Tongbo's "Target Kiln" was ignited on November 15, 1992, and was cooled with water on April 16, 1998. After 1970 days of operation.
With its advanced furnace structure, high-quality supporting refractory materials, and reasonable and effective use and maintenance, the overall design goals of improving glass quality, reducing energy consumption, extending furnace life, and increasing economic benefits have been achieved. Promoted the improvement of the overall technical level of my country's glass melting furnaces.
Brief Introduction to the Final State of "Target Kiln"
The "target kiln" that has been in operation for 65 months is still relatively intact on the whole, but some parts of the damage are still extraordinary and even extremely serious. The brief introduction of each part after the water release is as follows.
Regenerator
1. The top of the grid body: the first and second layers of fused magnesia bricks (containing 97% MgO) are seriously damaged, most of the bricks are in disorder, and the grid holes are blurred. Most of the bricks near the middle have been broken, with a loss on ignition of about 40%. Although the bricks near the edge have relatively few broken, their loss on ignition is no less than 30%, and there are light blue deposits in many holes. The 3rd, 4th, and 5th layers of checker bricks can still distinguish the grid holes, and the bricks themselves are only slightly burnt. From the 6th floor down, especially the part of the fused magnesia brick containing 95% MgO, the bricks and grid holes are basically intact. To the lower part of the lattice body, that is, the part of the magnesia-chrome brick, the blockage of the grid holes begins to increase again; the blockages near the sides are mostly light blue needle-like glass bodies, which are more beautiful like sculptures; while the blockages in the middle are mostly grayish white, namely It is often referred to as alkaline sintered product. The blockage depth varies, and the deepest can reach about 1m. Its position is basically fixed within 2m above the grate. Many checker bricks in this part have been broken, and some parts have also partially collapsed. This is the main factor that affects the smooth flow of the grid.
2. Stove and regenerator bottom: low-porosity clay bridge bricks are mostly broken, and the grate and ballast bricks also have individual breaks. However, there are many bulges at the bottom of the regenerator, such as 2#, 3#, 4#, etc. The bottom steel plate has been corroded, and the ventilation ducts have been disordered. This phenomenon is mainly caused by oil leakage and heating.
3. Regenerator wall: The serious burn damage is mainly concentrated in the upper silicon brick wall and magnesia-chromium brick wall. The target wall is the magnesia-chromium brick wall, which has been peeling since the day of production, and the peeling depth is as high as about 160mm; the retaining wall at this part has been burned to be incomplete. The silicon brick wall is deeply damaged due to the influence of brick joints, observation holes, etc., with an average of about 50-70mm, and there are many holes cut out, and some have been burned through. And the part corresponding to the upper layer of the checker brick has the most prominent erosion, and a deep groove appears, the deepest can reach about 150mm.
4. The roof of the regenerator: this part is slightly eroded, but only partially pierced into the fire. The brick loss is about 20mm.
5. Steel parts: The side columns of the regenerator are heated and deformed seriously at the palm iron. The entire column can no longer guarantee the span size and verticality of the column. The slap iron is also burnt to varying degrees, and the severe ones have been burned. The lower flanges of the channel steel of the steel ballast beam have been burnt out, and some have burned to the web. These are all caused by the gaps between the ballast and the wall are not tightly packed and through the fire.
Small furnace
1. Small furnace spout chuck: There are many horizontal cracks in the chrysanthemum bricks, and the crack width has reached 30mm; the whole chrysanthemum brick of South 3# is broken vertically in half; and part of the brick chrysalis of North 1# is also broken. Fortunately, no more than half.
2. Other parts: small furnace kang, side wall, oblique chute, rear flat chute, etc. are relatively normal, and the average loss is not more than 40mm. Only the nozzle bricks and nozzle spacer bricks, although they have been replaced and repaired many times, are still cracked.
3. Steel components: small furnace oblique and rear flat ballast angle irons are seriously burnt, and some of the lower sides have been completely burned; small furnace braces are also deformed and even burned; most of the front pallet of the small furnace bottom plate Deformed or burned out.
Melting part
1. L-shaped suspended wall: the sintered AZS brick at the lower part of the nose area of ??the suspended wall is ablated by 100~120mm. In the combined part of the fused AZS brick and the sintered mullite brick, most of the fused bricks on the lower two layers and on both sides have been burned, and the mullite brick loses about 50~70mm. The more serious one is that at the joints of the silica bricks on both sides, about 1 square meters of holes were fired, which caused serious burns to the external ventilation steel pipes and hanging steel parts. Two air ducts on each side were burnt at the corner and a section of about 400 mm in length was broken. Most of the upper silicon bricks are relatively complete, with an average damage of 30-40mm
2. Front and rear gables: The front wing walls are severely burned, and individual fused bricks are broken. There are many ablation grooves and holes in the back gable. The average loss is about 40~50mm.
3. Pool bottom: large clay bricks explode more frequently, and ramming materials and paving bricks are basically intact.
4. Pool wall: The erosion of the pool wall is mainly concentrated in the upper 500mm range, and the erosion depth can be seen in the figure 1 of the figure. The damaged state can be seen in Figure 2.
In addition, where there are horizontal cracks in the pool wall tiles, there are obvious erosion grooves on the inner side.
5. Breast wall: The erosion of the breast wall is mainly concentrated in the melting zone. Although they are all fused AZS bricks, 80% of the hook bricks are still broken from the protruding parts; and between the parapet wall and the large ballast, between the parapet wall and the small furnace vent and between the vent flat and the ballast There are many holes in the crevices, and some have penetrated the fire to threaten the iron parts, and the average erosion depth is about 40-50mm. Silica brick parapets in the clarification zone are relatively lighter, but the phenomenon of broken bricks and digging holes also exists.
6. Big chute: The big chute in the melting zone is the most damaged part of the kiln, and it is also the key to affecting the life of the kiln. Damaged parts are mainly concentrated on the third large plaque corresponding to the 3# and 4# small furnaces; from the inside, there are dry sores and holes. Large holes can be connected to small holes. The large hole can reach a radius of 1m, and the small hole can reach about 2cm. ; The remaining thickness, some only a dozen centimeters, and all honeycombs, it can be described as dangerous, and it is likely to fall off at the touch of a touch. As for the other large arches, there are only some holes in some parts, and they cannot be connected to each other, and the erosion depth also ranges from 20 to 80 mm.
7. Steel components: the more serious burning damage is the steel ballast beam and the parapet pallet. 30-40% of the steel ballast beams in the melting zone can no longer be used; while about 50% of the breast wall pallets cannot be used anymore, the maximum loss on ignition can reach 70-90mm. Although the other steel components are also slightly burnt, it does not affect the use.
Card neck
1. Pool wall: The erosion depth at the front and rear corners is about 100~200mm, while the straight wall in the middle is only 50~80mm.
2. Card neck hanging wall: Most of it has been sunk in the kiln, and piled up at the bottom of the kiln with a height of 300~400 mm. The remaining part happened to completely seal the opening of the hanging wall, but the hanging iron parts were burnt to varying degrees.
3. Others: The burning damage of various parts is still normal; only the corner pallets, ballast angle iron and other steel parts are badly damaged and can no longer be used.
Cooling part
1. Large arches: the overall erosion is relatively light, the erosion depth is about 10-20mm, only the four corners of the arched bricks are broken, if they are properly treated, they can still be used.
2. Others: The pool wall bricks, including α-β corundum bricks around the overflow, have an average erosion depth of only about 10-20mm, and they only concentrate on the liquid surface. Except for the more cracked bricks at the bottom of the pool, they are all in good condition.
Overview
From the perspective of the time, 1. Tongbo "target kiln" has a better structural design, strong and durable (the kiln age has reached 5.4 years, which is a lot better than the previous kiln age of 2 to 3 years); 2. Full kiln automation High level to achieve stable control operation; 3. Reasonable matching of refractory materials, basically achieving the goal of simultaneous damage to all parts of the kiln, and good economy; 4. During the operation of the kiln, the maintenance measures are stable to ensure the safety of the entire kiln. run.
Experience
The melting operation is one of the keys to the use of the furnace. Different kiln structures correspond to different operating concepts and operating methods. To produce high-quality glass and use a longer furnace life, it is necessary to use reasonable production operations with appropriate furnace design concepts.
The structure of each part of the furnace must be reasonable, otherwise it will affect the use. For example, the grid holes of the grid body are small and easy to be blocked, thus affecting the operation.
The processing of refractory materials is also very important, it will directly affect the masonry quality of the furnace, and even the life of the furnace. For example, the flat chute of the small furnace vent has undesirable gaps and sinking.
The quality of refractory materials is also critical, otherwise the damage to defective parts will be particularly prominent. For example, the pool wall tiles have deep grooves on the inside where there are transverse cracks.
The installation and selection of steel components used in the kiln is extremely important, otherwise there will be danger. For example, small furnace columns and braces have been individually damaged due to small selections and improper installation positions.
Tongbo's "Target Kiln" (1992.11.15~1998.4.16) has long been history, but it represents the first era of glass kilns in our country. The experience and lessons left to us will be the most precious. , The most practical and valuable information. If we say that we need to make an evaluation: the "target kiln" is very successful from design to use, and it has created a precedent for the supporting use of domestic refractories.
