Segmented Ceramic Impact Pad for Melt Distribution
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Solution Overview
Problem
Existing impact pads in metallurgical vessels suffer from inadequate melt distribution and significant 'dead volumes' due to insufficient melt velocity, primarily caused by their offset position within the vessel, leading to inefficient flow patterns.
Innovation Solution
A fireproof ceramic impact pad design featuring a channel-type outlet passage created by splitting one wall into two overlapping walls with distinct free end sections, forming a meandering flow pattern that encourages a U-turn of the melt stream before exit, enhancing melt distribution and reducing dead volumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the impact pad is positioned offset within the vessel, then the vessel structure is simplified, but dead volumes and insufficient melt velocity occur
Solution Approach 1:
The impact pad wall is segmented into two separate walls (first wall and second wall) that are arranged in an overlapping fashion. This segmentation creates channel-type outlet passages between the walls, which redirect the melt flow to eliminate dead volumes and improve melt distribution efficiency while maintaining the offset position benefits.
2Device complexity
If a classical pot-shape impact pad is used, then the structure is simple, but melt flow creates turbulence and insufficient velocity in dead zones
Solution Approach 1:
The wall is divided into two overlapping walls creating channel-type outlet passages. This segmentation guides the melt flow through defined channels, eliminating turbulence and ensuring sufficient velocity throughout the entire impact pad area, including previously dead zones.
Solution Approach 2:
The outlet passage is designed with a channel-type structure that extends in multiple dimensions, creating a meandering flow path. This dimensional approach redirects melt flow horizontally and vertically to eliminate dead zones and maintain high velocity throughout the flow path.
3Device complexity
If the impact pad has a closed wall, then the structure is simple, but melt flow creates dead volumes
Solution Approach 1:
The closed wall is segmented into two overlapping walls, creating channel-type outlet passages between them. This segmentation eliminates dead volumes by providing dedicated flow paths for the melt, while the overall structure remains relatively simple and easy to manufacture.
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 design improves melt flow behavior by directing the melt stream into previously underutilized areas, increasing homogeneity and reducing 'dead volumes' within the metallurgical vessel, thereby enhancing the overall efficiency of melt treatment.
Implementation Method 1
Because of the relatively small slit width, the metal melt flowing through the slit can feature a significant flow speed. Thereby, further flow turbulences are caused.
Implementation Method 2
the metal melt initially flows along the base, then upwards along the inside of the wall and finally around the narrowed impact pad opening upwards into the vessel
Data Source
AI summary
The invention relates to a fireproof (refractory) ceramic impact pad (also called impact pot, German: Pralltopf), which is typically installed along the bottom of a vessel treating metallurgical melts at an area where the metal melt, poured into the vessel, normally hits the vessel bottom. Insofar the impact pot has the task to protect the refractory bottom of the metallurgical vessel (to reduce its wear) and/or to distribute the metal melt within the vessel.