Segmented Burner Port Block Resists Thermal Shock
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Solution Overview
Problem
Monolithic refractory port blocks in fiber-lined furnaces are prone to thermal shock failure due to rapid heating and cooling, leading to cracking and degradation, with no suitable solution having been identified in existing technologies.
Innovation Solution
A burner port block assembly comprising a refractory block with a central passageway and a ceramic extension piece, where the extension piece is connected to the refractory block using engagement structures and a gasket, providing a modular design that includes ceramic fiber boards for improved thermal resistance and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If monolithic refractory port blocks are used in fiber-lined furnaces, then the furnace can be heated and cooled quickly, but the port blocks crack and fall apart under rapid thermal cycling
Solution Approach 1:
The port block is divided into two separate components: a refractory block and a ceramic insert. The refractory block provides structural support and can withstand rapid thermal cycling, while the ceramic insert maintains the passageway geometry and handles the hot gases. This segmentation allows each component to be optimized for its specific function, resolving the contradiction between rapid thermal cycling capability and structural integrity.
2Reliability
If thick monolithic refractory port blocks are used, then structural integrity is maintained, but the furnace cannot be heated and cooled quickly
Solution Approach 1:
The port block is divided into two separate components: a refractory block and a ceramic insert. The refractory block provides structural support and can withstand rapid thermal cycling, while the ceramic insert maintains the passageway geometry and handles the hot gases. This segmentation allows each component to be optimized for its specific function, resolving the contradiction between rapid thermal cycling capability and structural integrity.
3Ease of manufacture
If the port block is made as a single monolithic unit, then manufacturing is simple, but the component cannot withstand rapid thermal cycling
Solution Approach 1:
The port block is divided into two separate components: a refractory block and a ceramic insert. The refractory block provides structural support and can withstand rapid thermal cycling, while the ceramic insert maintains the passageway geometry and handles the hot gases. This segmentation allows each component to be optimized for its specific function, resolving the contradiction between rapid thermal cycling capability and structural integrity.
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 assembly effectively withstands high heat and cooling rates without significant degradation, allowing for rapid heating and cooling cycles, and enables independent replacement of components, enhancing structural integrity and operational flexibility.
Implementation Method 1
the extension piece is connected to the refractory block using engagement structures and a gasket, providing a modular design that includes ceramic fiber boards for improved thermal resistance and flexibility
Data Source
AI summary
A burner port block assembly having a refractory block with a central passageway therethrough and a ceramic extension piece disposed at least partially in the central passageway of the refractory block. The extension piece has a distal end, a proximal end, and a sidewall that defines a central passageway extending between the distal end and the proximal end. The central passageway of the refractory block is provided with a first engagement structure and the sidewall of the extension piece is provided with a second engagement structure. Engagement of the first engagement structure with the second engagement structure connects the extension piece to the refractory block. The burner port block assembly may further include at least one ceramic fiber board having a hole therethrough disposed at the distal end of the refractory block and/or a gasket positioned between the refractory block and the extension piece.