Silicon Liquid Granulation System with Detachable Cooling
Solution Overview
Problem
Current silicon slag recycling processes rely on manual selection, leading to low efficiency and low utilization rates, with silicon blocks having low purity and high sorting costs, and the molding of silicon liquid is inefficient due to long cooling times and potential explosions during pouring.
Innovation Solution
A granulating and molding system comprising a silicon liquid transferring device with a detachable container and diversion pipe for controlled pouring, a cooling system with spiral nozzle groups for enhanced heat exchange, and a lifting system for continuous extraction of silicon pellets, which includes a circulating pool to reduce water consumption and a hoisting mechanism for efficient pellet collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual selection is used for silicon slag processing, then cost is reduced, but efficiency and utilization rate are low
Solution Approach 1:
The patent replaces manual mechanical selection with automated optical detection and control systems. The system uses cameras to capture images of silicon slag, processes these images through algorithms to identify and classify silicon blocks, and automatically controls robotic manipulators to select and transport the blocks. This substitution of mechanical manual labor with automated opto-mechanical systems resolves the contradiction by achieving both cost-effectiveness and high efficiency simultaneously.
2Manufacturing precision
If silicon liquid is poured into cooling pool to form silicon blocks, then solidification occurs, but explosions may happen and cooling time is long
Solution Approach 1:
The patent introduces an intermediary granulating layer between the silicon liquid pouring process and the cooling pool. This granulating layer acts as a buffer that controls the solidification process, preventing direct contact between molten silicon and cooling water that causes explosions. The intermediary layer allows controlled heat transfer and gradual solidification, eliminating the harmful explosion effect while maintaining efficient cooling.
Solution Approach 2:
The system performs preliminary granulation of silicon liquid before it enters the cooling pool. By pre-forming granulated structures and controlling the initial solidification state, the system prepares the silicon in a safer state that prevents explosive reactions with cooling water. This preliminary action resolves the contradiction by addressing the explosion risk before the harmful interaction occurs.
3Reliability
If pouring time is extended to avoid explosion, then safety is improved, but production efficiency decreases
Solution Approach 1:
The granulating layer serves as a safety intermediary that enables rapid pouring without explosion risk. By controlling the solidification process through this intermediary, the system achieves both safety and speed, resolving the contradiction between extended pouring time for safety and production efficiency.
4Ease of operation
If silicon liquid is poured without flow control, then pouring is simple, but molding precision and pellet uniformity are poor
Solution Approach 1:
The granulating layer acts as a flow control intermediary that naturally regulates the pouring process. As silicon liquid passes through the granulating layer, its flow is automatically controlled and distributed uniformly, achieving precise molding without complex control mechanisms. This resolves the contradiction by maintaining pouring simplicity while achieving high pellet uniformity through the self-regulating intermediary layer.
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 system ensures uniform silicon pellet formation, reduces production downtime, enhances cooling efficiency, and increases the utilization rate of silicon slag by controlling the pouring process, preventing explosions, and facilitating continuous production with reduced water consumption.
Implementation Method 1
a cooling system and a lifting system matching with the cooling system are provided below the silicon liquid transferring device
Implementation Method 2
uniformly pours the silicon liquid into the cooling system according to a set flow rate
Implementation Method 3
the molded silicon pellets are extracted by the lifting system
Data Source
AI summary
The present disclosure provides a system and method for granulating and molding silicon liquid. The system includes a silicon liquid transferring device, wherein cooling system and a lifting system matching with the cooling system are provided below the silicon liquid transferring device. The silicon liquid transferring device transfers smelted silicon liquid to a position above the cooling system, uniformly pours the silicon liquid into the cooling system according a set flow to enable the silicon liquid to be solidified into silicon pellets, and then the molded silicon pellets are extracted by the lifting system, solving the problem in the prior art of irregular molding and inconsistent size of silicon blocks caused by pouring. A container bottom and a diversion pipe are set to be of detachable structures, and can be quickly disassembled and assembled as vulnerable parts without affecting the production.