Refractory Tile Spacers for Incinerator Tube Wall Alignment
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Solution Overview
Problem
Current refractory linings for incinerator tube walls are time-consuming to align and assemble, prone to cracking due to thermal expansion, and risk damage from hydrostatic pressure during mortar application, limiting the number of rows that can be built and increasing the risk of mortar ejection and tile displacement.
Innovation Solution
The use of tile spacers adjacent to the edges of refractory tiles for precise alignment and to prevent mortar displacement, combined with a head bolt and wedge element for improved positioning and anchoring, allows for easier and faster assembly of multiple rows with a homogeneous mortar layer, reducing the risk of damage and enhancing thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional refractory lining assembly methods are used with manual alignment and mortar application, then the lining can be assembled, but the process is time-consuming and prone to imprecise alignment
Solution Approach 1:
The patent introduces tile spacers as intermediary elements that facilitate precise alignment between refractory tiles and the tube wall. These spacers act as mediators during the assembly process, ensuring uniform gaps and proper positioning without requiring complex manual measurement and adjustment, thereby improving both assembly speed and alignment precision.
Solution Approach 2:
The tile spacers are pre-installed on the tube wall before the refractory tiles are placed. This preliminary action establishes the correct positioning and gap dimensions in advance, allowing tiles to be quickly installed without time-consuming alignment adjustments, thus improving productivity while maintaining manufacturing precision.
2Reliability
If mortar is applied to fill the free space between tiles and tube wall, then the lining is secured, but hydrostatic pressure causes mortar ejection and tile displacement
Solution Approach 1:
The tile spacers are installed beforehand to prevent mortar ejection and tile displacement before the mortar is applied. These spacers create physical barriers and maintain proper spacing, counteracting the harmful effects of hydrostatic pressure during mortar application. This preliminary protective measure ensures lining stability while preventing mortar ejection and tile displacement.
Solution Approach 2:
The spacers provide beforehand cushioning by maintaining uniform gaps between tiles and the tube wall, which distributes the hydrostatic pressure of the mortar more evenly. This prevents concentrated pressure points that would otherwise cause mortar ejection and tile displacement, thereby securing the lining stability during the mortar application process.
3Temperature
If the free space between tiles and tube wall is made thin to improve heat transmission, then thermal efficiency increases, but pouring compound cannot flow out well causing incomplete filling
Solution Approach 1:
The tile spacers act as intermediaries that maintain an optimal gap thickness between the tiles and tube wall. This gap is thin enough to allow good heat transmission but thick enough to enable proper mortar flow and filling. The spacers ensure uniform distribution of the pouring compound throughout the free space, resolving the contradiction between thermal efficiency and mortar distribution uniformity.
4Productivity
If multiple rows of tiles are assembled simultaneously, then productivity increases, but the risk of mortar ejection and tile displacement increases
Solution Approach 1:
Tile spacers are pre-installed on the tube wall before multiple rows of tiles are assembled. This preliminary action provides a stable framework that prevents mortar ejection and tile displacement even when multiple rows are installed simultaneously. The spacers distribute and manage the hydrostatic pressure of the mortar, allowing high-speed assembly while maintaining lining stability.
Solution Approach 2:
The spacers serve as intermediary elements that facilitate the simultaneous assembly of multiple tile rows by providing consistent positioning and gap control throughout the structure. They mediate the interaction between the mortar and tiles, preventing instability and ensuring reliable lining formation during high-productivity assembly operations.
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 enables quicker and more accurate alignment and assembly of refractory linings, allowing for multiple rows to be built without mortar ejection, reducing tile displacement, and enhancing the lining's thermal stability and service life by ensuring optimal joint distances and mortar distribution.
Implementation Method 1
the anchor is welded onto a connection strip between the tubes
Implementation Method 2
The felt is preferably adhered (glued) onto the tiles, for example by using a quick-drying spray adhesive (glue). The purpose of the felt is to space apart the tiles from each other at some distance in order to compensate for reversible and non-reversible expansion of the tiles during operation at high furnace temperatures.
Implementation Method 3
The purpose of the felt is to space apart the tiles from each other at some distance in order to compensate for reversible and non-reversible expansion of the tiles during operation at high furnace temperatures
Implementation Method 4
In use, water and/or steam flows through the tubes of the furnace, taking in the released combustion heat
Implementation Method 5
water and/or steam flows through the tubes of the furnace, taking in the released combustion heat
Data Source
AI summary
This invention relates to a refractory lining of a tube wall (2) for an incinerator including at least four refractory tiles (3) of ceramic material which are arranged next to and above one another, wherein the tiles at their rear side, which is facing the tube wall (2), are provided with a vertical insertion channel (10) for mounting the tiles upon the holders (7) of the tube wall, wherein a free space (11) is formed between the tiles (3) and the tube wall (2), which space is filled with a curable pouring compound, and wherein a spacer (20) is provided adjacent to four mutually adjoining edges (12) of the at least four refractory tiles (3). Alternative embodiments are characterized by the use of a head bolt, and/or wedge element (50) and/or a flip-element (60).