Centrifugal Slurry Blasting for Scale Removal

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Solution Overview

Problem

The existing pickling process for removing scale from processed sheet metal is hazardous, environmentally unfriendly, and requires significant space and resources, with issues like 'black edge' formation and uneven surface texture.

Innovation Solution

A centrifugal impeller-based apparatus that uses a liquid/particle slurry to remove scale from sheet metal surfaces, eliminating the need for hazardous chemicals and providing adjustable surface texture and processing options.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the pickling process is used to remove scale from sheet metal, then the scale removal effectiveness is improved, but the environmental hazard and safety risk increase due to corrosive acid

Engineering Contradiction:

Improvescale removal effectivenessVSAvoidenvironmental hazard and safety risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the chemical pickling system with a mechanical slurry blasting system. The slurry blasting apparatus uses high-velocity abrasive particles in a liquid medium to mechanically remove scale from sheet metal surfaces, eliminating the need for corrosive acids while achieving effective scale removal through mechanical impact and abrasion

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs hydraulic principles by using a liquid carrier medium (water or other liquids) to transport and deliver abrasive particles to the sheet metal surface. The slurry is pumped and pressurized through hydraulic systems, allowing controlled delivery of the abrasive mixture at high velocity to achieve effective scale removal without chemical hazards

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Reliability

If the pickling process is used to remove scale from sheet metal, then the scale removal effectiveness is improved, but the space requirement and resource consumption increase

Engineering Contradiction:

Improvescale removal effectivenessVSAvoidfacility space requirement

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent extracts the scale removal function from the large-scale chemical pickling line and concentrates it into a compact slurry blasting apparatus. By removing the acid bath infrastructure, rinse stations, and drying equipment associated with traditional pickling, the system achieves effective scale removal in a significantly reduced footprint

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the fundamental operating parameters from chemical concentration and immersion time to abrasive particle velocity, slurry flow rate, and impact energy. This parameter transformation allows scale removal to be achieved through high-velocity mechanical impact rather than prolonged chemical exposure, reducing the space and time required for the process

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the pickling process is used to remove scale from sheet metal, then the scale removal effectiveness is improved, but the surface texture uniformity deteriorates due to black edge formation

Engineering Contradiction:

Improvescale removal effectivenessVSAvoidsurface texture uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by allowing selective adjustment of slurry blasting parameters for different areas of the sheet metal surface. The system can vary abrasive particle size, slurry flow rate, and impact velocity across different zones to achieve uniform scale removal throughout the surface, preventing the black edge defect that occurs with uniform chemical pickling

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent introduces dynamic control of the slurry blasting process, where parameters such as slurry flow rate, abrasive particle velocity, and nozzle positioning can be adjusted in real-time based on the local scale conditions. This dynamic adaptation allows the system to respond to variations in scale thickness and composition across the sheet metal surface, achieving uniform results that static chemical pickling cannot provide

Inventive Principle:

Principle #15Dynamics

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 offers a safer, more efficient, and cost-effective scale removal process with improved surface texture control, reduced environmental impact, and the ability to handle varying sheet metal widths and types without hazardous residues or line speed variations.

Implementation Method 1

A centrifugal impeller-based apparatus that uses a liquid/particle slurry to remove scale from sheet metal surfaces

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

propelling a scale removing medium, specifically a liquid/particle slurry, against opposite sides of the material

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS8074331B2Slurry blasting apparatus for removing scale from sheet metal

Publication Date: 2011.12.13 LLOYDS ENGINEERING WORKS LTD

AI summary

An apparatus and method of removing scale from the surfaces of processed sheet metal and tubular metal employs a scale removing medium propelled by counter-rotating pairs of wheels positioned in close proximity to the metal surfaces.