CN111018340B - Flame injection method and system - Google Patents
Flame injection method and system Download PDFInfo
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- CN111018340B CN111018340B CN202010005563.5A CN202010005563A CN111018340B CN 111018340 B CN111018340 B CN 111018340B CN 202010005563 A CN202010005563 A CN 202010005563A CN 111018340 B CN111018340 B CN 111018340B
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B37/00—Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags
- C03B37/01—Manufacture of glass fibres or filaments
- C03B37/06—Manufacture of glass fibres or filaments by blasting or blowing molten glass, e.g. for making staple fibres
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C13/00—Fibre or filament compositions
Abstract
The present invention relates to a flame injection system and method, the system comprising: the system comprises a natural gas station, a natural gas conveying pipeline, a natural gas pressure regulating device and a natural gas flow device; the system comprises a combustion-supporting air station, a combustion-supporting air conveying pipeline, a combustion-supporting air pressure regulating device and a compressed air flow device; the oxygen station, the oxygen conveying pipeline, the oxygen pressure regulating device and the oxygen flow device; the gas premixing device comprises a gas premixing chamber for mixing the natural gas after the pressure and the flow are adjusted and the combustion-supporting gas after the combustion-supporting air and the oxygen are premixed, and a combustion chamber for combusting the mixed gas formed in the gas premixing chamber. The glass microfiber slag ball prepared by the system and the method is low in content.
Description
Technical Field
The invention relates to a flame spraying method and a system for manufacturing glass microfiber, belonging to the field of inorganic non-metallic material manufacturing.
Background
The manufacturing process of the glass fiber is mainly divided into a centrifugal method and a flame blowing method. The glass fibres produced by the centrifugal process generally have an average diameter of 3 to 8 μm, whereas those produced by the flame-blowing process can have an average diameter of up to 0.1 to 2.0. mu.m, and are therefore also referred to as glass microfibres. The glass microfiber has the advantages of small fiber diameter, soft processed product, low heat conductivity coefficient, good sound absorption effect, strong adsorption capacity and the like, and is often used as a material in the aspects of heat insulation, sound absorption, filtration and the like. Depending on the specific field and place of application, the size of the glass microfibers required varies, and for example, when the glass microfibers are used as a thermal insulator for producing a thermal insulation mat, glass microfibers having an average diameter of 1.5 to 2.0 μm are required, and when the glass microfibers are used as a filter material for producing a fiber paper, glass microfibers having an average diameter of 0.1 to 0.5 μm are required.
Although the prior art has made some improvements to the centrifugal process to produce glass fibers having average diameters of 1.5 to 3 μm, it has not achieved the finer aspect of the flame blowing process and the shot content of the glass fibers produced is high. Therefore, for some special applications, such as glass fiber with high shot content requirement, it is still necessary to use flame blowing method for production, i.e. flame blowing method is still widely used in industry.
Referring to fig. 5, a blowing system of a flame blowing method in the prior art specifically includes: the natural gas station comprises a natural gas station, a natural gas conveying pipeline, a natural gas manual pressure regulating valve and a natural gas manual flowmeter, wherein the natural gas manual pressure regulating valve and the natural gas manual flowmeter are sequentially used for regulating the pressure and the flow of natural gas; the system comprises a combustion-supporting air station, a combustion-supporting air conveying pipeline, a combustion-supporting air manual pressure regulating valve and a combustion-supporting air manual flowmeter, wherein the combustion-supporting air manual pressure regulating valve and the combustion-supporting air manual flowmeter are sequentially used for regulating the pressure and the flow of combustion-supporting air; the natural gas and the combustion air after the pressure and the flow are adjusted are respectively conveyed to a gas premixing chamber to be mixed; and the combustion chamber is used for combusting the mixed gas output from the gas premixing chamber.
In practical application, when some glass varieties with higher melting points are treated by the flame injection system, the produced glass fibers have high coarse fiber ratio (causing coarse average diameter) and high shot content. Those skilled in the art have considered that the reason for the above problem is that the temperature of the flame emitted from the injection port of the combustion chamber is low, and therefore, it is necessary to further increase the injection temperature of the flame; and the flow of the natural gas and the combustion air is required to be correspondingly increased when the injection temperature is increased, but the flow corresponding to the injection temperature cannot be reached even if equipment (such as a blower) in an old flame injection system is started to the maximum power. Therefore, only more powerful equipment (such as blowers) can be replaced, and the structure of the combustion chamber is redesigned in order to provide for adequate combustion of the natural gas and combustion air in the combustion chamber. Therefore, the method has the defects of large modification on the existing equipment, large early investment, low energy utilization rate, high production cost and the like in the later use process because a large amount of combustion-supporting air needs to be introduced and is heated from the room temperature to the injection temperature to consume a large amount of heat.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a flame injection method and a system thereof, the method and the system are suitable for preparing glass microfiber by using glass varieties with high melting points as raw materials, the existing system does not need to be greatly modified, the early investment is small, the energy utilization rate is high in the later use process, the production cost is low, the average diameter of the prepared glass microfiber meets the requirement, and the slag ball content is low.
In order to achieve the above object, the present invention provides a flame injection method, comprising the steps of:
the natural gas is conveyed to a gas premixing chamber after the pressure and the flow are regulated;
the combustion-supporting air and the oxygen are respectively mixed after the pressure and the flow are regulated to obtain combustion-supporting gas, and the combustion-supporting gas is conveyed to a gas premixing chamber;
and conveying the mixed gas obtained in the gas premixing chamber to a combustion chamber for combustion.
The pressure before the pressure regulation of the natural gas, the combustion air and the oxygen is respectively 100-300kpa, 300-600kpa and 300-500 kpa; the pressure ratio after adjusting the pressure is (0.8-1): (0.4-0.5): 0.8-1); specifically, the pressure of the natural gas, the combustion air and the oxygen is respectively 80-100kPa,40-50kPa and 80-100 kPa.
The flow ratio of the natural gas, the combustion air and the oxygen after the flow regulation is (0.3-0.8) to (2.5-8) to (0.1-1); preferably, the flow range of the natural gas after the flow regulation is 15-40m3H, more preferably from 25 to 35m3H; the flow range of the combustion air after the flow regulation is 125-400m3H; the flow range of the oxygen after the flow regulation is 5-50m3/h。
The flow ratio and the pressure ratio of the natural gas, the combustion air and the oxygen are controlled by a DCS control system.
The upper temperature limit of the high-temperature airflow sprayed out from the blowing port after being combusted in the combustion chamber can reach 1500-1600 ℃.
The blowing speed of the high-temperature air flow sprayed out from the blowing opening after being combusted in the combustion chamber is 300-500 m/s.
A system for a method of flame injection, comprising:
the natural gas station, the natural gas conveying pipeline, and the natural gas pressure regulating device and the natural gas flow device which are used for regulating the pressure and the flow of the natural gas in sequence;
the system comprises a combustion-supporting air station, a combustion-supporting air conveying pipeline, a combustion-supporting air pressure regulating device and a combustion-supporting air flow device, wherein the combustion-supporting air pressure regulating device and the combustion-supporting air flow device are sequentially used for regulating the pressure and the flow of combustion-supporting air;
the oxygen station, the oxygen conveying pipeline, and the oxygen pressure regulating device and the oxygen flow device which are used for regulating the pressure and the flow of oxygen in turn; the oxygen conveying pipeline behind the oxygen flow device is connected with the combustion air conveying pipeline behind the combustion air flow device so that combustion air and oxygen are mixed in advance to form combustion-supporting gas;
the gas premixing chamber is used for mixing the natural gas with the regulated pressure and flow and the combustion-supporting gas;
and the combustion chamber is used for combusting the mixed gas output from the gas premixing chamber.
The system also includes a DCS control system for adjusting the flow and pressure ratios of the natural gas, combustion air and oxygen.
In the DCS control system, the pressure regulating device and the flow device are execution units in the DCS control system, and the DCS converts parameters (flow ratio and pressure ratio of each gas) input by a user into execution signals and transmits the execution signals to the pressure regulating device and the flow device so as to realize regulation operation.
The natural gas pressure regulating device, the combustion air pressure regulating device and the oxygen pressure regulating device are pressure regulating valves, and the natural gas flow device, the combustion air flow device and the oxygen flow device are flow meters.
The high-melting-point glass varieties mentioned in the invention refer to glass varieties with the blowing temperature not lower than 1500 ℃.
The technical scheme of the invention has the beneficial effects that:
1) the flame injection method of the invention increases the input of oxygen on the basis of the prior art, thereby reducing the input amount of combustion-supporting air, namely reducing the total consumption of combustion-supporting gas (in order to make natural gas fully burn, when the combustion-supporting air is used alone, the volume ratio of the combustion-supporting air to the natural gas needs to be controlled at 10: when oxygen is used alone, the volume ratio of oxygen to natural gas needs to be controlled to be 2: 1) therefore, the input quantity of low-temperature gas and the output quantity of high-temperature gas are reduced, the heat loss is reduced, the energy consumption and the production cost are reduced, the injection temperature is effectively improved, and the problem that the injection temperature can be improved only by replacing and modifying the existing equipment in the prior art is solved.
2) Through updating equipment, such as replacing a blower with higher power, optimizing a structure of a blowing furnace end and the like, the blowing temperature can be improved to a certain extent, and the blowing requirement of glass with high melting point is met, but through intensive research, the inventor of the invention finds that when the method is used, the blowing speed is higher when the blowing temperature meets the requirement, the fiber is thinner, and vice versa, in the prior art, in order to improve the blowing temperature and enable the blowing temperature to meet the blowing requirement, the flow rates of natural gas and combustion-supporting air are correspondingly increased, so that the blowing speed is further improved, the average diameter of the glass microfiber is thin, in order to enable the blown glass microfiber to meet the production requirement according to the specific application field, the monofilament diameter of the previous fiber needs to be increased, and after the diameter of the primary fiber is increased, the blowing requirement can be met only by higher blowing temperature, so that the adjusting process is very complicated, the work efficiency is not improved; meanwhile, the direct harm brought by the improvement of the blowing speed is that the blowing noise is further increased, so that serious noise pollution is caused.
The flame injection system and the method of the invention can achieve the purposes of meeting the injection temperature and the required injection speed by adjusting the flow of natural gas, combustion-supporting air and oxygen because the oxygen input branch is additionally arranged, overcome the defects of complicated adjustment process, increased injection noise and the like of the prior art, and meet the requirements of producing the desired glass microfiber with average diameter and low slag ball content.
Furthermore, by adjusting the flow ratio (volume ratio) of the natural gas, the combustion air and the oxygen to (0.3-0.8) to (2.5-8) to (0.1-1), different injection temperatures and injection speeds can be adjusted according to different melting points (including high melting point and low melting point) of glass varieties, so as to achieve the purpose of producing the glass microfiber which meets the requirements and has low slag ball content and simple adjustment process.
More preferably, the flow rate of the natural gas after flow rate regulation is 15-40m3H, more preferably 25 to 35m3The flow rate of the combustion air after the flow rate is adjusted is 125-400m3The flow rate of the oxygen after adjusting the flow rate is 5-50m3The blowing temperature is increased (can reach 1500-1600 ℃), and the blowing speed can be adjusted within the range of 300-500m/s, thereby meeting the requirements of producing glass microfibers with various sizes and low slag ball content by using high-melting-point glass as a raw material.
3) According to the flame injection method, the pressure ratio of the natural gas, the combustion air and the oxygen after pressure regulation is (0.8-1): (0.4-0.5): (0.8-1), and the pressure ratio is more favorable for fully mixing the combustion air formed by the natural gas, the oxygen and the combustion air in the gas premixing chamber, so that the combustion is more sufficient.
4) The flame injection system of the invention is additionally provided with a group of oxygen supply devices (an oxygen station, an oxygen conveying pipeline, an oxygen pressure regulating device and an oxygen flow device) under the condition of not changing the prior equipment, and the design solves a series of problems in the prior art, including: in order to improve the injection temperature, the flow of the combustion air must be synchronously increased according to the proportion of 10:1 while increasing the natural gas flow, and although the flame injection temperature can be improved by the method, the problems of large engineering quantity, waste of original equipment and large investment are caused by the need of replacing an air blower with larger power and modifying the structure of a combustion chamber; in addition, due to the increase of combustion air, the heat quantity taken away by the waste gas is further increased, so that the energy utilization rate is reduced and the production cost is increased in the injection process.
5) In the prior art, the pressure and the flow of natural gas and combustion-supporting air are manually adjusted through a manual valve, so that the operation difficulty is high, the operation precision is low, and the requirements on the level and experience of an operator are high; the DCS control system is adopted, the pressure regulating device and the flow device are execution units in the DCS control system, and the DCS converts parameters (flow ratio and pressure ratio of each gas) input by a user into execution signals and transmits the execution signals to the pressure regulating device and the flow device so as to realize regulation operation.
6) In the flame injection system, the oxygen conveying pipeline behind the oxygen flow device is not connected with the gas premixing chamber, but is connected with the combustion air conveying pipeline between the combustion air flow meter and the gas premixing chamber, so that the design basically does not change related original equipment, and the flame injection system is simple and convenient and has low cost; in addition, the oxygen and the combustion air are combined in advance, so that the oxygen and the combustion air are fully mixed in the conveying process, the temperature of the blowing flame is more stable, and the diameter distribution of the prepared glass fiber is more uniform.
7) The system and the method are particularly suitable for the reconstruction of old flame injection process lines, and the reconstructed system is not only suitable for high-melting-point glass varieties, but also suitable for low-melting-point glass varieties and has wide application range.
8) By adopting the method and the system, the improvement of the blowing temperature and the adjustment of the blowing speed can be realized under the condition that the total air input is the same as that in the prior art, and various requirements for producing the glass microfiber are met.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
FIG. 1 is a schematic view of a system for use in the flame injection method of the present invention.
FIG. 2 is a schematic diagram of a system and method used in embodiments of the invention.
FIG. 3 is an electron microscope scan of a glass microfiber produced in example 1 of the present invention.
FIG. 4 is an electron microscope scan of the glass fiber obtained in comparative example 1.
FIG. 5 is a schematic view of a system used in a prior art flame injection method.
Detailed Description
The starting materials and equipment used in the following examples are all commercially available.
Referring to fig. 1 and 2, the system used in the flame injection step in the following embodiments includes:
the natural gas station is sequentially connected with a natural gas pressure regulating valve, a natural gas flowmeter and a gas premixing chamber through a natural gas conveying pipeline, and the natural gas pressure regulating valve and the flowmeter are respectively used for regulating the pressure and the flow of natural gas. The combustion-supporting air station is sequentially connected with a combustion-supporting air pressure regulating valve, a combustion-supporting air flow meter and a gas premixing chamber through a combustion-supporting air conveying pipeline, and the combustion-supporting air pressure regulating valve and the combustion-supporting air flow meter are respectively used for regulating the pressure and the flow of combustion-supporting air. The oxygen station is sequentially connected with an oxygen pressure regulating valve, an oxygen flow meter and a combustion air conveying pipeline between the combustion air flow meter and the gas premixing chamber through an oxygen conveying pipeline. The gas premixing chamber is used for fully mixing natural gas and combustion-supporting gas obtained by premixing combustion-supporting air and oxygen. The combustion chamber is used for combusting the mixed gas obtained by mixing in the gas premixing chamber.
The system also comprises a DCS control system used for adjusting the flow ratio and the pressure ratio of the natural gas, the combustion air and the oxygen, wherein each pressure regulating valve and each flowmeter are execution units in the DCS control system, and the DCS system converts the flow ratio and the pressure ratio of each gas into execution signals and transmits the execution signals to each pressure regulating valve and each flowmeter.
Example 1
Preparation of glass microfibers having a Heat resistance temperature of 600 ℃
The raw material components are as follows:
| composition of | SiO2 | Al2O3 | Fe2O3 | MgO | B2O3 | TiO2 |
| Content (%) | 60.0 | 20.0 | 8.0 | 8.0 | 2.0 | 2.0 |
Referring to fig. 2, glass batch is prepared according to the formula requirements, the batch is put into a tank furnace for melting, the melting temperature is controlled at 1550 +/-20 ℃, and glass liquid with stable temperature and good homogenization is formed in a material channel by adopting a mode of mixing and heating electrodes and flame and is conveyed to a bushing; the molten glass passes through a bushing and a bushing nozzle, forms primary fibers with the diameter of 100-300 mu m under the drawing of a rubber covered roll drawing machine, and then is sent to a blowing opening of a combustion chamber through a guide mechanism, and is melted and drawn to be thinned to the required size (the average diameter is 1.5-2.0 microns) to form the glass microfiber.
In the embodiment, 100 holes are selected for the bushing, the hole diameter of the bushing is 1.7mm, the temperature of the bushing is adjusted to 1400 +/-20 ℃, and the linear speed of the wire-leading rubber roller is controlled at 5 m/min.
The pressure before adjusting the pressure of the natural gas, the combustion air and the oxygen is respectively 150kPa, 450kPa and 350kPa, the pressure of the natural gas, the combustion air and the oxygen is adjusted to respectively 98kPa, 50kPa and 98kPa by a DCS control system, and the flow of the combustion air, the oxygen and the natural gas is respectively adjusted to 220m3/h、14m3H and 29m3The blowing temperature reaches 1530-1550 ℃, and the blowing speed is 330 m/s.
The measurement gave glass microfibers having an average diameter of 1.71 μm and a shot content of 0.42% (measured according to the national standard GB/T5480). The heat-resistant temperature of the glass microfibers thus obtained was determined by measuring the thermal load shrinkage temperature of the glass microfibers (measured in accordance with GB/T11835-2016). An electron microscope scan of the glass microfibers produced is shown in FIG. 3.
Example 2
Preparation of glass microfibers having a Heat resistance temperature of 600 ℃
The raw material components are as follows:
| composition of | SiO2 | Al2O3 | Fe2O3 | MgO | B2O3 | TiO2 |
| Content (%) | 60.0 | 20.0 | 8.0 | 8.0 | 2.0 | 2.0 |
Referring to fig. 2, glass batch is prepared according to the formula requirements, the batch is put into a tank furnace for melting, the melting temperature is controlled at 1550 +/-20 ℃, and glass liquid with stable temperature and good homogenization is formed in a material channel by adopting a mode of mixing and heating electrodes and flame and is conveyed to a bushing; the molten glass passes through a bushing and a bushing nozzle, forms primary fibers with the diameter of 100-300 mu m under the drawing of a rubber covered roll drawing machine, and then is sent to a blowing opening of a combustion chamber through a guide mechanism, and is melted and drawn to be thinned to the required size (the average diameter is 1.5-2.0 microns) to form the glass microfiber.
In the embodiment, 100 holes are selected for the bushing, the hole diameter of the bushing is 1.7mm, the temperature of the bushing is adjusted to 1400 +/-20 ℃, and the linear speed of the wire-leading rubber roller is controlled at 5 m/min.
The pressure before adjusting the pressure of the natural gas, the combustion air and the oxygen is respectively 150kPa, 450kPa and 350kPa, the pressure of the natural gas, the combustion air and the oxygen is adjusted to respectively 98kPa, 50kPa and 98kPa by a DCS control system, and the flow of the combustion air, the oxygen and the natural gas is respectively adjusted to 260m3/h、10m3H and 31m3The blowing temperature reaches 1530-1550 ℃ and the blowing speed is 360 m/s.
The measurement results show that the glass microfiber with the average diameter of 1.53 micron and the shot content of 0.28 percent (measured according to the national standard GB/T5480) can be obtained, and the heat-resisting temperature of the prepared glass microfiber can be obtained by measuring the thermal load shrinkage temperature of the glass microfiber (measured according to the GB/T11835-2016).
Example 3
Preparation of glass microfibers having a Heat resistance temperature of 650 ℃
The raw material components are as follows:
| composition of | SiO2 | Al2O3 | MgO | B2O3 | TiO2 |
| Content (%) | 65.0 | 23.0 | 8.0 | 2.0 | 2.0 |
Referring to fig. 2, glass batch is prepared according to the formula requirements, the batch is put into a tank furnace for melting, the melting temperature is controlled to be 1570 +/-20 ℃, and glass liquid with stable temperature and good homogenization is formed in a material channel by adopting a mode of mixing and heating electrodes and flames and is conveyed to a leakage plate; the molten glass passes through a bushing and a bushing nozzle, forms primary fibers with the diameter of 100-300 mu m under the drawing of a rubber covered roll drawing machine, and then is sent to a blowing opening of a combustion chamber through a guide mechanism, and is melted and drawn to be thinned to the required size (the average diameter is 1.5-2.0 microns) to form the glass microfiber.
In the embodiment, 100 holes are selected for the bushing, the hole diameter of the bushing is 1.7mm, the temperature of the bushing is adjusted to 1450 +/-20 ℃, and the linear speed of the wire-leading rubber roller is controlled at 5 m/min.
The pressure before adjusting the pressure of the natural gas, the combustion air and the oxygen is respectively 150kPa, 450kPa and 350kPa, the pressure of the natural gas, the combustion air and the oxygen is adjusted to respectively 96kPa, 45kPa and 96kPa by a DCS control system, and the flow of the combustion air, the oxygen and the natural gas is respectively adjusted to 260m3/h、20m3H and 36m3The temperature of the flame for blowing reaches 1560-1580 ℃, and the blowing speed is 380 m/s.
The measurement results show that the glass microfiber with the average diameter of 1.76 microns and the shot content of 0.33 percent (measured according to the national standard GB/T5480) is obtained, and the heat-resistant temperature of the prepared glass microfiber is obtained by measuring the thermal load shrinkage temperature of the glass microfiber (measured according to GB/T11835-2016).
Example 4
Preparation of glass microfibers having a Heat resistance temperature of 400 ℃
The raw material components are as follows:
| composition of | SiO2 | Al2O3 | CaO | MgO | B2O3 | TiO2 | Na2O |
| Content (%) | 55.0 | 15.0 | 15.0 | 8.0 | 6.0 | 0.5 | 0.5 |
Referring to fig. 2, glass batch is prepared according to the formula requirements, the batch is put into a tank furnace for melting, the melting temperature is controlled to be 1500 +/-20 ℃, and glass liquid with stable temperature and good homogenization is formed in a material channel by adopting a mode of mixing and heating electrodes and flames and is conveyed to a bushing; the molten glass passes through a bushing and a bushing nozzle, forms primary fibers with the diameter of 100-300 mu m under the drawing of a rubber covered roll drawing machine, and then is sent to a blowing opening of a combustion chamber through a guide mechanism, and is melted and drawn to be thinned to the required size (the average diameter is 1.5-2.0 microns) to form the glass microfiber.
In the embodiment, 100 holes are selected for the bushing, the hole diameter of the bushing is 1.6mm, the temperature of the bushing is adjusted to 1280 +/-20 ℃, and the linear speed of the wire-leading rubber roller is controlled at 5 m/min.
The pressure before adjusting the pressure of the natural gas, the combustion air and the oxygen is respectively 150kPa, 450kPa and 350kPa, the pressure of the natural gas, the combustion air and the oxygen is respectively adjusted to 98kPa, 50kPa and 98kPa by a DCS control system, and the flow of the combustion air, the oxygen and the natural gas is respectively adjusted to 210m3/h、6m3H and 24m3The temperature of the blowing flame is 1460-1480 ℃, and the blowing speed is 300 m/s.
The measurement gave glass microfibers having an average diameter of 1.62 μm and a shot content of 0.36% (measured according to the national standard GB/T5480). The heat-resistant temperature of the glass microfibers thus obtained was determined by measuring the thermal load shrinkage temperature of the glass microfibers (measured in accordance with GB/T11835-2016).
The tank furnace process in the above embodiments may be replaced by a crucible process without affecting the practice and effectiveness of the injection method and system of the present invention.
The pressure regulating valve and the flow meter in the above embodiments can also be replaced by a manual pressure regulating valve and a manual flow meter, i.e. by manual regulation without DCS system control, and such replacement can also achieve the main object of the present invention.
Comparative example 1
Preparation of glass microfiber cotton with heat resistance temperature of 600 DEG C
The system used in the flame injection step in this comparative example is shown in FIG. 5.
The raw material components are as follows:
| composition of | SiO2 | Al2O3 | Fe2O3 | MgO | B2O3 | TiO2 |
| Content (%) | 60.0 | 20.0 | 8.0 | 8.0 | 2.0 | 2.0 |
Preparing a glass batch according to the formula requirement, putting the glass batch into a tank furnace for melting, controlling the melting temperature to be 1550 +/-20 ℃, forming glass liquid with stable and good homogenization temperature in a material channel by adopting a mixed heating mode of electrodes and flames, and conveying the glass liquid to a leakage plate; the molten glass passes through a bushing and a bushing nozzle, forms primary fibers with the diameter of 100-300 mu m under the drawing of a rubber covered wire drawing machine, and then is sent to a blowing opening of a combustion chamber through a guide mechanism, and is melted and drawn down to the desired size (the desired average diameter is 1.5-2.0 microns) to form glass fibers.
The bushing plate is selected to have 100 holes, the hole diameter of the bushing plate is 1.7mm, the temperature of the bushing plate is adjusted to 1400 +/-20 ℃, and the linear speed of the wire-leading rubber roller is controlled to be 5 m/min.
The pressures before the natural gas and combustion air regulation pressure were 150kPa and 450kPa respectively, and after the pressure was manually regulated, the pressures were 98kPa and 50kPa respectively, due to equipment limitations (the maximum combustion air flow rate that can be provided by the blower was 310 m)3H) the maximum flow of combustion air is 310m3H, correspondingly adjusting the flow rate of the natural gas to be 31m3The temperature of the blowing flame can only reach 1470 ℃ and 1490 ℃, and the blowing speed is 430 m/s.
As can be seen from FIG. 4, the blown glass fibers contain a large amount of coarse fibers, and the glass fibers with an average diameter of 2.6 microns and a shot content of up to 6.7 percent (measured according to the national standard GB/T5480) are obtained through measurement, and the heat resistance temperature of the prepared glass microfibers is obtained through measurement of the thermal load shrinkage temperature of the glass fibers (measured according to GB/T11835-2016).
Comparative example 2
Preparation of glass microfiber cotton with heat resistance temperature of 600 DEG C
The system used in the flame injection step in this comparative example is shown in FIG. 5.
The comparative example adopts a modified production line, comprising a combustion chamber, a pipeline, a blower and the like which are modified, and the maximum flow of combustion air can reach 400m3/h。
The raw material components are as follows:
| composition of | SiO2 | Al2O3 | Fe2O3 | MgO | B2O3 | TiO2 |
| Content (%) | 60.0 | 20.0 | 8.0 | 8.0 | 2.0 | 2.0 |
Preparing a glass batch according to the formula requirement, putting the glass batch into a tank furnace for melting, controlling the melting temperature to be 1550 +/-20 ℃, forming glass liquid with stable and good homogenization temperature in a material channel by adopting a mixed heating mode of electrodes and flames, and conveying the glass liquid to a leakage plate; the molten glass passes through a bushing and a bushing nozzle, forms primary fibers with the diameter of 100-300 mu m under the drawing of a rubber covered wire drawing machine, and then is sent to a blowing opening of a combustion chamber through a guide mechanism, and is melted and drawn down to the desired size (the desired average diameter is 1.5-2.0 microns) to form glass fibers.
The bushing plate is selected to have 100 holes, the hole diameter of the bushing plate is 1.7mm, the temperature of the bushing plate is adjusted to 1400 +/-20 ℃, and the linear speed of the wire-leading rubber roller is controlled to be 5 m/min.
Natural gas and combustion-supporting airThe pressure before pressure adjustment was 150kPa and 450kPa, respectively, the pressure after manual pressure adjustment was 98kPa and 50kPa, respectively, and the flow rate of combustion air was 380m3H, correspondingly adjusting the flow rate of the natural gas to 38m3The temperature of the injected flame reaches 1530-1550 ℃, and the injection speed is 480 m/s.
It was measured to obtain glass microfibers having an average diameter of 1.32 microns (which is smaller than the desired size) and a shot content of 0.44% (measured according to the national standard GB/T5480). The heat-resistant temperature of the glass microfibers thus obtained was determined by measuring the thermal load shrinkage temperature of the glass microfibers (measured in accordance with GB/T11835-2016).
Comparative example 3
The system used in the flame injection step of this comparative example was the same as that of comparative example 1.
Preparation of glass microfibers having a Heat resistance temperature of 650 ℃
The raw material components are as follows:
| composition of | SiO2 | Al2O3 | MgO | B2O3 | TiO2 |
| Content (%) | 65.0 | 23.0 | 8.0 | 2.0 | 2.0 |
Preparing glass batch according to the formula requirements, putting the glass batch into a tank furnace for melting, controlling the melting temperature to be 1570 +/-20 ℃, forming glass liquid with stable temperature and good homogenization in a material channel by adopting a mode of mixing and heating electrodes and flames, and conveying the glass liquid to a leakage plate; the molten glass passes through a bushing and a bushing nozzle, forms primary fibers with the diameter of 100-300 mu m under the drawing of a rubber covered wire drawing machine, and then is sent to a blowing opening of a combustion chamber through a guide mechanism, and is melted and drawn down to the desired size (the desired average diameter is 1.5-2.0 microns) to form glass fibers.
In the embodiment, 100 holes are selected for the bushing, the hole diameter of the bushing is 1.7mm, the temperature of the bushing is adjusted to 1450 +/-20 ℃, and the linear speed of the wire-leading rubber roller is controlled at 5 m/min.
The pressures before the natural gas and combustion air pressure regulation are respectively 150kPa and 450kPa, the pressures after the pressure regulation by the manual pressure regulating valve are respectively 96kPa and 45kPa, and due to equipment limitation (the maximum combustion air flow rate which can be provided by the blower is 310 m)3H) the maximum flow of combustion air is 310m3H, correspondingly adjusting the flow rate of the natural gas to be 31m3The temperature of the blowing flame can only reach 1470 ℃ and 1490 ℃, and the blowing speed is 430 m/s.
The measurement results show that the glass fiber with the average diameter of 3.5 microns and the shot content of up to 7.8 percent (measured according to the national standard GB/T5480) is obtained, and the heat-resistant temperature of the prepared glass microfiber is obtained by measuring the thermal load shrinkage temperature of the glass fiber (according to GB/T11835-2016).
Comparative example 4
Preparation of glass microfibers having a Heat resistance temperature of 400 ℃
The system used in the flame injection step of this comparative example was the same as that of comparative example 1.
The raw material components are as follows:
| composition of | SiO2 | Al2O3 | CaO | MgO | B2O3 | TiO2 | Na2O |
| Content (%) | 55.0 | 15.0 | 15.0 | 8.0 | 6.0 | 0.5 | 0.5 |
Preparing glass batch according to the formula requirements, putting the glass batch into a tank furnace for melting, controlling the melting temperature to be 1500 +/-20 ℃, forming glass liquid with stable temperature and good homogenization in a material channel by adopting a mode of mixing and heating electrodes and flames, and conveying the glass liquid to a leakage plate; the molten glass passes through a bushing and a bushing tip, is drawn by a rubber-covered wire drawing machine to form primary fibers with a diameter of 100-300 μm, and is then fed through a guide mechanism into a blowing opening of a combustion chamber where it is melted and drawn down to a desired size (desired average diameter of 1.5-2.0 μm to form glass microfibers).
In the embodiment, 100 holes are selected for the bushing, the hole diameter of the bushing is 1.6mm, the temperature of the bushing is adjusted to 1280 +/-20 ℃, and the linear speed of the wire-leading rubber roller is controlled at 5 m/min.
The pressure before the pressure adjustment of the natural gas and the combustion air is respectively 150kPa and 450kPa, the pressure of the natural gas and the pressure of the combustion air are manually adjusted to respectively 98kPa and 50kPa, and the flow rates of the combustion air and the natural gas are respectively adjusted to 300m3H and 30m3The temperature of the blowing flame reaches 1460-1480 ℃, and the blowing speed is 410 m/s.
The measurement results show that the glass microfiber with the average diameter of 1.58 microns and the shot content of 0.35 percent (measured according to the national standard GB/T5480) is obtained, and the heat-resistant temperature of the prepared glass microfiber is obtained by measuring the thermal load shrinkage temperature of the glass microfiber (measured according to GB/T11835-2016).
As can be seen from the comparison of example 1 with comparative examples 1 and 2, when glass microfibers having a heat resistant temperature of 600 ℃ are blown, the maximum flow rate of combustion air can be only up to 310m using the prior art due to the limited blower capacity3H, so that the natural gas flow can only be increased to 31m at most3The blowing temperature is low, the average diameter of the produced glass microfiber is thick, and the shot content is high; comparative example 2 the flow rates of natural gas and combustion air were increased by replacing and upgrading the equipment in the system to bring the blowing temperature to the desired temperature, but the average diameter of the glass microfibers produced was smaller than the desired size due to the corresponding increase in blowing speed, and could not better meet the product production requirements under the existing process conditions. After the technology of the invention is adopted, under the condition that hardware equipment (including an air blower, a combustion chamber and the like) is not changed, the temperature of the blowing flame is increased and the proper blowing speed is matched, so that the blowing requirement of the glass microfiber is met, and the qualified glass microfiber is produced.
Comparison of example 3 with comparative example 3 shows that when glass microfibers having a heat resistant temperature of 650 ℃ are blown, the use of the prior art is natural due to limited blower capacityThe maximum air flow can only be increased to 31m3The blowing temperature is lower, the average diameter of the produced glass fiber is thicker, and the slag ball content is higher; after the technology of the invention is adopted, under the condition that hardware equipment (including a fan, a combustion chamber and the like) is not changed, the temperature of the blowing flame is increased by increasing the oxygen consumption, and the proper blowing speed is matched, so that the blowing requirement of the glass microfiber is met, and qualified glass fiber cotton is produced.
Compared with the comparative example 4, the comparison of the example 4 and the comparative example 4 shows that when the glass microfiber with the heat resistance temperature of 400 ℃ is blown (the blowing temperature is lower than 1500 ℃, so the glass microfiber belongs to low-melting-point glass), although the product produced by adopting the prior art meets the production requirement, compared with the technology of the invention, the same glass microfiber blown by the prior art needs to consume more natural gas and combustion-supporting air, so the production cost is higher, compared with the prior art, the invention is beneficial to energy conservation and emission reduction, not only can reduce the production cost, but also can reduce the pollution to the environment in the production process.
It should be understood that the above examples are only for clarity of illustration and are not intended to limit the embodiments. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. And obvious variations or modifications therefrom are within the scope of the invention.
Claims (10)
1. A method of flame injection comprising the steps of:
the natural gas is conveyed to a gas premixing chamber after the pressure and the flow are regulated;
the combustion-supporting air and the oxygen are respectively mixed after the pressure and the flow are regulated to obtain combustion-supporting gas, and the combustion-supporting gas is conveyed to a gas premixing chamber;
delivering the mixed gas obtained in the gas premixing chamber to a combustion chamber for combustion;
wherein, the flow ratio of the natural gas, the combustion air and the oxygen after the flow regulation is (0.3-0.8) to (2.5-8) to (0.1-1);
the flow range after the flow of the natural gas is adjusted is 15-40 m/h, and the flow range after the flow of the combustion air is adjusted is 400 m/h; and carrying out oxygen regulation on the flow rate, wherein the flow rate range is 5-50 m/h.
2. The method according to claim 1, wherein the natural gas flowrate ranges from 25 to 35m during a year.
3. The method as claimed in any one of claims 1-2, wherein the upper temperature limit of the high-temperature air stream ejected from the injection port after combustion in the combustion chamber is up to 1500-.
4. The method as claimed in any one of claims 1-2, wherein the blowing speed of the high-temperature air flow ejected from the blowing port after combustion in the combustion chamber is 300-500 m/s.
5. The method according to any one of claims 1-2, wherein the natural gas, combustion air and oxygen are adjusted to a pressure ratio of (0.8-1): 0.4-0.5): 0.8-1.
6. The method according to claim 5, wherein the pressure of the natural gas, the combustion air and the oxygen after the pressure adjustment is 80-100kPa,40-50kPa,80-100kPa, respectively.
7. The method according to any one of claims 1-2, wherein the flow ratio and pressure ratio of natural gas, combustion air and oxygen are controlled by a DCS control system.
8. The method of claim 7, wherein the flame injection method is employed with a system comprising:
the natural gas station, the natural gas conveying pipeline, and the natural gas pressure regulating device and the natural gas flow device which are used for regulating the pressure and the flow of the natural gas in sequence;
the system comprises a combustion-supporting air station, a combustion-supporting air conveying pipeline, a combustion-supporting air pressure regulating device and a combustion-supporting air flow device, wherein the combustion-supporting air pressure regulating device and the combustion-supporting air flow device are sequentially used for regulating the pressure and the flow of combustion-supporting air;
the oxygen station, the oxygen conveying pipeline, and the oxygen pressure regulating device and the oxygen flow device which are used for regulating the pressure and the flow of oxygen in turn; the oxygen conveying pipeline behind the oxygen flow device is connected with the combustion air conveying pipeline behind the combustion air flow device so that combustion air and oxygen are mixed in advance to form combustion-supporting gas;
the gas premixing chamber is used for mixing the natural gas with the regulated pressure and flow and the combustion-supporting gas;
and the combustion chamber is used for combusting the mixed gas output from the gas premixing chamber.
9. The method of claim 8, wherein the system further comprises a DCS control system for adjusting the flow and pressure ratios of natural gas, combustion air and oxygen.
10. The method according to claim 8 or 9, wherein the natural gas pressure regulating device, the combustion air pressure regulating device and the oxygen pressure regulating device are all pressure regulating valves, and the natural gas flow device, the combustion air flow device and the oxygen flow device are all flow meters.
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| US7089745B2 (en) * | 2002-10-10 | 2006-08-15 | Lpp Combustion, Llc | System for vaporization of liquid fuels for combustion and method of use |
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| CN2199435Y (en) * | 1994-06-23 | 1995-05-31 | 日照市建材总厂 | Fuel gas blowing burner |
| CN1986463A (en) * | 2005-12-21 | 2007-06-27 | 约翰斯曼维尔公司 | Burner apparatus and methods for making inorganic fibers |
| CN101626985A (en) * | 2006-12-18 | 2010-01-13 | 圣戈班研究公司 | The ring flame stove that is used for fiberglass |
| CN201923949U (en) * | 2010-12-20 | 2011-08-10 | 巨石集团有限公司 | Glass fiber tank furnace capable of realizing oxygen reinforced combustion |
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