The technical solutions for extending the life of kiln castable materials mainly include the following three points:
1, optimize the design of the kiln mouth structure
The kiln mouth structure has been redesigned. One set 24 boards is kept unchanged, and each board is changed from the original one-piece to the box type, which is composed of the inner guard and the outer box. The kiln shell is between them. The bolts are connected as a whole, and the outer casing is filled with castables to protect the fixing bolts and the cylinder from high-temperature burning and deformation. It should be said that the protection of the fixed bolts and cylinders also means that the firmness of the kiln mouth structure is protected, and the kiln mouth casting material can be protected from excessive mechanical external forces.
The kiln mouth guard cooling cover is redesigned and integrated with the outer body of the guard plate. The bubbling cool air cools the guard plate and the barrel body and then discharges into the atmosphere. At the same time, it prevents the cold air from flowing into the kiln and increases the heat loss. Secondary air temperature; cooling air is evenly blown in from the circumferential 12 air outlets to improve the overall cooling effect.
The thickness of the pouring material of the straight wall below the kiln mouth is appropriately thickened to ensure that the end face of the kiln shrinks in the straight wall without affecting the clinker falling into the grate cooler, so that the kiln mouth is directly washed and burned by the hot gas of the grate cooler. damage.
2, construction technology program improvement and improvement
(1) The thickness of kiln castable material is increased from 200mm to 260mm so that the thickness of castable exceeds about 50mm of firebrick, and the effective thickness of castable above the kiln guard plate is increased from 150mm to 200mm to 220mm. Grinding.
(2) The structure of anchor nails is improved from single-angle welding forming to double-angle cold bending into undulations. The welding surface changes from "-" to "U". This completely solves the quality problems caused by welding; reasonable control of dowel layout, staggered three-dimensional Arrangement, especially key areas between the guard plate and the guard plate, between the guard plate and the cylinder body, and the top of the baffle ring, etc. to set key points to improve the overall tension; specific company senior welder welding kiln mouth nails, multi-spot welding Firm, and send someone to check and confirm.
(3) Casting materials should be cast and cast several times during construction, and construction should be strictly performed from 7:00 to 9:00 in the week.
(4) Special person is responsible for stirring, and is now mixing, dry-blended evenly, and the water is strictly weighed and water is controlled within the minimum range.
(5) Expansive joints are carefully accounted for by the rate of expansion of the castables and combined with practical experience. All anchors are wrapped in black cloth to compensate for the expansion space.
(6) The material is changed from high-performance castable to high-strength mullite castable to improve wear resistance and high temperature resistance.
(7) Change overhaul ideas. Each time the maintenance is over, the kiln bricks shall be suspended after the first 5 meters of construction, prior to the construction of the kiln mouth castable materials, to extend the curing time as much as possible.
3, improve the ventilation system to ensure that the kiln head negative pressure
(1) Improve the ventilation capacity of the kiln tail. The total slope of the sloping refractories is adjusted from 245 mm (100 mm calcium plate + 145 mm firebrick) to 150 mm. The 100 mm thick calcium silicate board is removed and all the high strengths are used. High aluminum refractory castables. In order to ensure that the vertical distance from the dome to the slope is as large as possible, the overall design of the slope and its feed tongue castable ensures that the slope transitions smoothly into the kiln at three slanting angles. The upper section is maintained at 50°C and the middle section is secured at both ends with a 150 mm lining thickness. In order to control the benchmark, the actual tilt angle is about 42.5°, and the lower part of the feed tongue, which is about 1000 mm long, enters the kiln at a tilt angle of 33°, correspondingly reducing the total lining thickness of the inlet tongue from 300 mm to 200 mm. Increasing the inclination eliminates the horizontal transition of approximately 150 mm in length from the end of the inlet tongue. The length of the dome of the kiln tail is shortened, and the connection between the dome and the smoke chamber is designed as a chamfer of about 50°, basically parallel to the slope, and the thickness of the refractory lining is thinned to further increase the dome section.
(2) Improvement of the after-wind treatment system In view of the fact that the capacity of the after-wind treatment is relatively small, the corresponding improvement is made under the condition that the capacity of the wind turbine is unchanged: to expand the cooling tower of the after-wind, the cooling-air-duct is doubled than the original, and the wind speed and resistance are reduced. Reduce the air temperature; add a large settling chamber between the grate cooler and the cooling tower to collect the kiln dust particles carried by the wind, and increase the natural heat dissipation, further reducing the residual air temperature and dust content. The air temperature and dust contained in the remaining air are improved. Concentration is greatly reduced, the resistance of the fiberglass bag dust collector is reduced, and the air volume capacity of the co-wind fan is improved, which basically meets the production requirements.
Second, improve the effect of analysis
After all-round optimization and improvement, the service life of the kiln castable material has achieved a qualitative leap, and the replacement cycle not only satisfies the need for kiln brick overhaul, but even surpasses the life of the kiln brick and avoids the passive situation in which the used castable material is difficult to remove during maintenance. .
Xiao Bian thinks that the kiln mouth operation condition is related to the fate of the entire production line. Its position in production is very unusual. Care must be taken from material selection to use and maintenance. Every detail must be controlled in order for production to enter. Virtuous cycle.
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