CN109053209B - Method for controlling reducing atmosphere of foamed ceramic kiln - Google Patents
Method for controlling reducing atmosphere of foamed ceramic kiln Download PDFInfo
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- CN109053209B CN109053209B CN201810907073.7A CN201810907073A CN109053209B CN 109053209 B CN109053209 B CN 109053209B CN 201810907073 A CN201810907073 A CN 201810907073A CN 109053209 B CN109053209 B CN 109053209B
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/02—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/64—Burning or sintering processes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B9/00—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity
- F27B9/12—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity with special arrangements for preheating or cooling the charge
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B9/00—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity
- F27B9/14—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity characterised by the path of the charge during treatment; characterised by the means by which the charge is moved during treatment
- F27B9/20—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity characterised by the path of the charge during treatment; characterised by the means by which the charge is moved during treatment the charge moving in a substantially straight path tunnel furnace
- F27B9/26—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity characterised by the path of the charge during treatment; characterised by the means by which the charge is moved during treatment the charge moving in a substantially straight path tunnel furnace on or in trucks, sleds, or containers
- F27B9/262—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity characterised by the path of the charge during treatment; characterised by the means by which the charge is moved during treatment the charge moving in a substantially straight path tunnel furnace on or in trucks, sleds, or containers on or in trucks
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B9/00—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity
- F27B9/30—Details, accessories, or equipment peculiar to furnaces of these types
- F27B9/36—Arrangements of heating devices
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/658—Atmosphere during thermal treatment
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B9/00—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity
- F27B9/30—Details, accessories, or equipment peculiar to furnaces of these types
- F27B9/36—Arrangements of heating devices
- F27B2009/3638—Heaters located above and under the track
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27M—INDEXING SCHEME RELATING TO ASPECTS OF THE CHARGES OR FURNACES, KILNS, OVENS OR RETORTS
- F27M2001/00—Composition, conformation or state of the charge
- F27M2001/03—Charges containing minerals
- F27M2001/035—China
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)
Abstract
The invention discloses a method for controlling the reducing atmosphere of a foamed ceramic kiln, which comprises the following steps: an upper burner is arranged in the kiln space of the kiln head, and a lower burner is arranged in the kiln shed plate space; arranging a smoke exhaust flue at the kiln head of the kiln, not arranging the smoke exhaust flue between the smoke exhaust flue at the kiln head and the middle section of the foaming section, and arranging one or more smoke exhaust flues behind the middle section of the foaming section; and adjusting the combustor between the preheating section and the middle section of the foaming section to be under-oxygen combustion and positive pressure. The invention makes the kiln in a reducing atmosphere state before foaming by arranging an upper burner, a lower burner, a smoke exhaust flue and adjusting the burners from a preheating section to a middle section of a foaming section to be under-oxygen combustion and positive pressure, thereby preventing the foaming agent on the surface of the foamed ceramic batch from being oxidized; the method is beneficial to eliminating the porcelain phenomenon on the surface and improving the surface quality and the finished product rate of cut materials of the foamed ceramic blank.
Description
Technical Field
The invention relates to the technical field of foamed ceramic preparation, in particular to a method for controlling the reducing atmosphere of a foamed ceramic kiln, relates to a preparation process of light foamed ceramic and a kiln thereof, and is particularly suitable for the preparation process of the light foamed ceramic heated by adopting a gas mode and the kiln thereof.
Background
The foamed ceramic is prepared through setting the material mixture in a kiln, decomposing or oxidizing the foaming agent in the material mixture at certain temperature to produce gas, forming liquid phase in the material mixture at the temperature, covering the gas with the liquid glass phase to form foamed pores, cooling and annealing to obtain foamed ceramic blank with great amount of foamed pores and homogeneous structure. In order to obtain high productivity, large blank cutting rate and low energy consumption per unit yield, a tunnel kiln is generally adopted to produce the foamed ceramics. According to the inlet and outlet direction of the foamed ceramic batch, the kiln can be divided into a preheating section, a foaming section, a cooling section, an annealing section and a cooling section according to the preparation process of the foamed ceramic, as shown in fig. 1. The kiln car filled with the foamed ceramic batch enters from a kiln opening and is heated through a preheating section. In the foaming section, the batch materials generate a glass liquid phase under the action of temperature, meanwhile, the foaming agent in the batch materials generates gas, the gas pressure swells the viscous glass liquid phase to form foam holes, and a large number of foam holes are generated to form the foam material. After the foamed ceramic batch enters the cooling section, the temperature is reduced to fix the foam holes, and then the foamed ceramic batch passes through the annealing section and the cooling section and comes out of the kiln tail of the kiln car to form a foamed ceramic blank.
The principle of the gas generated by the foaming agent is that the foaming agent and oxygen in the foaming ceramic batch material are subjected to chemical reaction to generate gas. Carbon-containing blowing agents, such as carbon black, graphite, silicon carbide, and the like, which react with oxygen to form carbon monoxide or carbon dioxide, are currently widely used in the industry.
The fuel is burnt to obtain the temperature required by the kiln, the foamed ceramic batch on the surface obtains oxygen (oxygen for combustion assistance and oxygen permeated by the kiln) from a burning space, so that the foaming agent on the surface of the foamed ceramic batch is subjected to oxidation reaction before foaming is not finished, the foaming agent on the surface of the batch is consumed in advance, and the foamed ceramic batch on the surface which is lack of foaming gas cannot effectively generate cells. Meanwhile, the surface of the foamed ceramic blank cannot be fully foamed, so that a layer of relatively dense and smooth sintering material which is not fully foamed is generated, the main phase of the sintering material is a glass phase, the phenomenon is generally called as vitrification in the industry, and vitrification reduces the yield of cut materials of the foamed ceramic blank.
Disclosure of Invention
Aiming at the defects in the problems, the invention provides a method for controlling the reducing atmosphere of a foamed ceramic kiln.
In order to achieve the above object, the present invention provides a method for controlling a reducing atmosphere of a ceramic foam kiln, comprising:
an upper burner is arranged in the kiln space of the kiln head, and a lower burner is arranged in the kiln shed plate space;
arranging a smoke exhaust flue at the kiln head of the kiln, not arranging the smoke exhaust flue between the smoke exhaust flue at the kiln head and the middle section of the foaming section, and arranging one or more smoke exhaust flues behind the middle section of the foaming section;
and adjusting the combustor between the preheating section and the middle section of the foaming section to be under-oxygen combustion and positive pressure.
As a further improvement of the invention, the kiln body of the kiln is welded and sealed by a steel shell.
As a further improvement of the invention, the smoke exhaust flue arranged at the kiln head is positioned between the kiln opening of the kiln and the upper burner and the lower burner arranged at the kiln head.
As a further improvement of the invention, the oxygen-deficient combustion is that the ratio of fuel to theoretical air is controlled to be 80-95% in a complete combustion state, and the positive pressure is that the pressure of the kiln is 1-5 Pa higher than the pressure outside the kiln.
As a further improvement of the invention, sand sealing is adopted between the side part of the kiln car filled with the foamed ceramic batch and the inner wall of the kiln.
Compared with the prior art, the invention has the beneficial effects that:
the invention makes the kiln in a reducing atmosphere state before foaming by arranging an upper burner, a lower burner, a smoke exhaust flue and adjusting the burners from a preheating section to a middle section of a foaming section to be under-oxygen combustion and positive pressure, thereby preventing the foaming agent on the surface of the foamed ceramic batch from being oxidized; the method is beneficial to eliminating the porcelain phenomenon on the surface and improving the surface quality and the finished product rate of cut materials of the foamed ceramic blank.
Drawings
FIG. 1 is a schematic structural diagram of a conventional ceramic foam kiln;
FIG. 2 is a schematic structural diagram of a kiln of the method for controlling the reducing atmosphere of a foamed ceramic kiln disclosed in one embodiment of the present invention;
fig. 3 is a schematic structural diagram of a kiln of the method for controlling the reducing atmosphere of the foamed ceramic kiln, which is disclosed by the other embodiment of the invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.
The invention is described in further detail below with reference to the attached drawing figures:
in order to solve the problems in the prior art, one effective method is to keep the kiln in a reducing atmosphere state before foaming, so as to prevent the surface foaming agent from being oxidized. The invention is provided based on the principle, which is helpful to eliminate the porcelain phenomenon on the surface and improve the surface quality and the yield of cut materials of the foaming ceramic blank.
The invention provides a method for controlling the reducing atmosphere of a foamed ceramic kiln, which comprises the following steps:
a. an upper burner is arranged in the kiln space of the kiln head, and a lower burner is arranged in the kiln shed plate space; the upper burner and the lower burner are positioned on the same vertical surface;
b. a smoke exhaust flue is arranged at the kiln head of the kiln, and the smoke exhaust flue arranged at the kiln head is positioned between the kiln opening of the kiln and an upper burner and a lower burner arranged at the kiln head; a smoke exhaust flue is not arranged between the smoke exhaust flue at the kiln head and the middle section of the foaming section, and one or more smoke exhaust flues are arranged behind the middle section of the foaming section;
c. adjusting the combustor between the preheating section and the middle section of the foaming section to be under-oxygen combustion (namely a reducing atmosphere state) and positive pressure;
d. sand sealing is adopted between the side part of the kiln car filled with the foamed ceramic batch and the inner wall of the kiln;
e. the kiln body of the kiln is welded and sealed by a steel shell.
Further, the oxygen-deficient combustion is that the ratio of fuel and theoretical air is controlled to be 80% -95% in a complete combustion state, and the positive pressure is that the pressure of the kiln is 1 Pa-5 Pa higher than the pressure outside the kiln.
The kiln of the invention performs the above design functions as follows:
in order to create a reducing atmosphere, it is essential to seal the kiln system, and in the case of tunnel kilns, which are commonly used for foamed ceramics, the moving kiln car is sealed with sand to prevent cold air from penetrating into the bottom of the kiln car, thus preventing energy consumption due to convection heat transfer and preventing oxygen from entering. Furthermore, sand sealing is adopted between the side part of the kiln car filled with the foamed ceramic batch and the inner wall of the kiln, so that the sealing of the sintering space of the moving batch is enhanced. The kiln is also sealed during masonry so as to prevent energy loss caused by smoke leakage; because the kiln expands in the heating operation process, the gap existing in the kiln is difficult to eliminate so that air (namely oxygen) permeates, and the kiln body is welded and sealed by a steel shell so as to prevent the air from permeating, and the metal and the welding thereof have good reliability.
The foamed ceramic batch enters from the kiln head, and the kiln head is an open system in order to ensure the entry of the foamed ceramic batch. On the basis of burners arranged in the existing kiln, an upper burner is arranged in the kiln head kiln space, a lower burner is arranged in the kiln shed board space, and when the burners of the kiln head are opened, a flame curtain is formed to prevent air from entering from the kiln head to a certain degree. Furthermore, a smoke exhaust flue is arranged at the kiln head and is positioned at the outer sides of a burner at the upper part of the kiln space and a burner at the lower part of the kiln shed board space, namely the smoke exhaust flue arranged at the kiln head is positioned between the kiln opening of the kiln and the upper burner and the lower burner arranged at the kiln head; due to the suction effect of the smoke exhaust flue, the burning smoke moves towards the kiln mouth, and the air outside the kiln mouth is prevented from permeating into the kiln. Further, the flame curtain is required to be formed effectively so as to ensure that a complete flame blocking curtain is formed; the length of the burner at the upper part of the kiln space and the length of the burner at the lower part of the kiln shed plate space are adjusted by the pressure of the burners, and the flame has a certain width which is adjusted by the number of the burners according to the width of the flame of a single burner. The flame curtain is designed according to the specific size of the kiln, and the skilled person in the art knows how to design. Meanwhile, the pumping force of the smoke exhaust flue arranged on the kiln head is proper, too small smoke exhaust flue can not move to the flue, and too large smoke exhaust flue can deform the fire curtain and can not cover the required blocking area. It is also known in the art to coordinate the setting of the draft of the flue to form a relationship with the fire curtain.
In order to remove the smoke generated by the burner between the kiln head smoke exhaust flue and the middle section of the foaming section, the invention does not arrange the smoke exhaust flue between the kiln head smoke exhaust flue and the middle section of the foaming section, and one or more smoke exhaust flues are arranged behind the middle section of the foaming section; the device ensures that smoke generated between the kiln head smoke exhaust flue and the middle section of the foaming section moves towards the kiln tail direction, and the generated airflow prevents airflow possibly brought in from the kiln tail direction, and has the function of ensuring a kiln head fire curtain.
Because the burners, the observation holes and the like in the kiln cannot be completely sealed, the burners (comprising the burners at the upper part of the kiln space and the burners at the lower part of the kiln shed plate space) between the preheating section and the middle section of the foaming section are adjusted to be micro-under-oxygen combustion and micro-positive pressure, the under-oxygen combustion is 80-95% of the fuel-theoretical air ratio controlled in a complete combustion state, and the positive pressure is that the kiln pressure is 1-5 Pa higher than the external kiln pressure. Only oxygen-deficient combustion can ensure that the kiln atmosphere is a reducing atmosphere, wherein the oxygen-deficient combustion is obtained by setting the ratio of fuel to air; the micro-positive pressure makes the kiln pressure higher than the kiln external pressure, and the air outside the kiln can not be sucked into the kiln.
Further, the fuel-to-air ratio of the burner at the upper part of the kiln space of the kiln head and the burner at the lower part of the kiln shelf space is preferably 80-90% in the theoretical completely-burnt state, and the fuel-to-air ratio of the other burners between the kiln head and the middle section of the foaming section is preferably 90-95% in the theoretical completely-burnt state. In actual operation, black smoke is not emitted as a bottom line.
By the measures of the invention, a kiln reducing atmosphere can be established; those skilled in the art will know how to design and use a particular kiln, and the following examples are representative and not representative of the entirety of this patent.
Example 1:
as shown in figure 2, the invention arranges a smoke exhaust flue 1, a burner at the upper part of the kiln space and a burner at the lower part of the kiln shed plate space on the kiln head, the burner at the upper part of the kiln space and the burner at the lower part of the kiln shed plate space form a fire curtain, and the smoke exhaust flue 1 is arranged between the kiln opening and the burners at the upper part of the kiln space and the burners at the lower part of the kiln shed plate space; a smoke exhaust flue is not arranged between the rear part of the smoke exhaust flue of the kiln head and the middle section of the foaming section, a smoke exhaust flue 2 is arranged behind the middle section of the foaming section, and any smoke exhaust flue 3 is arranged behind the smoke exhaust flue 2 according to smoke exhaust requirements; the burners between the preheating section and the middle section of the foaming section are adjusted to be under-oxygen combustion and positive pressure.
Example 2:
as shown in fig. 3, the invention arranges a smoke exhaust flue 1 at the kiln head, a burner at the upper part of the kiln space at the top and a burner at the lower part of the kiln shed plate space, in view of the height difference of the kiln, in order to prevent the burner at the upper part of the kiln space from blowing the batch, thereby influencing the normal process; the furnace top is raised and provided with a burner channel. The upper burner of the kiln space and the lower burner of the kiln shed board space cooperate to form a fire curtain, and the smoke exhaust flue 1 is positioned between the kiln opening and the upper burner and the lower burner; a smoke exhaust flue is not arranged between the rear part of the smoke exhaust flue of the kiln head and the middle section of the foaming section, the smoke exhaust flue 2 is arranged at the front end of the cooling section, and any smoke exhaust flue 3 is arranged behind the smoke exhaust flue 2 according to smoke exhaust requirements; the burners between the preheating section and the middle section of the foaming section are adjusted to be under-oxygen combustion and positive pressure.
The invention makes the kiln in a reducing atmosphere state before foaming by arranging an upper burner, a lower burner, a smoke exhaust flue and adjusting the burners from a preheating section to a middle section of a foaming section to be under-oxygen combustion and positive pressure, thereby preventing the foaming agent on the surface of the foamed ceramic batch from being oxidized; the method is beneficial to eliminating the porcelain phenomenon on the surface and improving the surface quality and the finished product rate of cut materials of the foamed ceramic blank.
The above is only a preferred embodiment of the present invention, and is not intended to limit the present invention, and various modifications and changes will occur to those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (3)
1. A method of controlling a reducing atmosphere in a ceramic foam kiln, comprising:
an upper burner is arranged in the kiln space of the kiln head, and a lower burner is arranged in the kiln shed plate space;
arranging a smoke exhaust flue at the kiln head of the kiln, not arranging the smoke exhaust flue between the smoke exhaust flue at the kiln head and the middle section of the foaming section, and arranging one or more smoke exhaust flues behind the middle section of the foaming section; the smoke exhaust flue arranged on the kiln head is positioned between the kiln opening of the kiln and the upper burner and the lower burner arranged on the kiln head;
adjusting the combustor between the preheating section and the middle section of the foaming section to be under-oxygen combustion and positive pressure; wherein, the under-oxygen combustion is 80-95% of theoretical air-fuel ratio controlled in a complete combustion state, and the positive pressure is 1-5 Pa higher than the kiln pressure.
2. The method for controlling the reducing atmosphere of a ceramic foam kiln as recited in claim 1, wherein the kiln body of the kiln is sealed by welding with a steel outer shell.
3. The method for controlling the reducing atmosphere of a ceramic foam kiln as recited in claim 1, wherein the side of the kiln car containing the ceramic foam batch is sand sealed to the interior wall of the kiln.
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CN115265212B (en) * | 2022-07-21 | 2023-06-16 | 广州能源检测研究院 | Hydrogen fuel combustion system of ceramic kiln and energy-saving process |
CN115403401B (en) * | 2022-09-02 | 2023-07-11 | 东北大学 | Method for preparing foamed ceramic wallboard based on high-temperature jet process |
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CN102617020A (en) * | 2012-03-02 | 2012-08-01 | 浙江振申绝热科技有限公司 | Process for producing foam glass by using natural gas as fuel and roller kiln used by same |
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CN2830392Y (en) * | 2005-10-26 | 2006-10-25 | 屈培元 | Front mounted sintering channel type foamed glass foaming kiln |
AT513430A1 (en) * | 2012-10-04 | 2014-04-15 | Horst Wustinger | Oven for the heat-induced foaming of particles of a bulk material |
CN204689874U (en) * | 2015-06-15 | 2015-10-07 | 胡斯友 | Full-automatic foam glass foaming kiln |
CN104909547B (en) * | 2015-06-15 | 2017-03-15 | 胡斯友 | The high-efficient energy-saving kiln production line of production high-performance foam glass |
CN205133647U (en) * | 2015-11-02 | 2016-04-06 | 唐山奥特斯科技有限公司 | Energy -efficient tunnel cave of large -scale reduced iron |
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CN102617020A (en) * | 2012-03-02 | 2012-08-01 | 浙江振申绝热科技有限公司 | Process for producing foam glass by using natural gas as fuel and roller kiln used by same |
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