Refractory Slurry Batch Mixing for Continuous Spray Supply
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Solution Overview
Problem
Existing methods for producing and applying refractory slurries struggle to maintain a constant supply and achieve desired density values, particularly in transitioning between batch and continuous processes, without precise control over mixing energy and component ratios.
Innovation Solution
A device and process that integrate a batch reactor with controlled charging inlets and actuators, a product vessel, and an applicator system, utilizing sensors and a controller to regulate the flow and mixing of refractory slurry components, ensuring continuous application and maintaining a consistent supply by monitoring and adjusting the batch production based on sensor data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If batch mixing process is used to produce refractory slurry, then mixing conditions (stirring intensity, energy, air entrainment) can be precisely controlled, but the supply to the spray nozzle may be interrupted and requires monitoring of consumption rate
Solution Approach 1:
The system divides the slurry supply into two segments: a batch reactor for precise mixing and a storage vessel for continuous supply. The batch reactor produces slurry in controlled batches while the storage vessel maintains a constant supply to the spray nozzle, eliminating interruptions in the spraying process.
Solution Approach 2:
The storage vessel acts as an intermediary between the batch reactor and the spray nozzle. It receives slurry from the batch reactor and maintains a constant level supply to the nozzle, decoupling the batch production process from the continuous spraying requirement.
2Productivity
If continuous mixing process is used to produce refractory slurry, then constant supply to spray nozzle is maintained, but controlling process conditions (stirring intensity, energy, air entrainment) becomes difficult
Solution Approach 1:
The system separates the mixing function (batch reactor with precise control) from the supply function (storage vessel with constant level). This segmentation allows batch mixing to maintain precise control over mixing conditions while the storage vessel ensures continuous supply to the spray nozzle.
3Manufacturing precision
If batch mixing is used with multiple batches to feed spray nozzle, then mixing control is maintained, but the rate of slurry consumption and amount available must be monitored
Solution Approach 1:
The storage vessel automatically maintains a constant slurry level through its own level sensor and control system. When the level drops, the system automatically initiates transfer from the batch reactor, eliminating the need for external monitoring of slurry consumption and availability.
Solution Approach 2:
The storage vessel incorporates a level sensor that provides feedback to the control system. When the slurry level drops below a threshold, the system automatically responds by initiating a transfer operation from the batch reactor, ensuring continuous supply without manual intervention.
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
Enables the production of refractory slurries with a range of densities from a single formulation, allowing for seamless transition between batch and continuous processes, ensuring a constant supply and precise control over mixing conditions, thereby extending the life of permanent linings in metallurgical vessels.
Implementation Method 1
The aqueous slurry is mechanically stirred to foam and/or swell the surfactant and the stirring power and/or speed and/or time are adjusted in order to control the foaming and/or swelling rate of the surfactant and thus vary the porosity of the sprayed coating.
Implementation Method 2
The slurry is conveyed under pressure to a spray nozzle, where compressed air is introduced to propel the slurry from the nozzle.
Implementation Method 3
In the spraying process for application of a refractory formulation to a permanent liner, refractory powder is mixed with water, and with such additives as binders, wetting agents and dispersants, to produce a slurry.
Data Source
Figure 1
Figure 2
AI summary
A device and a process for the continuous application of a refractory slurry to a surface incorporate a batch reactor (10) for the controlled mixing of the slurry, a product vessel (60) in communication with the batch reactor (10) to contain the mixed slurry, and a variable-rate spraying applicator or nozzle in communication with the product vessel and with an air supply. A controller (100) controls input to, output from, and the operation of, the batch mixer (10), and monitors batch production. The controller (100) monitors the amount of slurry contained in the product vessel (60). If the level of slurry in the product hopper is such that the product hopper cannot accommodate an additional batch of slurry, the controller interrupts batch production and resumes production when the product hopper can accept the contents of the batch reactor (10).