulation and inner sheet metal to form a compact, efficient chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If combustion chamber components are manufactured separately using steel and refractory materials, then manufacturing flexibility is maintained, but manufacturing time and labor requirements increase significantly
Solution Approach 1:
The patent combines multiple separate components (combustion chamber, primary stage air nozzles, ash removal, biomass and lignite feed, secondary stage air, burner and burner cooling air, and return inlets from seal pot) into a single integrated mold structure. This merging of previously separate manufacturing processes into one unified casting operation directly resolves the contradiction by dramatically reducing manufacturing time and labor while maintaining the functional complexity of individual components through integrated design
2Manufacturing precision
If components are manufactured separately based on years of experience through trial and error, then manufacturing precision can be achieved, but manufacturing time and labor requirements increase
Solution Approach 1:
The patent incorporates all design details, ports, and structural features directly into the mold design before casting. The mold is pre-configured with anchoring metals, insulation layers, and precise geometric features that will form the combustion chamber components. This preliminary preparation of the mold eliminates the need for time-consuming trial and error adjustments during manufacturing, as all precision requirements are built into the mold structure beforehand
Solution Approach 2:
The patent creates a precise replica of the final combustion chamber components through the mold casting process. The mold itself serves as a master copy that reproduces all necessary features (ports, nozzles, feed channels, cooling air passages) with high precision in a single operation, eliminating the need for repeated manual adjustments and experience-based iterations
3Strength
If thick sheet steel and refractory brick are used for combustion chamber construction, then structural strength is achieved, but creating ports and design details becomes very difficult
Solution Approach 1:
The patent changes the manufacturing parameter from mechanical assembly of thick steel and brick to a casting process using refractory concrete. This parameter change allows ports and design details to be created directly within the material during casting, eliminating the difficulty of cutting or forming such features in already-assembled thick-walled structures. The casting process naturally accommodates complex internal geometries, ports, and channels that would be extremely difficult to create through traditional assembly methods
4Adaptability or versatility
If anchorages are filled between inner and outer mold sheets with refractory concrete poured at the application site, then manufacturing flexibility is maintained, but the process becomes laborious and requires extensive experience
Solution Approach 1:
The patent segments the mold into distinct functional zones: inner mold sheets forming the combustion chamber cavity, anchoring metals providing structural support, insulation layers maintaining thermal efficiency, and outer mold sheets providing structural framework. This segmentation allows each component to be optimized independently while being assembled into a unified casting system, maintaining adaptability while simplifying the overall manufacturing process through clear functional separation
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
Facilitates rapid, labor-saving production of combustion chambers in desired capacities with reduced manufacturing defects, eliminating reliance on experience and enabling high insulation performance, thus reducing time and costs while ensuring compatibility with varying capacities.
Implementation Method 1
pouring and baking refractory material between insulation and inner sheet metal to form a compact, efficient chamber
Data Source
AI summary
Disclosed herein is a compact (e.g., one-piece) refractory cast iron combustion chamber mold for a circulating fluidized bed boiler for the combustion and/or gasification of biomass, waste, lignite and mixtures thereof, and a method of obtaining a combustion chamber with this mold.