The kiln is the core equipment of the glass factory. It is usually repaired once in a few years. The reasons for cold repair under normal conditions are as follows.
A. The refractory material in contact with the glass liquid is seriously damaged, there is a risk of material leakage, and it is difficult to perform local heat repair.
B. The upper structure refractory material is damaged, the fire leak is serious, the glass cannot be melted normally, and various heat repair measures are invalid.
C. The regenerator is clogged so much that the fuel consumption is increased, the ability to melt the glass is lowered, and the cost is significantly increased, and the replacement of the checker brick is economically uneconomical.
Of course, there are various special circumstances that cause the kiln to be shut down for cold repair. If the design is not proper enough to produce properly; the refractory material selection error causes a large number of stones and streaks; due to various reasons, the tank kiln is seriously leaking.
The simplest cold repair only replaces the fluid hole, the pool wall brick and the regenerator compartment brick. Medium-scale cold repairs will have to rebuild the bottom of the pool, small furnaces and large rafts. Large-scale cold repairs must be completely repaired except for the foundation and the flue. Generally, cold repair is not simply repaired as it is, but must be combined with technical transformation.
Preparation before cold repair
One. Design and material preparation Before the cold repair, according to the new kiln production plan and the experience of the old kiln, the need for cold repair parts and technical transformation plan, and then the theoretical calculation and structural design, and the material design required for cold repair according to the structural design.
The materials used for the masonry preparation of the bricks (mainly refractory materials) should be carefully inspected after they arrive at the factory. The bricks to be processed should be ground and cut, and special parts should be pre-built.
C. It is planned to arrange the schedule of the project in detail before the cold repair, so that the specific construction personnel can clearly define the operation method and quality requirements, and do a good job in the editing and training of the personnel.
D. Review the drawings and draw all the drawings in detail before drawing the line, and find the errors and correct them immediately. Before the construction, the location of the masonry should be determined on the site according to the drawings and the line should be drawn. The most important line is to determine the center line, the drip center and the liquid level.
That is to say, in order to ensure the accurate size of the masonry in standard line and sample masonry, there must be a standard line or a model. The standard line is generally marked with a string to indicate the vertical and horizontal lines of each part, and the sample is measured by the standard shape of steel or wood. Before laying the masonry, you should pull the standard line and make a good model.
F. Prepare masonry tools such as bricklaying, brick cutting, and mud.
The release of the molten glass from the furnace is an important part of the cold repair work. The requirements for the discharge work are safe and thorough. At present, there are two methods for discharging float glass furnaces: one is to discharge the material by using a glass discharge tank; the other is to release water by water quenching. Taking the glass discharge tank as an example, the work of discharging the material is prepared, and the operation steps are as follows.
initial preparation work
One. The glass discharge tank, one week before the discharge, drains the water in the pool, removes all the impurities in the pool, rinses the bottom of the pool, and sludges from the tank wall. Pour the cullet layer at the bottom of the pool to a thickness of about 10 mm to avoid sticking the released glass to the bottom of the pool. In the vicinity of the discharge gutter, the glass crucible should be smashed, and then the purified water should be placed to a sufficient depth to prepare for adding water. Pipes and related work tools.
Bay discharge hole, the day before the discharge, remove the iron parts and ducts of the corresponding parts outside the discharge hole, open and remove the two layers of bricks except the hole bricks, ready to hit the big iron of the third layer of eye bricks Bar.
C. Discharge the ditch, one week before the discharge, clean the discharge gutter and rebuild it. Place a quartz sand with a thickness of about 20mm on the bottom of the ditch, and then put a piece of wood with a thickness of about 100mm to avoid condensation of the molten glass. Rogue.
d. Prepare one diesel fuel gun and the corresponding oil supply system and barreled diesel at the outlet of the discharge hole and the tail of the discharge gutter for the preheating of the discharge gutter and the outlet of the heating discharge hole.
That is to contact the power supply, steam supply, water supply unit to ensure that the power supply, steam supply and water supply can be stabilized normally during the discharge of the furnace.
F. Check all oil, gas, and gas systems, and prepare various tools to prepare for the oil system after the ceasefire. And prepare the large pipe wrench and afterburner steel pipe for the purpose of tightening the bar.
G. The day before the discharge, add kerosene or oil lubrication to each of the drawbar screws of the furnace, so that it is easy to loosen the drawstring when the cold kiln is removed from the kiln.
H. Check the fire protection facilities around the melting furnace, and the fire truck should be kept on standby.
I. Arrange the division of labor, safety education and tool preparation for the furnace discharge operation.
1 8h before the discharge, notify the raw material workshop to stop the ingredients, and prepare the semi-storage glass on the kiln head silo (for the front cover feeding tank).
2 After the batch is used up, cover the feeding pool with broken glass, pull out the feeding machine, and close the feeding pool.
3 After the melting furnace stops feeding, the tin bath part continues to pull the glass until the glass can not be pulled normally. = The safety gate is dropped, and the tin bath starts to be cleaned.
4 After the batch is used up, remove the liquid level meter.
5 8H before discharging, according to the situation, the two pairs of small furnace flames should be properly opened to increase the temperature of the glass in the cooling section. The first few pairs of furnaces can maintain normal flame, and pay attention to the temperature in the kiln is not too high, avoiding the kiln Do not use too high a temperature to avoid accidents involving flowing glass.
6 When the tin bath cannot pull the glass normally, drop the safety curtain of the runner. Pull the large neck pipe, pull out the horizontal mixer, stop the fan, and block all the fire holes on the furnace.
1 Ign the firewood in the discharge ditches 1 hour in advance, and ignite the fuel spray gun at the tail of the ditch, and bake the discharge ditch.
2 After the water discharge ditch is heated, open the material hole brick with a large iron bar and start discharging. During the entire discharge period, monitor the flow of molten glass in the hole of the hole, and deal with it when the flow is not smooth.
3 Determine the stop time according to the falling speed of the glass surface in the kiln. After the ceasefire, the combustion air blower, the wall cooling fan, the steel fan, the L-shaped wall fan and other temporary kiln fans were shut down, and the exhaust switch panel was adjusted to the middle position.
4 During the discharge period and during the subsequent cooling period, according to the cooling of the glass liquid in the glass pool, water is continuously added in an appropriate amount to accelerate the cooling rate. The kiln body is inspected and monitored during the discharge.
Fuel system operation
1 The amount of residual glass liquid discharged to the bottom of the melting section is as small as possible. After the ceasefire, it is required to ensure the steam supply to the heating network.
2 When the fire is stopped, the oil pump room stops supplying oil, and immediately after the oil is stopped, the pipeline is purged. All valves (bypass valves) and membrane valves are opened to maximum position before steam purge. After the oil is stopped, the tubing with the hot steam does not stop, and the hot steam is stopped after the purge is completed. The fuel gun can be removed after purging.
3 The fuel flow meter is purged with the pipe (the valve should not be closed before and after the flowmeter).
Cold kiln operation
1 The chimney root gate, the total flue rotation gate, and the branch flue rams are all open.
2 Remove the equipment and instruments of the fuel system around the melting furnace such as the purge valve, spray gun bracket, and pressure gauge. Remove the thermocouple, pressure transmitter and other instruments on and around the furnace. Remove the wall-walled kiln air duct and steel stern cooling air duct and temporary kiln air duct and fan. After the wall cooling duct is removed, the outlet of the mother tube below it should be covered with a prefabricated cover to prevent debris from falling into the duct when the kiln is removed.
3 When the temperature of the concrete is lowered to 1000 °C, the kiln body is inspected. According to the speed of the sag, the personnel are tightly tied and the records are made. Make sure that the cymbal falls back evenly and the tension bar is kept until the temperature of the sputum drops to 100 °C.
4 After 24 hours of discharge, according to the kiln temperature, open the regenerator door and continue the cold kiln.
5 After the cold kiln, the kiln body inspection was carried out, and the erosion was photographed and detailed records were made. The entire process should have a dedicated person to do a variety of records for the record. On the third day, it began to transfer to the kiln and was carried out according to the cold repair plan.