Spin Casting with Separate Activator Channels for Thick Refractory Linings
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Spin casting methods are limited to thin concrete thicknesses due to plugging issues in transport lines caused by rapid setting formulations, leading to inefficiencies in achieving desired thicknesses, as multiple passes are required with lengthy delays for curing.
Innovation Solution
A method involving the delivery of a foaming agent activator to a wet mix of refractory concrete through separate channels, allowing mixing in an air space between the applicator and spin head, which reduces plugging and enables thicker linings without layering, using foaming agents like alkylbenzene sulfonates and air-entraining additives like methylcellulose.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rapid setting concrete formulations are used to address thin lining limitations, then the concrete can set quickly, but the likelihood of plugging in transport lines increases significantly
Solution Approach 1:
The activator is pre-positioned in the transport line ahead of the concrete mix, so that when the concrete arrives at the spin head, the activator is already in place to immediately trigger rapid setting upon deposition, eliminating the need for the concrete to remain fluid throughout the entire transport process
Solution Approach 2:
The setting activation function is extracted from the concrete mix itself and separated into a distinct activator component that is delivered separately through the same transport line, allowing the concrete to remain uncured during transport while enabling rapid setting only at the point of application
2Manufacturing precision
If multiple passes are made to achieve desired thickness for linings thicker than 5.08 cm, then the concrete can be deposited in manageable layers, but the time required to achieve the desired thickness substantially increases
Solution Approach 1:
The activator concentration and type are adjusted to control the setting speed, allowing the concrete to remain workable during transport and application while setting rapidly once deposited, enabling thicker single-pass applications without sacrificing thickness control
Solution Approach 2:
The rapid setting action continues uniformly throughout the deposited layer immediately after application, allowing the entire thickness to set simultaneously in one continuous process rather than requiring intermittent stopping and curing periods between multiple passes
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
This approach significantly reduces the likelihood of plugging in transport lines and allows for thicker concrete linings to be applied in a single pass, enhancing efficiency and reducing the time required to achieve desired thicknesses.
Implementation Method 1
The activator comprises a foaming agent, and the method further includes adding an air-entraining additive to the foaming agent
Implementation Method 2
Spin casting is based on pumping a fine grain concrete-type mix to a head that is spinning at high speed. The head, using centrifugal force, projects the concrete outward and toward the surface of the pipe to be coated
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A spin caster for spraying a surfacing material upon an interior surface of a vessel includes a spin head (53) configured to rotate about an axis, the spin head (53) including an input port (533), and a supply line (52a, 52b) coupled to the input port (533) and configured to convey a first material to the spin head (53) and a second material to the spin head (53). The supply line (52a, 52b) comprises a first channel configured to convey the first material to the spin head (53) and a second, different channel configured to convey the second material to the spin head (53).