Dry Refractory Mix Nozzle Binder Injection
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Solution Overview
Problem
Existing methods for applying refractory materials, such as casting, pumping, and dry gunning, face issues like high costs, equipment expenses, material plugging, uneven distribution of setting agents, increased porosity, and reduced compressive strength due to excessive water usage, leading to inefficiencies and safety hazards.
Innovation Solution
A dry refractory mix process using a modified binder system where a liquid binder is introduced at the nozzle of a pneumatic gunite machine, allowing for homogeneous mixing with the dry refractory material, reducing the need for cement and water, and utilizing a pressurized binder delivery system to enhance wetting and mixing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water is introduced at the nozzle to hydrate cement in dry gunning, then cement hydration is achieved, but compressive strength decreases due to excessive water
Solution Approach 1:
The patent changes the water-to-cement ratio parameter to optimize both hydration and strength. By controlling the amount of water introduced at the nozzle to be sufficient for hydration but not excessive, the method achieves complete cement hydration while maintaining high compressive strength, resolving the contradiction between reliable hydration and strength preservation
Solution Approach 2:
The method introduces water at the nozzle based on feedback about the actual mixing conditions and material composition. This localized water introduction allows precise control of hydration, ensuring sufficient moisture for cement reaction without over-saturating the mix, thereby maintaining both hydration reliability and compressive strength
2Reliability
If a large amount of water is introduced at the nozzle to ensure proper cement hydration, then hydration is achieved, but the compressive strength of the finished product is weakened
Solution Approach 1:
The patent optimizes the water-to-cement ratio parameter by introducing water locally at the nozzle rather than using excessive water throughout the mix. This controlled parameter adjustment ensures adequate hydration while preventing the strength reduction that occurs with high water content, simultaneously achieving both hydration reliability and strength preservation
3Stability of the object's composition
If water is introduced into the nozzle to wet fine components, then mixing is achieved, but material bounces off the surface due to poor mixing
Solution Approach 1:
The patent performs preliminary mixing of the dry refractory material and cement in the hose before water introduction. This pre-mixing action ensures uniform distribution of components, and then water is added at the nozzle to complete the wetting process, achieving both thorough wetting of fine components and uniform mixing that prevents material rebound
Solution Approach 2:
The patent uses the compressed air stream as an intermediary to pre-mix the dry materials uniformly before water introduction. This intermediary mixing action ensures that fine components are evenly distributed throughout the coarse aggregate, creating a homogeneous mix that accepts water uniformly at the nozzle and adheres properly to the surface without bouncing off
4Reliability
If water is introduced at the nozzle, then cement hydration occurs, but significant dust is created that is hazardous to operators
Solution Approach 1:
The patent uses a controlled pneumatic system to introduce water at the nozzle in a manner that suppresses dust generation. The pressurized water application and the contained air stream environment minimize the aerosolization and dispersion of cement particles, achieving proper cement hydration while significantly reducing the dust hazard to operators
5Ease of operation
If pumping wet castable is used to apply refractory, then material can be applied, but plugging and setting in hoses occurs shutting down the job
Solution Approach 1:
The patent segments the material application process into two distinct stages: first transporting dry refractory material through the hose using compressed air, then introducing water at the nozzle for mixing and application. This segmentation prevents the wet material plugging and setting problems that occur in continuous pumping operations, ensuring both ease of operation and continuous job performance
Solution Approach 2:
The patent performs the material transport action preliminarily in a dry state through the hose system using compressed air, eliminating the risk of plugging and setting before the water introduction step. This preliminary dry transport ensures continuous operation capability, while the subsequent water addition enables proper material application
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 approach results in refractory products with improved thermal shock resistance, lower porosity, and enhanced resistance to chemical attacks, while reducing operational costs and hazards, and improving the application process efficiency.
Implementation Method 1
The dry mix is conveyed by air though hoses to a nozzle
Implementation Method 2
A liquid binder is introduced into the air flow for mixing with the suspended dry refractory material
Implementation Method 3
Refractory materials are designed to retain their strength at high temperatures
Data Source
AI summary
A dry refractory mix and a method for apply the dry refractory mix to a surface. One aspect of the invention utilizes gunning mixes without cement. The dry refractory mix also may include a setting agent that is homogeneously blended with the refractory mix. In operation, when used with pneumatic systems, dry refractory material is fed into a hopper of a gunnite machine, introduced into an air flow, and conveyed by air through one or more hoses to a nozzle. A liquid binder is introduced into the air flow for mixing with the suspended dry refractory material at or before the nozzle. A fitting, such as a water ring with holes, may be used for injecting the binder into the air flow containing the dry refractory material. The mixed refractory/binder material is discharged through the nozzle for application to a surface.