Removable Breaker Bar for Ash Hopper Slag Cleaning
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Solution Overview
Problem
Traditional ash hoppers in power plants require frequent manual cleaning due to clogged slag deposits and ash, which involves shutting down the boiler and building scaffolding for access, posing operational inefficiencies and safety risks.
Innovation Solution
A system comprising a breaker bar apparatus that can be selectively secured between surfaces of a hopper and drops towards the bottom upon fastener removal, facilitating the removal of slag deposits and ash without shutting down the boiler or using scaffolding, featuring a triangular body with a leading edge and fastener mechanism for secure attachment and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional breaker bars are permanently secured in place within a hopper, then slag deposits can be broken apart on impact, but the breaker bars cannot be easily removed to clear lodged slag deposits, requiring complex scaffolding and boiler shutdown
Solution Approach 1:
The breaker bar is segmented into modular components that can be easily assembled and disassembled. The breaker bar includes a body portion and end portions that can be selectively positioned and secured, allowing the central body to be accessed for cleaning while maintaining the overall structural integrity and slag-breaking function during operation
Solution Approach 2:
The breaker bar transitions from a static, permanently secured component to a dynamic, reconfigurable component. The breaker bar can be selectively positioned at different locations within the hopper and easily removed when cleaning is needed, transforming the cleaning process from a complex operational procedure to a simple component replacement task
2Productivity
If manual cleaning of lodged slag deposits is performed from above the breaker bars, then clogged hoppers can be cleared, but the process requires shutting down the boiler and building complex scaffolding
Solution Approach 1:
The breaker bar is extracted from its traditional fixed position and redesigned as a removable component. This allows the breaker bar itself to be used as the access point for cleaning, eliminating the need for external scaffolding structures and enabling direct access to lodged slag deposits by simply removing the breaker bar
Solution Approach 2:
The breaker bar design enables self-service cleaning where the breaker bar component itself provides the access pathway for cleaning operations. By making the breaker bar removable, the system allows maintenance personnel to access and clean lodged slag deposits directly through the breaker bar opening without requiring external support structures
3Productivity
If breaker bars are used to break apart falling slag deposits, then most slag can be broken, but some deposits remain intact and become lodged above the bars, causing clogging
Solution Approach 1:
The cleaning approach is inverted from the traditional method of accessing slag deposits from above the breaker bar to removing the breaker bar itself to access deposits. This inversion allows direct removal of lodged slag that traditional methods cannot reach, eliminating the clogging problem that persists despite breaker bar operation
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 efficient and safe cleaning of ash hoppers without stopping the power plant operation or requiring complex scaffolding, improving operational efficiency and reducing manual labor by allowing for the removal of accumulated slag and ash directly to the bottom of the hopper.
Implementation Method 1
a body configured to be selectively secured via a fastener between two surfaces of a container and to break apart the substance upon impact
Implementation Method 2
At least a portion of the body is operative to drop towards a bottom surface of the container upon removal of the fastener
Data Source
AI summary
An apparatus for breaking apart a substance is provided. The apparatus includes a body configured to be selectively secured via a fastener between two surfaces of a container and to break apart the substance upon impact. At least a portion of the body is operative to drop towards a bottom surface of the container upon removal of the fastener so as to facilitate removal of the substance from the container.