Precast Refractory Ring Lining for Faster Furnace Relining
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Solution Overview
Problem
Existing refractory linings in furnaces face challenges such as mechanical instability, frequent repairs, environmental toxicity, high energy consumption, and extended downtimes, posing safety risks and inefficiencies.
Innovation Solution
A precast ring with a protruding portion and recessed areas, combined with a dry vibration material, is installed off-site and vibrated on-site to form a seamless refractory lining, enhancing mechanical strength and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional refractory lining materials are used to ensure mechanical strength, then the lining can resist furnace conditions, but the materials become toxic and increase environmental impact
Solution Approach 1:
The refractory lining uses a composite structure combining a precast ring made of refractory concrete or castable material with dry vibration material filling the gaps. This composite approach achieves mechanical strength through the precast ring while using environmentally friendly dry vibration material (without toxic binders) to complete the lining, thus resolving the contradiction between strength and toxicity.
2Reliability
If refractory lining is installed using traditional methods to ensure mechanical stability, then the lining integrity is maintained, but the installation process is time intensive and causes extended furnace downtime
Solution Approach 1:
The precast ring is manufactured off-site before furnace installation, allowing the majority of the refractory lining structure to be prepared in advance. This preliminary action significantly reduces on-site installation time and furnace downtime while maintaining lining integrity through the pre-cured, structurally sound precast ring that integrates with the dry vibration material.
3Strength
If the refractory lining towards the top of the furnace is made with traditional materials, then the lining can be formed, but the strength is lower and the lining crumbles or cracks
Solution Approach 1:
The precast ring structure provides enhanced mechanical strength particularly at the top of the furnace where traditional linings are weakest. The combination of the precast ring with dry vibration material creates a composite lining that resists crumbling and cracking, improving both strength and reliability in the critical upper furnace zones.
4Duration of action of stationary object
If conventional refractory materials are used to ensure lining durability, then the lining can withstand furnace conditions, but energy consumption increases
Solution Approach 1:
The composite lining structure of precast ring plus dry vibration material creates a thermally efficient barrier that reduces heat loss while maintaining durability. The dry vibration material without toxic binders provides good thermal insulation properties, allowing the furnace to maintain operating temperatures with reduced energy consumption while preserving lining durability.
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 provides easy installation, improved mechanical strength, reduced leakage, enhanced safety, and increased furnace efficiency with reduced environmental impact.
Implementation Method 1
a dry vibration material
Data Source
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AI summary
The present invention relates to a precast ring for use in a furnace, a refractory lining comprising a precast ring and a dry vibration material and a method of forming a refractory lining.