Monolithic Refractory Spray Application Water Injector
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Solution Overview
Problem
The stability of spray application in monolithic refractory methods is compromised due to inadequate water mixability and carriage properties, leading to variations in discharge volume and separation between the spray material and application water, particularly in dry application methods.
Innovation Solution
Optimizing the ratio of application water carrier gas to spray material carrier gas flow volume and setting a compressibility index of 32% or less for the spray material, along with a specific gas-to-water volume ratio, improves water mixability and carriage properties, enhancing the stability of the spray application process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If dry application method is used to simplify spray apparatus and improve operation efficiency, then device complexity is reduced and ease of operation is improved, but manufacturing precision deteriorates due to insufficient water mixability and nonuniform refractory structure
Solution Approach 1:
The patent applies preliminary action by injecting application water into the spray material upstream in the material carrier pipe before the spray material reaches the distal spray nozzle. This preliminary water injection ensures adequate mixing occurs during the carriage process, preventing the nonuniform refractory structure problem while maintaining the operational simplicity of the dry application method.
Solution Approach 2:
The patent uses a water injector as an intermediary device that facilitates water injection into the gas-carried spray material. This intermediary mechanism enables controlled water addition without requiring complex kneading equipment, thus maintaining ease of operation while achieving sufficient water mixability for uniform refractory structure.
2Device complexity
If dry application method is used with simple water injection, then device complexity is reduced, but manufacturing precision deteriorates due to large amount of dust generation and deterioration in bonding strength
Solution Approach 1:
The patent implements preliminary water injection upstream in the material carrier pipe to ensure adequate mixing occurs before spraying. This preliminary action prevents dust generation and ensures proper bonding strength without requiring complex apparatus, as the mixing happens during the carriage process rather than requiring pre-kneading equipment.
Solution Approach 2:
The patent employs pneumatic principles by using compressed air to carry the spray material through the material carrier pipe while simultaneously injecting application water. This pneumatic-hydraulic combination achieves effective mixing and dust control while maintaining simple apparatus structure, avoiding the need for mechanical kneading devices.
3Manufacturing precision
If water injector is disposed in material carrier pipe to improve water mixability, then manufacturing precision is improved, but reliability deteriorates due to variation in discharge volume and separation between spray material and application water
Solution Approach 1:
The patent applies parameter changes by optimizing the injection timing and水量 of application water in the material carrier pipe. By controlling when and how much water is injected upstream, the patent achieves stable mixing without separation, ensuring both good water mixability and reliable, consistent discharge volume throughout the spray application process.
Solution Approach 2:
The patent ensures continuity of useful action by injecting application water continuously during the carriage of spray material through the material carrier pipe. This continuous water injection maintains consistent mixing throughout the process, preventing separation between spray material and water, and ensuring stable, reliable spray application with consistent discharge volume.
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 improved method achieves stable spray application by ensuring effective mixing and carriage of the spray material, reducing dust generation and enhancing the uniformity and bonding strength of the refractory structure.
Implementation Method 1
a spray material is carried by gas in a dry state
Implementation Method 2
application water is injected from the water injector into a spray material that is being carried through the material carrier pipe
Data Source
AI summary
To improve the stability of spray application of a monolithic refractory in which a water injector is disposed in a material carrier pipe extending from a material supply device to a distal spray nozzle, and application water is injected from the water injector into a spray material that is being carried through the material carrier pipe, a ratio of a flow volume of an application water carrier gas for carrying the application water to be introduced into the water injector to a flow volume of a spray material carrier gas for carrying the spray material is set to 0.07 to 2, and a compressibility index of the spray material is set to 32% or less. Alternatively, a ratio of a flow volume of an application water carrier gas for carrying the application water to be introduced into the water injector to an application water volume is set to 100 to 1,000.