CN104677089A - Construction method for prolonging service cycles of kiln mouth castables in cement clinker production lines - Google Patents
Construction method for prolonging service cycles of kiln mouth castables in cement clinker production lines Download PDFInfo
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- CN104677089A CN104677089A CN201510055466.6A CN201510055466A CN104677089A CN 104677089 A CN104677089 A CN 104677089A CN 201510055466 A CN201510055466 A CN 201510055466A CN 104677089 A CN104677089 A CN 104677089A
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Abstract
The invention discloses a construction method for prolonging service cycles of kiln mouth castables in cement clinker production lines. The construction method includes steps of sweeping kiln shells; mounting and checking the kiln shells and protective iron of brick check rings; welding anchoring parts and carrying out expansion treatment on the anchoring parts; erecting molds; casting the kiln mouth castables; maintaining the kiln mouth castables, removing the molds and checking the kiln mouth castables. The construction method has the advantages that the service cycles of the kiln mouth castables can be synchronized with service cycles of brick materials in kilns, configuration schemes for the castables with high abrasion resistance and the bricks with high abrasion resistance are adopted in designs of refractory materials of kiln mouths, certain castable protection effects can be realized by the bricks with the high abrasion resistance and the lengths of approximately 1 meter, accordingly, the service lives of the kiln mouth castables can be prolonged, and the average service cycles of the kiln mouth castables can reach 10-12 months and are basically synchronized with the cycles of the bricks in the kilns; the kiln mouth castables can be saved by 4 tons every year, and 28000 yuans can be saved every year.
Description
Technical field
The present invention relates to the construction method extending kilneye castable life cycle in a kind of cement clinker production line.
Background technology
At present, kilneye castable bears the heat radiation that combustor flame temperature reaches 1700 DEG C, simultaneously the grog of nearly 1400 DEG C of bearing temperature wearing and tearing with wash away, also to bear in stress that barrel distortion produces, kiln brick along the shearing force etc. in cylindrical shell direction.Therefore kilneye castable its life cycle compared with brick in kiln is relatively short, and the life cycle of general kilneye castable is 6-8 month.
The analysis of causes that kilneye castable life cycle shortens:
1, anchoring piece: anchoring piece impact point two aspects, one is material, and General Requirements is heat resisting steel, and that kilneye is conventional is 1Cr18Ni9Ti; Two is welding qualities of anchoring piece, if welding rod and welding parameter select mistake, can affect firm welding degree, castable is come off in advance, especially the firm welding degree of break iron position anchoring piece.
2, check ring for blocking bricks: the effect of check ring for blocking bricks mainly prevents brick in kiln from gliding to kilneye, if check ring for blocking bricks scaling loss sealing-off and can't stop brick in kiln, good thrust function can not be played, the sliding force that in kiln, refractory brick produces then is easy to the anchoring piece of kilneye fire resistant pouring material to cut off, and causes castable monoblock to come off.
3, kilneye cap iron: the object of installing kilneye cap iron prevents kilneye to be out of shape, but the kilneye of distortion produces effect of stress to break iron, makes kilneye cap iron occur loosening, easily causes castable to ftracture.
4, castable curing time is inadequate: if the curing time of castable is inadequate, one is that castable can not give full play to its due performance, if two is pour into a mould rotary kiln in latter 16 hours at (water material), easily there is phenomenon of coming to nothing between castable and kiln cylinder body, thus cause anchoring piece to burn out from root.
5, castable job specfication: if castable adds water or glue is too much, cause intensity decline to affect life cycle, if vibrate not in place in construction or once-cast amount is too large, dilatation joint is reserved inadequate etc. simultaneously, finally all will affect result of use.
6, technological operation: easily make castable or refractory brick scaling loss if kilneye thermic load is too high and peels off, making kilneye fire resistant material premature breakdown.
Summary of the invention
The object of this invention is to provide the construction method extending kilneye castable life cycle in a kind of cement clinker production line, solve the problem extending kilneye castable life cycle.
The technical solution adopted for the present invention to solve the technical problems is:
Extend a construction method for kilneye castable life cycle in cement clinker production line, comprised the following steps; Kiln shell cleans---kiln shell and check ring for blocking bricks break iron installation check---and anchoring piece welding and expansion process---formwork---cast---maintenance and form removal, inspection, concrete following steps,
Check before described kiln trunk trunk cleaning comprises construction and confirm, first clearing up the dust and other impurities of construction part, and with inspection kilneye cap iron, check ring for blocking bricks scaling loss, kiln shell areal deformation and oxide layer situation;
Described kiln shell and check ring for blocking bricks break iron installation check are loosening kilneye cap iron appearance, carry out again fastening bolt and adjustment putting position, change scaling loss kilneye cap iron; The check ring for blocking bricks serious to scaling loss is changed; Kiln shell distortion position is confirmed or taken pictures, anchoring piece size is handled accordingly, pad polishing is carried out to the welding position of kiln shell already oxidised position anchoring piece;
Described trunk and check ring for blocking bricks break iron installation check are loosening kilneye cap iron appearance, carry out again fastening bolt and adjustment putting position, change scaling loss kilneye cap iron; The check ring for blocking bricks serious to scaling loss is changed; Barrel distortion position is confirmed or takes pictures, anchoring piece size is handled accordingly, pad polishing is carried out to the welding position of cylindrical shell already oxidised position anchoring piece;
Described kilneye anchoring piece welding and expansion process confirm anchoring piece material and welding rod kind before the welding of kilneye anchoring piece, weld spacing formulates corresponding spacing according to the kilneye anchoring piece of different model, and the head of kilneye anchoring piece will carry out expansion process;
Described formwork is that the size of detection formwork is accurate, and install firmly, formwork must not exist gap;
Described cast is the less general castable 4.5%--6% of water content of the castable in the use of kilneye castable, and in castable laying, the dilatation joint of castable stays to establish in casting process, arranges together between the every two pieces of break iron of hoop; Castable and refractory brick junction longitudinal length are middle more than 1m arrange together with L:120mm × 5mm castable stitch; Adopt five-ply board or plastic paper to separate in case refractory brick makes moist and castable dehydration in castable and refractory brick junction, being poured in rear 12h must not rotary kiln;
Described maintenance and form removal, inspection carry out temperature rise control with reference to the heating curve of castable, in temperature-rise period, suitably elongated by fire or suitably advanced in kiln by burner according to kilneye actual conditions, avoiding directly on high temperature dot.
For guaranteeing that in baking, castable does not burst, and will stay steam vent in construction in described cast step.
Cast step described in castable first time amount of agitation should with 15 minutes in constructed be one batch, the order stirred should divide secondary to carry out: first add aggregate, powder and bonding agent and be dry mixed, then the water of 80% is added, and add remaining water according to the dry wet situation of castable, the standard amount of water that total amount of water provides with reference to castable producer controls, be dry mixed mixing time 2 minutes, wet and stir 3 minutes
In cast step, castable pre-coated layer height is generally also excellent with plug-in type vibrating at 250mm, and castable thickness should not exceed 1.25 times of vibrating head agency part length.
Vibrating head vibrating time described in cast step should, stop vibrating when going out in the existing surface frost boiling of castable, vibrating head must not touch anchoring piece.
Beneficial effect of the present invention: the present invention makes kilneye castable synchronous with the life cycle energy of brick in kiln; kilneye fire resistant design of material have employed the allocation plan of high wear resistant castable refractory and high wear-resistant brick; wherein the high wear-resistant brick of about 1 meter plays the effect of certain molding casting material; the service time of kilneye castable is extended; the average life cycle of kilneye castable reaches 10-12 month, brick cycle synchronisation in basic and kiln.Annual saving kilneye pouring material 4 tons, can save 28000 yuan.
Detailed description of the invention
Embodiment 1:
Extend a construction method for kilneye castable life cycle in cement clinker production line, comprised the following steps; Kiln shell cleans---kiln shell and check ring for blocking bricks break iron installation check---anchoring piece welding and expansion process---formwork---cast---maintenance and form removal, inspection.Concrete following steps:
Check before described kiln trunk trunk cleaning comprises construction and confirm, first clearing up the dust and other impurities of construction part, and with inspection kilneye cap iron, check ring for blocking bricks scaling loss, kiln shell areal deformation and oxide layer situation;
Described kiln shell and check ring for blocking bricks break iron installation check are loosening kilneye cap iron appearance, carry out again fastening bolt and adjustment putting position, change scaling loss kilneye cap iron; The check ring for blocking bricks serious to scaling loss is changed; Kiln shell distortion position is confirmed or taken pictures, anchoring piece size is handled accordingly, pad polishing is carried out to the welding position of kiln shell already oxidised position anchoring piece;
Described kilneye anchoring piece welding and expansion process confirm anchoring piece material and welding rod kind before the welding of kilneye anchoring piece, weld spacing formulates corresponding spacing according to the kilneye anchoring piece of different model, and the head of kilneye anchoring piece will carry out expansion process;
Described formwork is that the size of detection formwork is accurate, and install firmly, formwork must not exist gap;
Described cast is the less general castable 4.5%--6% of water content of the castable in the use of kilneye castable, and in castable laying, the dilatation joint of castable stays to establish in casting process, arranges together between the every two pieces of break iron of hoop; Castable and refractory brick junction longitudinal length are middle more than 1m arrange together with L:120mm × 5mm castable stitch; Adopt five-ply board or plastic paper to separate in case refractory brick makes moist and castable dehydration in castable and refractory brick junction, being poured in rear 12h must not rotary kiln; For guaranteeing that in baking, castable does not burst, and will stay steam vent in construction in described cast step.
Cast step described in castable first time amount of agitation should with 15 minutes in constructed be one batch, the order stirred should divide secondary to carry out: first add aggregate, powder and bonding agent and be dry mixed, then the water of 80% is added, and add remaining water according to the dry wet situation of castable, the standard amount of water that total amount of water provides with reference to castable producer controls, be dry mixed mixing time 2 minutes, wet and stir 3 minutes
In cast step, castable pre-coated layer height is generally also excellent with plug-in type vibrating at 250mm, and castable thickness should not exceed 1.25 times of vibrating head agency part length.
Vibrating head vibrating time described in cast step should, stop vibrating when going out in the existing surface frost boiling of castable, vibrating head must not touch anchoring piece.
Described maintenance and form removal, inspection carry out temperature rise control with reference to the heating curve of castable, in temperature-rise period, suitably elongated by fire or suitably advanced in kiln by burner according to kilneye actual conditions, avoiding directly on high temperature dot.
The points for attention extending kilneye castable life cycle are as follows:
1, strengthen the usage monitoring to kilneye fire resistant material, prevent kilneye to be out of shape.
Because kiln cylinder body scanning system can not carry out effective monitoring to kilneye, find that coming off of kilneye fire resistant material is more delayed, often make kilneye barrel distortion, check ring for blocking bricks and kilneye cap iron can be burnt out simultaneously, cause the kilneye fire resistant materials'use life-span to shorten further.Some production lines also adhere to for a long time running after kilneye castable partial exfoliation, make kilneye fire resistant material enter vicious circle.Therefore, in daily production, patrol officer will strengthen patrolling and examining the frequency to kilneye fire resistant material, when finding that kilneye castable or refractory brick come off, should process in time, preventing kilneye be out of shape, for the life cycle of later stage raising kilneye fire resistant material provides Reliable guarantee.
2, the use of anchoring piece is paid attention to
Anchoring piece plays vital fastening effect to castable, with heat resisting steel on Material selec-tion, to note simultaneously the selection of welding rod kind and welding procedure supporting, specific requirement is as follows:
Anchoring piece material is checked on, and ten thousand tons of line kilneye anchoring pieces select material to be 0Cr25Ni20, and the kilneye anchoring piece of other scale kiln type selects material to be 1Cr18Ni9Ti; Welding rod material is A402 type, and welding current is 90-120A.
3, the kind of selecting properly kilneye castable
The selection kind of current kilneye castable is more, can select as the case may be, if the repair time is shorter or require that the cycle of operation is within half a year, should select sizing material, as PA803, this material for making clothes also can be placed on winter construction simultaneously, its curing time is shorter, and general maintenance 4h can light a fire; In the work progress of sizing material, will note the mix ratio (3%-5%) of cement especially, determine according to construction environment temperature, winter construction mix ratio is the upper limit, and hot weather construction mix ratio is lower limit.If scheduled major overhaul or new kiln should select water material, this kind of castable must note curing time.
4, ensure curing time and normally toast intensification
In order to ensure that kilneye castable has enough curing times, wanting the good cross-operation of reasonable arrangement when organization planning, making kilneye castable project construct in advance as far as possible.The curing in the mold time that can ensure 24 hours wanted by water material.
Heating curve (the baking heating-up time suggestion of water material is no less than 18h, and the baking heating-up time suggestion of sizing material is no less than 14h) to be toasted accordingly for the design of different castable performance requirements simultaneously, prevent castable premature deterioration.
5, cylindrical shell construction precautions has been out of shape to local
Because kiln cylinder distortion position stress is relatively large, therefore suitable process (as suitably reduced the distribute spacing etc. of anchoring piece) to be done to the anchoring piece at this position, strengthen the firmness of this place's anchoring piece, simultaneously larger to local deformation place suitably increases dilatation joint process.
6, the cylindrical shell forming oxide layer is polished
There is the place of oxide layer to carry out welding easily producing sealing-off, therefore carry out butt welding before welding and tap into row polishing, make anchoring piece and kiln cylinder body or break iron firm welding.
7, strengthening process operational administrative, prevents kilneye thermic load too high.
In regular job, stablize thermal technology's systematic parameter, especially will control kilneye thermic load well, prevent high temperature direct scaling loss kilneye fire resistant material.
8, in time strained check ring for blocking bricks, kilneye cap iron and cylindrical shell are changed.
Stopping in kiln inspection, carefully to check kilneye cap iron, check ring for blocking bricks and cylindrical shell, prevent them from loosening or sealing-off, the kilneye cap iron serious to scaling loss and check ring for blocking bricks are changed, and return to former designing requirement, advise should arranging to change, in order to avoid cause vicious circle to gross distortion cylindrical shell simultaneously.
Be example by 5000T/D clinker production line kilneye castable, with 1 year for cycle measuring and calculating: every kilneye pouring material about 8 tons, originally life cycle is 6-8 month, is 8-12 month after adopting new construction technology measure, annual saving kilneye pouring material 4 tons, saves 28000 yuan.
Above embodiment is only be described the preferred embodiment of the present invention; not scope of the present invention is limited; under not departing from the present invention and designing the prerequisite of spirit; the various distortion that the common engineers and technicians in this area make technical scheme of the present invention and improvement, all should fall in protection domain that claims of the present invention determine.
The part that the present invention does not relate to prior art that maybe can adopt all same as the prior art is realized.
Claims (5)
1. in a cement clinker production line, extend the construction method of kilneye castable life cycle, it is characterized in that having comprised the following steps: kiln shell cleans---kiln shell and check ring for blocking bricks break iron installation check---anchoring piece welding and expansion process---formwork---cast---maintenance and form removal, inspection, concrete as following steps
Check before described kiln trunk trunk cleaning comprises construction and confirm, first clearing up the dust and other impurities of construction part, and with inspection kilneye cap iron, check ring for blocking bricks scaling loss, kiln shell areal deformation and oxide layer situation;
Described kiln shell and check ring for blocking bricks break iron installation check are loosening kilneye cap iron appearance, carry out again fastening bolt and adjustment putting position, change scaling loss kilneye cap iron; The check ring for blocking bricks serious to scaling loss is changed; Kiln shell distortion position is confirmed or taken pictures, anchoring piece size is handled accordingly, pad polishing is carried out to the welding position of kiln shell already oxidised position anchoring piece;
Described kilneye anchoring piece welding and expansion process confirm anchoring piece material and welding rod kind before the welding of kilneye anchoring piece, weld spacing formulates corresponding spacing according to the kilneye anchoring piece of different model, and the head of kilneye anchoring piece will carry out expansion process;
Described formwork is that the size of detection formwork is accurate, and install firmly, formwork must not exist gap;
Described cast is the less general castable 4.5%-6% of water content of the castable in the use of kilneye castable, and in castable laying, the dilatation joint of castable stays to establish in casting process, arranges together between the every two pieces of break iron of hoop; Castable and refractory brick junction longitudinal length are middle more than 1m arrange together with L:120mm × 5mm castable stitch; Adopt five-ply board or plastic paper to separate in case refractory brick makes moist and castable dehydration in castable and refractory brick junction, being poured in rear 12h must not rotary kiln;
Described maintenance and form removal, inspection carry out temperature rise control with reference to the heating curve of castable, in temperature-rise period, suitably elongated by fire or suitably advanced in kiln by burner according to kilneye actual conditions, avoiding directly on high temperature dot.
2. extend the construction method of kilneye castable life cycle in cement clinker production line as claimed in claim 1, it is characterized in that: for guaranteeing that in baking, castable does not burst, and will stay steam vent in construction in described cast step.
3. in cement clinker production line as claimed in claim 1, extend the construction method of kilneye castable life cycle, it is characterized in that: cast step described in castable first time amount of agitation should with 15 minutes in constructed be one batch, the order stirred should divide secondary to carry out: first add aggregate, powder and bonding agent and be dry mixed, then the water of 80% is added, and add remaining water according to the dry wet situation of castable, the standard amount of water that total amount of water provides with reference to castable producer controls, be dry mixed mixing time 2 minutes, wet and stir 3 minutes.
4. in cement clinker production line as claimed in claim 1, extend the construction method of kilneye castable life cycle, it is characterized in that: in cast step, castable pre-coated layer height is generally also excellent with plug-in type vibrating at 250mm, and castable thickness should not exceed 1.25 times of vibrating head agency part length.
5. in cement clinker production line as claimed in claim 1, extend the construction method of kilneye castable life cycle, it is characterized in that: the vibrating head vibrating time described in cast step should, stop vibrating when going out in the existing surface frost boiling of castable, vibrating head must not touch anchoring piece.
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Cited By (6)
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| CN105115295A (en) * | 2015-08-23 | 2015-12-02 | 安徽芜湖海螺建筑安装工程有限责任公司 | Formwork erecting operation method applicable to rotary cement kiln combustor castable construction |
| CN106370010A (en) * | 2016-08-31 | 2017-02-01 | 安徽芜湖海螺建筑安装工程有限责任公司 | Novel liner structure implementation scheme for cement kiln opening |
| CN106595315A (en) * | 2016-12-10 | 2017-04-26 | 通达耐火技术股份有限公司 | Cement rotary kiln mouth refractory construction method |
| CN108214871A (en) * | 2017-12-29 | 2018-06-29 | 邯郸金隅太行水泥有限责任公司 | The casting of the vertical ladder casting mold of rotary kiln burner and the application mold |
| CN108759481A (en) * | 2018-06-02 | 2018-11-06 | 安徽芜湖海螺建筑安装工程有限责任公司 | Improve the design scheme of kilneye castable service life |
| CN112325654A (en) * | 2020-11-05 | 2021-02-05 | 安徽芜湖海螺建筑安装工程有限责任公司 | Method for constructing kiln mouth refractory material of rotary cement kiln |
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105115295A (en) * | 2015-08-23 | 2015-12-02 | 安徽芜湖海螺建筑安装工程有限责任公司 | Formwork erecting operation method applicable to rotary cement kiln combustor castable construction |
| CN106370010A (en) * | 2016-08-31 | 2017-02-01 | 安徽芜湖海螺建筑安装工程有限责任公司 | Novel liner structure implementation scheme for cement kiln opening |
| CN106370010B (en) * | 2016-08-31 | 2018-11-02 | 安徽芜湖海螺建筑安装工程有限责任公司 | A kind of lining structure embodiment of new type water stall kilneye |
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| CN106595315B (en) * | 2016-12-10 | 2018-08-31 | 通达耐火技术股份有限公司 | A kind of rotary cement kiln eye castable construction method |
| CN108214871A (en) * | 2017-12-29 | 2018-06-29 | 邯郸金隅太行水泥有限责任公司 | The casting of the vertical ladder casting mold of rotary kiln burner and the application mold |
| CN108759481A (en) * | 2018-06-02 | 2018-11-06 | 安徽芜湖海螺建筑安装工程有限责任公司 | Improve the design scheme of kilneye castable service life |
| CN112325654A (en) * | 2020-11-05 | 2021-02-05 | 安徽芜湖海螺建筑安装工程有限责任公司 | Method for constructing kiln mouth refractory material of rotary cement kiln |
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Application publication date: 20150603 |