CN115707757A - Method for ceramic welding repair of furnace wall of deep vertical flue of coke oven carbonization chamber - Google Patents
Method for ceramic welding repair of furnace wall of deep vertical flue of coke oven carbonization chamber Download PDFInfo
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- CN115707757A CN115707757A CN202110948148.8A CN202110948148A CN115707757A CN 115707757 A CN115707757 A CN 115707757A CN 202110948148 A CN202110948148 A CN 202110948148A CN 115707757 A CN115707757 A CN 115707757A
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- 239000000919 ceramic Substances 0.000 title claims abstract description 184
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Abstract
The invention discloses a method for ceramic welding repair of a furnace wall of a deep vertical flue of a carbonization chamber of a coke furnace, which comprises the following steps: pushing out the coke in the carbonization chamber; manufacturing a heat preservation and insulation device according to the width of a coke oven carbonization chamber; the furnace door frame on the upper part of the heat preservation and insulation device, the non-overhaul part and the exposed furnace wall are all insulated by adopting ceramic fiber blankets; opening a ventilation device of the heat preservation and insulation device, and allowing constructors to enter the heat preservation and insulation device to clean residues such as fire clay and graphite on furnace wall bricks of the carbonization chamber; sweeping the cleaned furnace wall, and then performing ceramic welding repair on the deep vertical flame path; the heat preservation and insulation device is dismantled and taken out after the furnace wall is welded and repaired by the ceramic; the method ensures that the furnace wall of the vertical flue at the deep part of the coking chamber of the coke furnace can be effectively repaired, is beneficial to improving the temperature of the coke furnace, ensures the temperature coefficient of the transverse row, can reduce the heat consumption of the coke furnace, reduces the temperature of the standard vertical flue, improves the temperature of the vertical flue and ensures the quality of coke.
Description
Technical Field
The invention relates to the technical field of repair and sealing of a furnace wall of a coke oven carbonization chamber, in particular to a method for ceramic welding repair of the furnace wall of a deep vertical flue of the coke oven carbonization chamber.
Background
In the normal production operation process of the coke oven, along with the increase of the furnace age, the temperature change of the oven wall of the coking chamber of the coke oven at the oven head part caused by repeated coal charging and coke pushing operations, the oven door is taken off and put on the production process, the mechanical stress and the physicochemical action generated during coke pushing cause the oven wall of the coke oven to generate denudation and pitted surface, the graphite accumulated on the surface of the damaged oven wall generates carburization on the oven wall brick of the coking chamber, the surface of the oven wall is further stripped, and the problems of denudation, pitted surface, crack, leakage, perforation and the like of the oven head and the oven wall of the coke oven (the oven head is 1-4 vertical flame paths and is 1-2 meters away from the oven door) are caused by a series of influences. The furnace wall damage at the positions has been treated by relatively abundant technologies and experiences after long-time accumulation, and has relatively good treatment effect, such as: furnace wall patching, semi-dry spray patching, ceramic welding patching, etc.
However, the problems of denudation, pitted surface, cracks, leakage, perforation and the like gradually appear in deep vertical flues of carbonization chambers of large-scale coke ovens and stamp-charging coke ovens, each combustion chamber of the large-scale coke ovens and stamp-charging coke ovens has 32-36 vertical flues, 16-18 vertical flues are also arranged at the farthest position no matter the machine side or the coke side is processed, and the distance is 8-9 meters. Based on the conditions that the deep vertical flue is far away and difficult to cool, the treatment method for the problems occurring on the furnace end and the furnace wall is adopted as follows: the wet plastering method, the furnace wall excavating method, the semi-dry spray-repairing sealing method and the like have great limitations and cannot be effectively treated. The adopted ceramic welding repair is the only treatment method at present, but a water jacket welding gun is required to be used, the welding gun is cooled by water for welding repair, and the problem and the limitation of the adoption of the water jacket welding gun are also caused:
1. the water jacket welding gun is used for penetrating into 16-18 vertical flame paths, the depth is 8-9 meters, at least 2 meters are required to be outside the furnace, so that the length of the welding gun is at least 10-11 meters, a coke pushing car and a coke guide car are required to be used for feeding the welding gun into a carbonization chamber on a coke oven machine side and a coke side walking platform, and the welding gun is frequently used, thereby bringing great difficulty to overhaul, and being impossible to meet the conditions especially under the full-load production condition of the coke oven.
2. The cooling water is used, which brings difficulty to the construction.
3. Using a 10-odd long welding gun, the quality cannot be guaranteed by remote welding.
4. The damaged furnace wall cannot be cleaned in the long-distance construction, and the repair quality is difficult to ensure.
The analysis shows that the furnace wall of the machine and coke square coke chamber can not use a long welding gun of a water jacket to weld and repair the ceramic of the furnace wall of the deep vertical flame path in principle due to the limitation of maintenance time and site space and considering the construction efficiency and construction safety factors. The long welding gun of the water jacket is inconvenient to move and cannot avoid a coming locomotive in time, and the normal production organization of the coke oven cannot meet the requirement of overhauling the long welding gun of the water jacket. Therefore, at present, no method for effectively treating the deep vertical fire channel exists.
Disclosure of Invention
The invention aims to provide a method for ceramic welding repair of a furnace wall of a vertical flue at the deep part of a coke oven carbonization chamber, which solves the problems in the prior art, ensures that the furnace wall of the vertical flue at the deep part of the coke oven carbonization chamber can be effectively repaired, is favorable for improving the temperature of a coke oven, ensures the temperature coefficient of transverse rows, can reduce the heat consumption of the coke oven, reduces the temperature of a standard vertical flue, improves the temperature of the vertical flue and ensures the quality of coke.
In order to achieve the purpose, the invention provides the following scheme:
the invention provides a method for ceramic welding repair of a furnace wall of a deep vertical flue of a carbonization chamber of a coke furnace, which comprises the following steps:
pushing out coke in a carbonization chamber to ensure that the coke is in an empty state before repair welding; when the ceramic welding repair is carried out on the furnace wall of the vertical flue at the deep part of the machine side or the coke side, constructors need to enter the carbonization chamber for ceramic welding repair construction, can carry out short-distance welding repair, ensure the construction quality, do not influence the forward and backward movement of a coke oven locomotive, and do not need to provide independent maintenance time;
step two, manufacturing a heat preservation and insulation device which can be quickly pushed into the carbonization chamber and quickly taken out according to the specific situation of the width of the carbonization chamber of the coke oven; the iron cage is manufactured according to the specific condition of the width of the coke oven carbonization chamber, is convenient to install and dismantle, and can ensure the heat preservation and insulation effects and construction. The length of the iron cage is 2 meters and the height is 1.9 meters under the general condition, the width is determined according to the width of the carbonization chamber, the iron cage can be quickly pushed into the carbonization chamber and quickly taken out, the construction is convenient, and 6 groups of iron cages are needed at most; the ceramic welding-repair deep vertical flue furnace wall needs to adopt a special heat-preservation and heat-insulation device, and the heat-preservation and heat-insulation device adopts a zirconium-containing ceramic fiber blanket for heat insulation. Because the common ceramic fiber blanket contains a large amount of slag balls and short fibers, the content of the common ceramic fiber slag balls is about 20 percent, the ceramic fibers are slender and 4.5 mu m, the space in the heat preservation and insulation device is narrow during construction, constructors need to work by sticking the ceramic fiber blanket, a large amount of slag balls and fibers are attached to the constructors, the conditions of skin itching, pricking pain and the like are caused, the cleaning is difficult, the health of the constructors is harmful, and the operation requirements can not be met. The zirconium-containing ceramic fiber blanket used by people has low slag ball content which is less than or equal to 12 percent in general, the zirconium-containing ceramic fiber is slender and 4 mu m, has good toughness and high strength, and the problems of skin itching, prickling and the like do not occur to staff after practical use;
thirdly, the furnace door frame on the upper part of the heat preservation and insulation device adopts a ceramic fiber blanket for heat preservation and insulation, the mode of hanging a heat insulation curtain cannot be adopted for heat insulation, the sealing effect of the heat insulation curtain is poor, the furnace wall is damaged due to too fast temperature reduction of the coke oven, in addition, the two sides of the heat insulation curtain are not sealed, the protection plate and the furnace door frame are easy to burn out due to high-temperature heat radiation of a carbonization chamber, the deformation of a furnace protection iron part is seriously caused, the overhauled part and the exposed furnace wall are all subjected to heat preservation by adopting the ceramic fiber blanket, and the heat preservation thickness is 40-50mm;
opening a ventilation device of the heat preservation and insulation device, allowing constructors to enter the heat preservation and insulation device, and cleaning residues such as fire clay and graphite on the wall bricks of the carbonization chamber; the ventilation device comprises a ventilation pipeline, each section of the ventilation pipeline is about 2.2m long and slightly longer than each section of the heat preservation and insulation device, so that splicing and installation are facilitated, and 6 sections are needed at most. The head of the first section of pipeline is provided with a special nozzle of my department as an air outlet, the air outlet of the nozzle is aligned to the upper part of constructors during installation, compressed air is introduced during construction, and air is blown towards the direction of the constructors. Compressed air is sprayed out through the spray head, rotating airflow is formed at the head and the upper part of the body of a constructor, the airflow distribution range is proper and uniform, the influence of hot airflow and heat radiation on the body of the constructor can be effectively isolated, the constructor can be cooled more effectively, and meanwhile, the constructor is guaranteed to have sufficient oxygen supply;
and step five, blowing and cleaning the cleaned furnace wall by using compressed air, and in order to ensure good combination of the ceramic soldering material and the brick surface, performing necessary cleaning on residues such as fire clay, graphite and the like on the furnace wall brick of the carbonization chamber before ceramic soldering is started every time, and cleaning the damaged furnace wall by using the vibration hammer in the department of patents to ensure the cleaning effect. After the surface of the furnace wall of the carbonization chamber is cleaned by the vibration hammer, the cleaned furnace wall is swept by compressed air, and then ceramic welding repair of the deep vertical flame path is carried out. The compressed air can not sweep the furnace wall for a long time so as to avoid secondary damage of the furnace wall caused by too fast local temperature reduction; then ceramic welding repair is carried out on the deep vertical flame path, the temperature of the furnace wall of the carbonization chamber is guaranteed to be maintained in the ceramic welding repair operation process, the temperature of the furnace wall of a repair area is more than or equal to 700 ℃, the temperature of the furnace wall of a non-repair area is more than or equal to 900 ℃, if the temperature of the furnace wall is lower than the set temperature, the temperature is firstly increased, and the temperature of the furnace wall reaches more than 700 ℃ and then ceramic welding repair is carried out;
step six, dismantling and taking out the heat preservation and insulation device after repairing the furnace wall by ceramic welding; after the furnace wall is welded and repaired by ceramic, the furnace wall of the carbonization chamber is heated, and the spring pressure of the iron part of the furnace protection is measured and adjusted periodically in the heating process; and (3) charging coal after the temperature of the standard vertical flame path reaches the standard, observing the flaming and leakage conditions of the vertical flame paths of the combustion chambers at two sides of the coking chamber after the coal is charged, and timely processing if problems exist.
The ceramic repair welding overhaul furnace number must be cooled and controlled: (1) the overhaul furnace number is an empty furnace, and if the combustion chambers at the two sides of the overhaul furnace number burn blast furnace gas, the burn coke furnace gas is converted to burn coke furnace gas, so that the overhaul furnace number temperature is controlled conveniently; (2) and (3) erecting a flame path for stopping heating in the period of overhauling the combustion chambers at two sides of the overhauling furnace number, and controlling the temperature of the flame path erected at the furnace end at the machine coke side to be not lower than 900 ℃. If the temperature is lower than the target value, starting the cock and raising the temperature; (3) the adjacent coking chambers on the two sides of the overhaul furnace number do not push coke during the overhaul period, the coking time needs to be prolonged, and the temperature control of the vertical flame path of the combustion chamber, which is alternated with the normal coking chamber, is determined by fire regulators according to the comprehensive consideration of the conditions of overhaul, temperature, production organization and the like. The temperature of the furnace wall of the carbonization chamber is guaranteed to be maintained in the ceramic welding operation process: the furnace wall temperature of the repair area is more than or equal to 700 ℃, the furnace wall temperature of the non-repair area is more than or equal to 900 ℃, if the furnace wall temperature is too low, the temperature is raised firstly, and the furnace wall temperature reaches more than 700 ℃ before ceramic welding repair is carried out.
Optionally, in the second step, the heat preservation and insulation device comprises a plurality of iron cages with cubic structures, a small platform needs to be installed or erected before a furnace mouth of the carbonization chamber is overhauled, the iron cages are convenient to install and work at the furnace mouth, the iron cages are manufactured on site, the width of the iron cages is generally about 400mm, the iron cages are specifically determined according to the actual width of the carbonization chamber, and therefore the iron cages are convenient to install and disassemble and can guarantee heat preservation and insulation effects and construction, communicating channels are formed in the front and rear ends of the iron cages, stainless steel wire meshes cover the two sides and the top of each communicating channel of the iron cages, zirconium-containing ceramic fiber blankets are fixedly wrapped on the outer sides of the stainless steel wire meshes, the content of ceramic fiber slag balls is about 20%, the content of ceramic fibers is 4.5 micrometers, the slag balls is high in content and the fibers are thick, a large number of slag balls and fibers are attached to bodies of operators during construction, the conditions of itching and stabbing pain of skin are caused and are difficult to clean, harmful to health, and the operation requirements cannot be met. The zirconium-containing ceramic fiber blanket has low shot content which is less than or equal to 12 percent under the general condition, so the fiber blanket can be used next to skin without causing the feeling of skin itch under the general condition. The zirconium-containing ceramic fiber is long and thin and has the length of 4 mu m, good toughness, high strength, convenient use and convenient construction; the technical parameters of the selected zirconium-containing ceramic fiber blanket are as follows:
1) Classification temperature (. Degree. C.): 1400
2) Thermal conductivity W/(m.k) (128 kg/m) 3 ) (average 500 ℃ C.): less than or equal to 0.153
3) Heating permanent line change (%): x is more than or equal to-3 at 1350 ℃ for 24h
4) Tensile strength (Mpa) (thickness 25 mm): not less than 0.06
5) Fiber diameter (μm): 4
6) Shot content (%) (∞ ≥ 0.212 mm): 12
7) The main chemical components are as follows:
A1 2 0 3 ：≥36％
Si0 2 ：≥48％
Zr O 2 ：≥15％
Fe 2 0 3 ：≤0.1％；
AL 2 O 3 +SiO 2 +Zr O 2 ：99％；
the top of the iron cage is of a smooth arched surface structure, so that the strength of the top of the device is guaranteed, the risk that the device is damaged or even injured by crashing due to the falling of graphite and bricks at the top is prevented, the top space of the device is enlarged, and a space is reserved for erecting a ventilating duct. The bottom surface of the iron cage is also required to be padded with a zirconium-containing ceramic fiber blanket after the device is pushed into a carbonization chamber during construction so as to achieve the heat insulation effect.
Optionally, in the fourth step, the ventilation device includes a ventilation duct horizontally arranged in the iron cage, and the ventilation duct is located below the top of the iron cage; the tail end of the ventilation pipeline is in threaded connection with an air nozzle close to the position of a constructor.
Optionally, the air nozzle includes with air pipe fixed connection's air inlet, air inlet keeps away from air pipe's one end intercommunication has the shower nozzle body, shower nozzle body one end is connected with the nozzle, and the sealed threaded connection of the other end has the back lid, this internal fixed water conservancy diversion piece that is provided with of shower nozzle, seted up a plurality of water conservancy diversion holes on the water conservancy diversion piece, the water conservancy diversion piece be located the nozzle with between the air inlet.
Optionally, the flow guide holes include six first flow guide holes uniformly arranged on the flow guide plate in a surrounding manner and a second flow guide hole located at the center of the flow guide plate; the second flow guide hole is of a vertical horn mouth-shaped structure, the diameter of the upper end of the second flow guide hole is 12mm, and the diameter of the lower end of the second flow guide hole is 7.5mm; first water conservancy diversion hole includes the upper portion passageway of horn mouth form and the lower part passageway that the slope set up, the degree of depth of upper portion passageway is 5mm, the top diameter of upper portion passageway is 12mm, and the bottom diameter of upper portion passageway is 7.5mm, upper portion passageway bottom with lower part passageway top intercommunication, the lower part passageway diameter is 7.5mm, just the lower part passageway is the inclined hole structure that degree of depth 10mm, gradient are 30 degrees.
Optionally, the flow deflector is disposed at the air inlet at the top of the nozzle, the diameter of the maximum position of the air inlet at the upper part of the nozzle is 50mm, the upper part of the nozzle is of a bell-mouth-shaped structure with gradually reduced diameter, the narrowest part of the diameter of the upper part of the nozzle is 15mm, the diameter of the lower part of the nozzle is gradually enlarged, and the diameter of the air outlet at the lowest part of the lower part of the nozzle is 25mm. When the nozzle is used, compressed air flows into the nozzle body from the air inlet and then enters the nozzle through the 7 flow guide holes of the flow guide sheet. When the compressed air passes through the 6 first flow guide holes, the compressed air is pressurized through the horn mouth of the upper half part, then the air is guided through the inclined holes of the lower half part to form a vortex rotating anticlockwise, and then the compressed air enters the nozzle under the action of pressure. The rotary vortex is gradually pressurized in the bell mouth at the upper half part of the nozzle and then is sprayed out through the positive bell mouth at the lower part of the nozzle to form rotary airflow. Like this, the rotatory air current of coniform is formed to air through air shower nozzle spun in constructor top, and is more suitable and even in constructor's head and health upper portion air distribution range, can effectively completely cut off the influence of hot gas flow and thermal radiation to the constructor health, carries out more effective cooling to the operating personnel, guarantees simultaneously that constructor has abundant oxygen supply.
Optionally, the existing ceramic welding material suitable for the coke oven contains combustible silicon and aluminum, and the combustible in the ceramic welding material of our deep vertical flue does not contain aluminum, for the following main reasons: 1) Aluminum in the original ceramic welding material is mainly used for promoting the combustion of the welding material, the temperature of a furnace wall of the deep vertical flue is higher than that of a furnace end, materials are easier to combust and melt, and aluminum does not need to be added. 2) Because the furnace wall temperature of the vertical flue at the deep part of the carbonization chamber is higher, the ceramic welding material is required to have higher refractoriness under load, and the alumina contained in the aluminum-containing ceramic welding material after sintering reduces the refractoriness under load, thereby not meeting the use requirement. 3) The ignition point of aluminum is low, so that the use of the aluminum-containing ceramic welding material in a high-temperature area at a short distance has a great risk, and the ceramic welding material cannot contain aluminum when the furnace wall is welded and repaired by the ceramic of the deep vertical flame path. Because the conveying distance of the deep vertical flame path is longer, larger granularity is not beneficial to long-distance conveying, the average granularity of the ceramic welding repair material is correspondingly required to be correspondingly reduced, and meanwhile, on the basis of improving a mixer, the granularity range is finally selected to be 0.1-2mm in order to ensure the conveying quantity and the conveying speed of the deep flame path welding repair; the ceramic welding material for the deep vertical flame path welding material comprises the following components in percentage by weight: 45 to 58 parts of fused quartz with the granularity of 0.1 to 2mm, 16 to 22 parts of electrically fused white corundum with the granularity of 0.04 to 0.1mm, 20 to 32 parts of calcium-stabilized zirconia with the granularity of less than 100 meshes and 6 to 10 parts of metallic silicon powder with the granularity of 300 to 500 meshes.
Optionally, the discharge amount of a mixer used for deep vertical flue repair welding is 30 kilograms per hour; the pressure of oxygen is 0.15-0.2 MPa; the mixer comprises a mixing chamber mixing section, a mixing chamber contraction section and a mixing chamber expansion section which are sequentially communicated, wherein a discharge hole is formed in the tail end of the mixing chamber expansion section, a feed hole is formed in one side of the mixing section of the mixing chamber, and one end, far away from the discharge hole, of the mixing section of the mixing chamber is communicated with an oxygen nozzle; an overflow hole is formed in the mixing section of the mixing chamber; the diameter of the oxygen nozzle is 6mm; the total length of the mixer is 195mm, the diameter of the contraction section of the mixing chamber is 12mm, and the length is 115mm; the diameter of the outlet of the expansion section of the mixing chamber is 14mm and the length is 35mm. If the external resistance is increased during material conveying, part of the soldering material can flow out of the overflow hole, so that the stable operation of the mixer is ensured; because oxygen pressure reduces, the oxygen nozzle enlarges, and the oxygen velocity of flow of oxygen nozzle department reduces, consequently the negative pressure that produces in feed opening department of mixing chamber reduces, and the mixing chamber will inhale less air volume when reducing the material conveying volume to improve the oxygen content when the ejection of compact of spray gun, higher oxygen content will promote the abundant burning of material, and then ensure ceramic repair welding quality.
Compared with the prior art, the invention has the following technical effects:
the method provided by the invention is used for ceramic welding repair of the furnace wall of the deep vertical flame path of the coke furnace, the ceramic welding repair depth can reach 18 vertical flame paths and 9 meters, and the ceramic welding repair material has long hanging time and is suitable for the coke furnace to be used under the condition of normal production temperature. The method ensures that the furnace wall of the vertical flue at the deep part of the coking chamber of the coke furnace can be effectively repaired, is beneficial to improving the temperature of the coke furnace, ensures the temperature coefficient of the transverse row, can reduce the heat consumption of the coke furnace, reduces the temperature of the standard vertical flue, improves the temperature of the vertical flue and ensures the quality of coke.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
FIG. 1 is a schematic structural view of an iron cage according to the present invention;
FIG. 2 is a schematic longitudinal cross-sectional view of a blender according to the present invention;
FIG. 3 is a schematic diagram of a transverse cross-section of a blender according to the present invention;
FIG. 4 is a schematic view of an air nozzle configuration according to the present invention;
FIG. 5 is a schematic cross-sectional view of an air nozzle of the present invention;
FIG. 6 is a schematic view of a baffle of the present invention;
FIG. 7 is a schematic cross-sectional view of a first guiding hole of the present invention;
FIG. 8 is a schematic cross-sectional view of a nozzle of the present invention;
wherein, 1 is the iron cage, 2 is the air pipe, 3 is the air inlet, 4 is the shower nozzle body, 5 is the nozzle, 6 is the back lid, 7 is the water conservancy diversion piece, 701 is first water conservancy diversion hole, 702 is the second water conservancy diversion hole, 8 is mixing chamber mixing section, 9 is mixing chamber shrink section, 10 is mixing chamber expansion section, 11 is the discharge gate, 12 is the feed inlet, 13 is the oxygen nozzle, 14 is the overflow hole.
Detailed Description
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 only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.
The invention aims to provide a method for ceramic welding repair of a furnace wall of a vertical flue at the deep part of a coke oven carbonization chamber, which solves the problems in the prior art, ensures that the furnace wall of the vertical flue at the deep part of the coke oven carbonization chamber can be effectively repaired, is favorable for improving the temperature of a coke oven, ensures the temperature coefficient of transverse rows, can reduce the heat consumption of the coke oven, reduces the temperature of a standard vertical flue, improves the temperature of the vertical flue and ensures the quality of coke.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
Referring to the attached drawings 1-8, the invention provides a method for ceramic welding repair of a furnace wall of a deep vertical flue of a carbonization chamber of a coke furnace, which comprises the following steps:
pushing out coke in a carbonization chamber to ensure that the coke is in an empty state before repair welding; when the ceramic welding repair is carried out on the furnace wall of the vertical flame path at the machine side or the deep coke side, constructors need to enter the carbonization chamber for ceramic welding repair construction, can carry out short-distance welding repair, ensure the construction quality, do not influence the forward and backward movement of a coke oven locomotive, and do not need to provide the maintenance time independently;
step two, manufacturing a heat preservation and insulation device which can be quickly pushed into the carbonization chamber and quickly taken out according to the specific condition of the width of the carbonization chamber of the coke oven; the heat preservation and insulation device is an iron cage 1, the iron cage 1 is manufactured according to the specific condition of the width of the coke oven carbonization chamber, the installation and the removal are convenient, and the heat preservation and insulation effect and the construction can be guaranteed. The iron cage 1 is 2 meters long and 1.9 meters high under the common conditions, the width is determined according to the width of the carbonization chamber, the iron cage can be quickly pushed into the carbonization chamber and quickly taken out, the construction is convenient, and 6 groups of iron cages are needed at most; the ceramic welding-on deep vertical flue furnace wall needs to adopt a special heat preservation and insulation device, and the heat preservation and insulation device adopts a zirconium-containing ceramic fiber blanket for heat insulation. Because the common ceramic fiber blanket contains a large amount of slag balls and short fibers, the content of the common ceramic fiber slag balls is about 20 percent, the ceramic fibers are slender and 4.5 mu m, the space in the heat preservation and insulation device is narrow during construction, constructors need to work by sticking the ceramic fiber blanket, a large amount of slag balls and fibers are attached to the constructors, the conditions of skin itching, pricking pain and the like are caused, the cleaning is difficult, the health of the constructors is harmful, and the operation requirements can not be met. The zirconium-containing ceramic fiber blanket used by people has low slag ball content which is less than or equal to 12 percent in general, the zirconium-containing ceramic fiber is slender and 4 mu m, has good toughness and high strength, and the problems of skin itching, pricking pain and the like of staff can not occur after practical use;
thirdly, the furnace door frame on the upper part of the heat preservation and insulation device adopts a ceramic fiber blanket for heat preservation and insulation, the mode of hanging a heat insulation curtain cannot be adopted for heat insulation, the sealing effect of the heat insulation curtain is poor, the furnace wall is damaged due to too fast temperature reduction of the coke oven, in addition, the two sides of the heat insulation curtain are not sealed, the protection plate and the furnace door frame are easy to burn out due to high-temperature heat radiation of a carbonization chamber, the deformation of a furnace protection iron part is seriously caused, the overhauled part and the exposed furnace wall are all subjected to heat preservation by adopting the ceramic fiber blanket, and the heat preservation thickness is 40-50mm;
opening a ventilation device of the heat preservation and insulation device, and allowing constructors to enter the heat preservation and insulation device to clean residues such as fire clay and graphite on the wall bricks of the carbonization chamber; the ventilation device comprises a ventilation pipeline 2, wherein each section of the ventilation pipeline 2 is about 2.2m long and slightly longer than each section of the heat preservation and insulation device, so that splicing installation is facilitated, and 6 sections are needed at most. The head of the first section of pipeline is provided with a special air nozzle as an air outlet, the air outlet of the nozzle is aligned to the upper part of a constructor during installation, compressed air is introduced during construction, and air is blown towards the direction of the constructor. Compressed air is sprayed out through the spray head, rotating airflow is formed at the head and the upper part of the body of a constructor, the airflow distribution range is proper and uniform, the influence of hot airflow and heat radiation on the body of the constructor can be effectively isolated, the constructor can be cooled more effectively, and meanwhile, the constructor is guaranteed to have sufficient oxygen supply;
and step five, blowing the cleaned furnace wall clean by using compressed air, and in order to ensure good combination of the ceramic soldering material and the brick surface, performing necessary cleaning on residues such as fire clay, graphite and the like on the furnace wall brick of the carbonization chamber before the ceramic soldering material starts each time, and cleaning the damaged furnace wall by adopting the vibratory hammer in the department of China to ensure the cleaning effect. After the surface of the furnace wall of the carbonization chamber is cleaned by the vibration hammer, the cleaned furnace wall is swept and cleaned by compressed air, and then ceramic welding repair of the deep vertical flame path is carried out. The compressed air can not sweep the furnace wall for a long time so as to avoid secondary damage of the furnace wall caused by too fast local temperature reduction; then ceramic welding repair is carried out on the deep vertical flame path, the temperature of the furnace wall of the carbonization chamber is guaranteed to be maintained in the ceramic welding repair operation process, the temperature of the furnace wall of a repair area is more than or equal to 700 ℃, the temperature of the furnace wall of a non-repair area is more than or equal to 900 ℃, if the temperature of the furnace wall is lower than the set temperature, the temperature is firstly increased, and the temperature of the furnace wall reaches more than 700 ℃ and then ceramic welding repair is carried out;
step six, dismantling and taking out the heat preservation and insulation device after repairing the furnace wall by ceramic welding; after the furnace wall is welded and repaired by ceramic, the furnace wall of the carbonization chamber is heated, and the spring pressure of the iron part of the furnace protection is measured and adjusted periodically in the heating process; and (4) charging coal after the temperature of the standard vertical flame path reaches the standard, observing the conditions of ignition and leakage of the vertical flame paths of the combustion chambers at two sides of the carbonization chamber after the coal is charged, and timely treating the problems if any.
The ceramic repair welding overhaul furnace number must be cooled and controlled: (1) the overhaul furnace number is an empty furnace, and if the combustion chambers at the two sides of the overhaul furnace number burn blast furnace gas, the burn coke furnace gas is converted to burn coke furnace gas, so that the overhaul furnace number temperature is controlled conveniently; (2) and (3) erecting a flame path for stopping heating in the period of overhauling the combustion chambers at two sides of the overhauling furnace number, and controlling the temperature of the flame path erected at the furnace end at the machine coke side to be not lower than 900 ℃. If the temperature is lower than the target value, starting the cock and heating; (3) the adjacent coking chambers on the two sides of the overhaul furnace number do not push coke during the overhaul period, the coking time needs to be prolonged, and the temperature control of the vertical flame path of the combustion chamber, which is alternated with the normal coking chamber, is determined by fire regulators according to the comprehensive consideration of the conditions of overhaul, temperature, production organization and the like. The temperature of the furnace wall of the carbonization chamber is guaranteed to be maintained in the ceramic welding repair operation process: the furnace wall temperature of the repair area is more than or equal to 700 ℃, the furnace wall temperature of the non-repair area is more than or equal to 900 ℃, if the furnace wall temperature is too low, the temperature is firstly increased, and the furnace wall temperature reaches more than 700 ℃ before ceramic welding repair is carried out.
Specifically, in the second step, the heat preservation and insulation device comprises a plurality of iron cages 1 with cubic structures, a small platform needs to be installed or erected before a furnace mouth of a carbonization chamber is overhauled, the heat preservation and insulation iron cages 1 are convenient to install and work at the furnace mouth, the iron cages 1 are manufactured on site, the width of each iron cage is about 400mm generally, and the iron cages are determined according to the actual width of the carbonization chamber, so that the iron cages are convenient to install and disassemble, and meanwhile, the heat preservation and insulation effect and construction can be guaranteed, communication channels are arranged at the front end and the rear end of each iron cage 1, stainless steel wire meshes cover the two sides and the top of each communication channel of each iron cage 1, zirconium-containing ceramic fiber blankets are fixedly wrapped on the outer sides of the stainless steel wire meshes, the content of ceramic fiber slag balls is about 20%, the ceramic fiber is long and thin and 4.5 micrometers, the slag balls are high in content and thick in fiber, a large amount of slag balls and fiber are attached to operating personnel during construction, the skin itch, stabbing pain and the like are difficult to clean, the health of harmful personnel cannot meet the operation requirements. The zirconium-containing ceramic fiber blanket has low shot content which is less than or equal to 12 percent under the general condition, so the fiber blanket can be used next to skin without causing the feeling of skin itch under the general condition. The zirconium-containing ceramic fiber is long and thin and has the length of 4 mu m, good toughness, high strength, convenient use and convenient construction;
the top of the iron cage 1 is of a smooth arched surface structure, the strength of the top of the device is guaranteed, the risk that the device is damaged or even injured by crashing due to dropping of graphite and bricks at the top is prevented, the top space of the device is enlarged, and a space is reserved for erection of the ventilation pipeline 2. The bottom surface of the iron cage 1 needs to be padded with a zirconium-containing ceramic fiber blanket after the device is pushed into a carbonization chamber during construction so as to achieve the heat insulation effect.
In the fourth step, the ventilation device comprises a ventilation pipeline 2 horizontally arranged in the iron cage, and the ventilation pipeline 2 is positioned below the top of the iron cage 1; the tail end of the ventilation pipeline 2 close to the position of a constructor is in threaded connection with an air nozzle.
Air nozzle includes the air inlet 3 with air pipe 2 fixed connection, the one end intercommunication that air pipe 2 was kept away from to air inlet 3 has shower nozzle body 4, 4 one ends of shower nozzle body are connected with nozzle 5, the sealed threaded connection of the other end has back lid 6, 4 internal fixation of shower nozzle are provided with water conservancy diversion piece 7, a plurality of water conservancy diversion holes have been seted up on water conservancy diversion piece 7, water conservancy diversion piece 7 is located between nozzle 5 and the air inlet 3.
The guide holes comprise six first guide holes 701 uniformly arranged on the guide vane 7 in a surrounding manner and a second guide hole 702 positioned at the center of the guide vane 7; the second flow guiding holes 702 are vertical bell mouth-shaped structures, the diameter of the upper ends of the second flow guiding holes 702 is 12mm, and the diameter of the lower ends of the second flow guiding holes 702 is 7.5mm; first water conservancy diversion hole 701 includes the upper portion passageway of horn mouth form and the lower part passageway that the slope set up, and the degree of depth of upper portion passageway is 5mm, and the top diameter of upper portion passageway is 12mm, and the bottom diameter of upper portion passageway is 7.5mm, upper portion passageway bottom and lower part passageway top intercommunication, and the lower part passageway diameter is 7.5mm, and the lower part passageway is the inclined hole structure of degree of depth 10mm, gradient for 30 degrees.
The guide vane 7 is arranged at the position of an air inlet at the top of the nozzle 5, the diameter of the maximum position of the air inlet at the upper part of the nozzle 5 is 50mm, the upper part of the nozzle 5 is of a bell-mouth-shaped structure with gradually reduced diameter, the narrowest part of the diameter of the upper part of the nozzle is 15mm, the diameter of the lower part of the nozzle 5 is gradually enlarged, and the diameter of an air outlet at the lowest part of the lower part of the nozzle 5 is 25mm. When the air nozzle is used, compressed air flows into the nozzle body from the air inlet and then enters the nozzle 5 through the 7 flow guide holes of the flow guide sheet 7. When compressed air passes through the 6 first flow guide holes 701, the compressed air is pressurized through the bell mouth of the upper half part, then the air is guided through the inclined holes of the lower half part, a counterclockwise rotating vortex is formed, and then the compressed air enters the nozzle 5 under the action of pressure. The swirling vortex flow is gradually pressurized in the bell mouth of the upper half part of the nozzle 5, and then is ejected through the positive bell mouth of the lower part of the nozzle 5 to form a swirling air flow. Like this, the rotatory air current of coniform is formed to air through air shower nozzle spun in constructor top, and is more suitable and even in constructor's head and health upper portion air distribution range, can effectively completely cut off the influence of hot gas flow and heat radiation to the constructor health, carries out more effective cooling to the operating personnel, guarantees that the constructor has abundant oxygen supply simultaneously.
The existing ceramic welding material suitable for the coke oven contains combustible silicon and aluminum, and the combustible in the ceramic welding material of the deep vertical flame path does not contain aluminum for the main reasons: 1) Aluminum in the original ceramic welding material is mainly used for promoting the combustion of the welding material, the temperature of a furnace wall of the deep vertical flue is higher than that of a furnace end, materials are easier to combust and melt, and aluminum does not need to be added. 2) Because the temperature of the furnace wall of the vertical flue at the deep part of the carbonization chamber is higher, the ceramic welding material is required to have higher refractoriness under load, and the alumina-containing ceramic welding material contains alumina after sintering, so that the refractoriness under load is reduced, and the use requirement cannot be met. 3) The ignition point of aluminum is low, so that the use of the aluminum-containing ceramic welding material in a high-temperature area at a short distance has a great risk, and the ceramic welding material cannot contain aluminum when the furnace wall is welded and repaired by the ceramic of the deep vertical flame path. Because the conveying distance of the deep vertical flame path is longer, larger granularity is not beneficial to long-distance conveying, the average granularity of the ceramic welding repair material is correspondingly required to be correspondingly reduced, and meanwhile, on the basis of improving a mixer, the granularity range is finally selected to be 0.1-2mm in order to ensure the conveying quantity and the conveying speed of the deep flame path welding repair; the ceramic welding material for the deep vertical flame path welding material comprises the following components in percentage by weight: 45 to 58 parts of fused quartz with the granularity of 0.1 to 2mm, 16 to 22 parts of electrically fused white corundum with the granularity of 0.04 to 0.1mm, 20 to 32 parts of calcium-stabilized zirconia with the granularity of less than 100 meshes and 6 to 10 parts of metallic silicon powder with the granularity of 300 to 500 meshes.
The discharging amount of a mixer used for the deep vertical flame path welding repair is 30 kilograms per hour; the pressure of oxygen is 0.15-0.2 MPa; the mixer comprises a mixing chamber mixing section 8, a mixing chamber contraction section 9 and a mixing chamber expansion section 10 which are sequentially communicated, wherein a discharge hole 11 is formed in the tail end of the mixing chamber expansion section 10, a feed hole 12 is formed in one side of the mixing chamber mixing section 8, and an oxygen nozzle 13 is communicated with one end, far away from the discharge hole 11, of the mixing chamber mixing section 8; an overflow hole 14 is arranged at the position of the mixing section 8 of the mixing chamber; the diameter of the oxygen nozzle 13 is 6mm; the total length of the mixer is 195mm, the diameter of the contraction section 9 of the mixing chamber is 12mm, and the length is 115mm; the mixing chamber expansion section 10 has an outlet diameter of 14mm and a length of 35mm. If the external resistance is increased during material conveying, part of the welding materials can flow out of the overflow holes 14, so that the stable operation of the mixer is ensured; because oxygen pressure reduces, oxygen nozzle 13 enlarges, and the oxygen velocity of flow of oxygen nozzle 13 department reduces, consequently the negative pressure that produces in feed opening department of mixing chamber reduces, and the mixing chamber will inhale less air volume when reducing the material conveying volume to improve the oxygen content when the ejection of compact of spray gun, higher oxygen content will promote the abundant burning of material, and then ensure ceramic repair welding quality.
Example 1: tamping coke oven with 4.3 m modification
1. Basic situation
In the prior art, a plurality of units change a top-mounted coke oven into a stamp-charging coke oven for reducing the cost of raw fuel, and the reformed coke oven can be produced, but some problems appear in a part of coke oven bodies, and the problems need to be solved in time, otherwise, the service life of the coke oven bodies and the quality and quantity production of the coke ovens are influenced.
2. Impact and cause analysis
1. The top-mounted coke oven is changed into a tamping coke oven, so that the oven walls of the coke oven have long horizontal cracks, and only one or two horizontal cracks appear on each oven wall mainly in the coal charging car track, and the horizontal cracks can be seen from the oven door by naked eyes. The furnace wall has serious blowby after horizontal cracks, and some units cannot meet the production due to serious blowby of the furnace wall. In order to prevent black smoke from being emitted from a coke oven chimney, the vertical flue fire observation hole cover with serious leakage is opened.
2. The furnace wall of the coke oven carbonization chamber has horizontal cracks to cause serious blow-by of the furnace wall, so that raw coke oven gas at the horizontal cracks of the blow-by is combusted, and the temperature is high; the raw gas leaks to the vertical flue to be combusted, so that the temperature of the vertical flue is also high. The local high temperature of the oven wall of the coke oven easily causes the damage of the oven wall, the temperature of the blowby oven wall and the vertical flue is very high, the blowby oven wall and the vertical flue are whitish seen by naked eyes, and no good method is available for treatment.
3 the blowby of the oven wall of the coke oven is serious, which causes the local high temperature at one side of the vertical fire channel of the oven wall, the brick of the oven wall falls off, the oven wall at one side of the carbonization chamber is still complete at the beginning, after a period of time, the oven wall will appear a molten hole, and the normal production of the coke oven can not be ensured.
3. Measures to be taken against the problems that arise:
the top mounting is changed to solve the problems of the tamping coke oven, and the method of ceramic welding repair of the deep vertical flame path is most effective no matter horizontal cracks, leakage of the oven wall, brick falling of the flame path and wall surface grooves are adopted.
4. Construction step
1. The ceramic welding repair of the coke oven deep flame path is carried out under the condition of empty oven by pushing out the coke in the carbonization chamber.
2. No matter in the machine side or in the coke side deep vertical flue furnace wall ceramic soldering, constructors need to enter the carbonization chamber to carry out ceramic soldering construction, can carry out close-range soldering, ensure construction quality, do not influence the forward and backward movement of a coke oven locomotive, and do not need to provide maintenance time independently.
3. The ceramic welding-repair deep vertical flue furnace wall needs to adopt a special heat-preservation and heat-insulation device, and the heat-preservation and heat-insulation device adopts a zirconium-containing ceramic fiber blanket for heat insulation. Because the common ceramic fiber blanket contains a large amount of slag balls and short fibers, the content of the common ceramic fiber slag balls is about 20 percent, the ceramic fibers are slender and 4.5 mu m, the space in the heat preservation and insulation device is narrow during construction, constructors need to work by sticking the ceramic fiber blanket, a large amount of slag balls and fibers are attached to the constructors, the conditions of skin itching, pricking pain and the like are caused, the cleaning is difficult, the health of the constructors is harmful, and the operation requirements can not be met. The zirconium-containing ceramic fiber blanket used by people has low slag ball content which is less than or equal to 12 percent in general, the zirconium-containing ceramic fiber is slender and 4 mu m, has good toughness and high strength, and the problems of itching, stabbing pain and the like of the skin of staff can not occur after practical use.
4. The heat preservation and insulation device is an iron cage manufactured on site, the iron cage is manufactured according to the specific condition of the width of the coke oven carbonization chamber, the iron cage is convenient to install and disassemble, and meanwhile, the heat preservation and insulation effect and construction can be guaranteed. The length of the iron cage is 2 meters under the general condition, the height is 1.9 meters, the width is determined according to the width of the carbonization chamber, the iron cage can be quickly pushed into the carbonization chamber and can be quickly taken out, the construction is convenient, and 6 groups of iron cages are needed at most.
5. The specially-made heat preservation and insulation device of my department is provided with a ventilation device, the ventilation device is composed of a pipeline erected at the top of the heat preservation and insulation device, the ventilation pipeline is arranged below the top surface D, each section of the pipeline is about 2.2m long and slightly longer than each section of the heat preservation and insulation device, so that splicing and installation are facilitated, and 6 sections are needed at most. The head of the first section of pipeline is provided with a special nozzle of my department as an air outlet, the air outlet of the nozzle is aligned to the upper part of constructors during installation, compressed air is introduced during construction, and air is blown towards the direction of the constructors. Compressed air forms rotatory air current through the shower nozzle blowout on constructor's head and health upper portion, and the air current distribution range is more suitable and even, can effectively completely cut off hot gas flow and heat radiation to the influence of constructor health, carries out more effectual cooling to the operation personnel, guarantees simultaneously that constructor has abundant oxygen supply.
6. The furnace door frame on the upper part of the iron cage adopts a mode of sticking a ceramic fiber blanket for heat preservation and heat insulation, a mode of hanging a heat insulation curtain cannot be adopted for heat insulation, the sealing effect of the heat insulation curtain is poor, the temperature reduction speed of the coke oven damages the furnace wall too fast, in addition, the two sides of the heat insulation curtain are not sealed, the protection plate and the furnace door frame are easy to burn out by high-temperature heat radiation of a carbonization chamber, and the deformation of a furnace protection iron piece is seriously caused.
7. The ceramic fiber blanket is adopted for heat preservation at the part which is not overhauled and the exposed furnace wall, and the heat preservation thickness is 40-50mm.
8. In order to ensure good combination of the ceramic repair welding material and the brick surface and carry out necessary cleaning on residues such as fire clay, graphite and the like on the furnace wall brick of the carbonization chamber before the ceramic repair welding begins each time, the vibration hammer disclosed by the department of China is adopted to clean the damaged furnace wall, so that the cleaning effect can be ensured.
9. After the surface of the furnace wall of the carbonization chamber is cleaned by the vibration hammer, the cleaned furnace wall is swept by compressed air, and then ceramic welding repair of the deep vertical flame path is carried out. The compressed air can not sweep the furnace wall for a long time so as to avoid secondary damage of the furnace wall caused by too fast local temperature reduction.
10. The ceramic repair welding overhaul furnace number must be cooled and controlled: (1) the overhaul furnace number is an empty furnace, and if the combustion chambers at the two sides of the overhaul furnace number burn blast furnace gas, the burn coke furnace gas is converted to burn coke furnace gas, so that the overhaul furnace number temperature is controlled conveniently; (2) and (3) erecting a flame path for stopping heating in the period of overhauling the combustion chambers at two sides of the overhauling furnace number, and controlling the temperature of the flame path erected at the furnace end at the machine coke side to be not lower than 900 ℃. If the temperature is lower than the target value, starting the cock and raising the temperature; (3) the adjacent carbonization chambers on two sides of the overhaul furnace number do not push coke during the overhaul period, the coking time is prolonged, and the temperature control of the vertical flame paths of the combustion chambers, which are alternated with the normal carbonization chambers, is determined by fire regulators according to comprehensive consideration of the overhaul, temperature, production organization and the like. The temperature of the furnace wall of the carbonization chamber is guaranteed to be maintained in the ceramic welding operation process: the furnace wall temperature of the repair area is more than or equal to 700 ℃, the furnace wall temperature of the non-repair area is more than or equal to 900 ℃, if the furnace wall temperature is too low, the temperature is firstly increased, and the furnace wall temperature reaches more than 700 ℃ before ceramic welding repair is carried out.
11. And (4) dismantling and taking out the heat-insulating iron cage after the furnace wall is repaired by ceramic welding.
12. And (3) after the furnace wall is welded and repaired by the ceramic, heating the furnace wall of the carbonization chamber, and periodically measuring and adjusting the spring pressure of the iron part of the furnace protection in the heating process.
13. And the coal can be charged after the temperature of the standard vertical flame path reaches the standard, the flaming and leakage situations of the vertical flame paths of the combustion chambers at two sides of the carbonization chamber after the coal is charged are observed, and if a problem exists, the problem is timely treated.
5. Effect
Aiming at the problem of leakage of a deep vertical flue in the process of transforming a coke oven, the ceramic welding repair technical method for the deep vertical flue of the company can thoroughly solve the problem and ensure the tight furnace wall of the deep vertical flue in a coking chamber of the coke oven. The hanging and sealing time can reach 10-15 years.
Original method
Some units have no good method for the furnace wall leakage, and only a method for improving the pressure of the gas collecting pipe is adopted, so that the leakage furnace wall is hoped to be multi-jointed with graphite to block the leakage. The method can play a certain role in a short time, but cannot completely solve the problem. The graphite is burned off when the production is abnormal or the furnace temperature fluctuates, and the problem of channeling still occurs.
Example 2: the furnace wall at the lower part of the 5.5 m tamping coke oven is perforated, corroded and melted
1. Basic situation
As the coal supporting plates of the 5.5 m tamping coke oven pass in and out, the bricks on the first layer and the second layer of the oven wall of the carbonization chamber are scraped and damaged seriously, and grooves with the depth of 30-50mm appear. The first layer and the second layer of brick furnace wall in the middle of the carbonization chamber have perforation and melting holes, the length relates to two vertical flame paths, 800mm, the height is 3-4 layers of bricks, and 300-400mm. Causing the fire holes at two sides to smoke and fire seriously after coal charging. The blowby is very serious, and the normal production of the coke oven is influenced.
2. Measures should be taken to address the emerging issues:
the tamping coke oven is changed by top loading, and the method of ceramic welding repair of the deep vertical flame path is most effective no matter horizontal cracks, furnace wall leakage, flame path brick falling and wall surface grooves occur.
3. Construction procedure
1. The ceramic welding repair of the coke oven deep flame path is carried out under the condition of empty oven by pushing out the coke in the carbonization chamber.
2. No matter the machine side or the coke side deep vertical flue furnace wall ceramic welding repair, constructors need to enter the carbonization chamber for ceramic welding repair construction, can perform short-distance welding repair, ensure the construction quality, do not influence the forward and backward movement of a coke oven locomotive, and do not need to provide independent maintenance time.
3. The ceramic welding-repair deep vertical flue furnace wall needs to adopt a special heat-preservation and heat-insulation device, and the heat-preservation and heat-insulation device adopts a zirconium-containing ceramic fiber blanket for heat insulation. Because the common ceramic fiber blanket contains a large amount of slag balls and short fibers, the content of the common ceramic fiber slag balls is about 20 percent, the ceramic fibers are slender and 4.5 mu m, the space in the heat preservation and insulation device is narrow during construction, constructors need to work by sticking the ceramic fiber blanket, a large amount of slag balls and fibers are attached to the constructors, the conditions of skin itching, pricking pain and the like are caused, the cleaning is difficult, the health of the constructors is harmful, and the operation requirements can not be met. The zirconium-containing ceramic fiber blanket used by people has low slag ball content which is less than or equal to 12 percent generally, the zirconium-containing ceramic fiber is slender and 4 mu m, has good toughness and high strength, and the problems of itching, stabbing pain and the like of skin of staff can not occur after practical use.
4. The heat preservation and insulation device is an iron cage manufactured on site, the iron cage is manufactured according to the specific condition of the width of the coke oven carbonization chamber, the iron cage is convenient to install and disassemble, and meanwhile, the heat preservation and insulation effect and construction can be guaranteed. The length of the iron cage is 2 meters under the general condition, the height is 1.9 meters, the width is determined according to the width of the carbonization chamber, the iron cage can be quickly pushed into the carbonization chamber and can be quickly taken out, the construction is convenient, and 6 groups of iron cages are needed at most.
5. The specially-made heat preservation and insulation device of my department is provided with a ventilation device, the ventilation device is composed of a pipeline erected at the top of the heat preservation and insulation device, the ventilation pipeline is arranged below the top surface D, each section of the pipeline is about 2.2m long and slightly longer than each section of the heat preservation and insulation device, so that splicing and installation are facilitated, and 6 sections are needed at most. The head of the first section of pipeline is provided with a special nozzle of my department as an air outlet, the air outlet of the nozzle is aligned to the upper part of constructors during installation, compressed air is introduced during construction, and air is blown towards the direction of the constructors. Compressed air forms rotatory air current through the shower nozzle blowout on constructor's head and health upper portion, and the air current distribution range is more suitable and even, can effectively completely cut off hot gas flow and heat radiation to the influence of constructor health, carries out more effectual cooling to the operation personnel, guarantees simultaneously that constructor has abundant oxygen supply.
6. The furnace door frame on the upper part of the iron cage adopts a mode of sticking a ceramic fiber blanket for heat preservation and heat insulation, a mode of hanging a heat insulation curtain cannot be adopted for heat insulation, the sealing effect of the heat insulation curtain is poor, the temperature reduction speed of the coke oven damages the furnace wall too fast, in addition, the two sides of the heat insulation curtain are not sealed, the protection plate and the furnace door frame are easy to burn out by high-temperature heat radiation of a carbonization chamber, and the deformation of a furnace protection iron piece is seriously caused.
7. The parts which are not overhauled and the exposed furnace wall are all insulated by adopting a ceramic fiber blanket, and the insulation thickness is 40-50mm.
8. In order to ensure good combination of the ceramic welding materials and the brick surface, residues such as fire clay, graphite and the like on the furnace wall brick of the carbonization chamber are cleaned necessarily before the ceramic welding materials are welded at each time, and the vibration hammer in the department of the patent is adopted to clean the damaged furnace wall so as to ensure the cleaning effect.
9. After the surface of the furnace wall of the carbonization chamber is cleaned by the vibration hammer, the cleaned furnace wall is swept by compressed air, and then ceramic welding repair of the deep vertical flame path is carried out. The compressed air can not sweep the furnace wall for a long time so as to avoid secondary damage of the furnace wall caused by too fast local temperature reduction.
10. The ceramic repair welding overhaul furnace number must be cooled and controlled: (1) the overhaul furnace number is an empty furnace, if the combustion chambers at two sides of the overhaul furnace number burn blast furnace gas, the coke furnace gas is converted to burn coke furnace gas, so that the temperature control of the overhaul furnace number is convenient; (2) and (3) erecting a flame path for stopping heating in the period of overhauling the combustion chambers at two sides of the overhauling furnace number, and controlling the temperature of the flame path erected at the furnace end at the machine coke side to be not lower than 900 ℃. If the temperature is lower than the target value, starting the cock and heating; (3) the adjacent carbonization chambers on two sides of the overhaul furnace number do not push coke during the overhaul period, the coking time is prolonged, and the temperature control of the vertical flame paths of the combustion chambers, which are alternated with the normal carbonization chambers, is determined by fire regulators according to comprehensive consideration of the overhaul, temperature, production organization and the like. The temperature of the furnace wall of the carbonization chamber is guaranteed to be maintained in the ceramic welding operation process: the furnace wall temperature of the repair area is more than or equal to 700 ℃, the furnace wall temperature of the non-repair area is more than or equal to 900 ℃, if the furnace wall temperature is too low, the temperature is firstly increased, and the furnace wall temperature reaches more than 700 ℃ before ceramic welding repair is carried out.
11. And (4) dismantling and taking out the heat-insulating iron cage after the furnace wall is repaired by ceramic welding.
12. The furnace wall of the carbonization chamber is heated after the ceramic welding repair of the furnace wall, and the spring pressure of the iron part of the furnace protection is measured and adjusted periodically in the heating process.
13. And the coal can be charged after the temperature of the standard vertical flame path reaches the standard, the flaming and leakage situations of the vertical flame paths of the combustion chambers at two sides of the carbonization chamber after the coal is charged are observed, and if a problem exists, the problem is timely treated.
5. Effect
Aiming at the problem of the leakage of the deep vertical flue in the process of transforming the coke oven, the ceramic welding repair technical method of the deep vertical flue of the company can thoroughly solve the problem and ensure that the oven wall of the deep vertical flue of the carbonization chamber of the coke oven is tight. The material hanging and sealing time can reach 10-15 years.
Example 3: upper furnace wall of 6m top-mounted coke oven
1. Basic situation
In the coke oven production process, the situation that the channel steel of the coke guide groove is brought to the carbonization chamber to scrape the oven wall by the coke pusher in the coke pusher recycling process sometimes occurs, the coke pusher is positioned at the top end of the coke pusher head, the scraped position is generally about 5 meters away from the bottom of the carbonization chamber, the depth can reach 14-18 flame paths, the damage height is generally about 2 layers of bricks, the oven wall leakage is caused, and the normal production is greatly influenced.
2. Measures should be taken to address the emerging issues:
for furnace wall damage caused by the mechanical accident, as the furnace wall damage position is higher and is positioned at a deeper position in the carbonization chamber, the conventional maintenance means cannot be solved at present, and only the ceramic repair welding method of the my deep vertical flame path can be adopted.
4. Construction step
1. The ceramic welding repair of the coke oven deep flame path is carried out under the condition of empty oven by pushing out the coke in the carbonization chamber.
2. No matter in the machine side or in the coke side deep vertical flue furnace wall ceramic soldering, constructors need to enter the carbonization chamber to carry out ceramic soldering construction, can carry out close-range soldering, ensure construction quality, do not influence the forward and backward movement of a coke oven locomotive, and do not need to provide maintenance time independently.
3. The ceramic welding-on deep vertical flue furnace wall needs to adopt a special heat preservation and insulation device, and the heat preservation and insulation device adopts a zirconium-containing ceramic fiber blanket for heat insulation. Because the common ceramic fiber blanket contains a large amount of slag balls and short fibers, the content of the common ceramic fiber slag balls is about 20 percent, the ceramic fibers are slender and 4.5 mu m, the space in the heat insulation device is narrow during construction, constructors need to attach the ceramic fiber blanket for operation, a large amount of slag balls and fibers are attached to the constructors, the conditions of itching and pricking pain of the skin are caused, the cleaning is difficult, the health of the constructors is harmful, and the operation requirements can not be met. The zirconium-containing ceramic fiber blanket used by people has low slag ball content which is less than or equal to 12 percent in general, the zirconium-containing ceramic fiber is slender and 4 mu m, has good toughness and high strength, and the problems of itching, stabbing pain and the like of the skin of staff can not occur after practical use.
4. The heat preservation and insulation device is an iron cage manufactured on site, the iron cage is manufactured according to the specific condition of the width of the coke oven carbonization chamber, the iron cage is convenient to install and disassemble, and meanwhile, the heat preservation and insulation effect and construction can be guaranteed. The length of the iron cage is 2 meters under the general condition, the height is 1.9 meters, the width is determined according to the width of the carbonization chamber, the iron cage can be quickly pushed into the carbonization chamber and can be quickly taken out, the construction is convenient, and 6 groups of iron cages are needed at most.
5. The specially-made heat preservation and insulation device of my department is provided with a ventilation device, the ventilation device is composed of a pipeline erected at the top of the heat preservation and insulation device, the ventilation pipeline is arranged below the top surface D, and the length of each section of the pipeline is about 2.2m and slightly longer than that of each section of the heat preservation and insulation device, so that splicing and installation are facilitated, and 6 sections are needed at most. The head of the first section of pipeline is provided with a special nozzle of my department as an air outlet, the air outlet of the nozzle is aligned to the upper part of constructors during installation, compressed air is introduced during construction, and air is blown towards the direction of the constructors. Compressed air forms rotatory air current through the shower nozzle blowout at constructor's head and health upper portion, and the air current distribution range is more suitable and even, can effectively completely cut off hot gas flow and heat radiation to the influence of constructor health, carries out more effective cooling to the operating personnel, guarantees simultaneously that constructor has abundant oxygen supply.
6. The furnace door frame on the upper part of the iron cage adopts a mode of sticking a ceramic fiber blanket for heat preservation and heat insulation, a mode of hanging a heat insulation curtain cannot be adopted for heat insulation, the sealing effect of the heat insulation curtain is poor, the temperature reduction speed of the coke oven damages the furnace wall too fast, in addition, the two sides of the heat insulation curtain are not sealed, the protection plate and the furnace door frame are easy to burn out by high-temperature heat radiation of a carbonization chamber, and the deformation of a furnace protection iron piece is seriously caused.
7. The parts which are not overhauled and the exposed furnace wall are all insulated by adopting a ceramic fiber blanket, and the insulation thickness is 40-50mm.
8. In order to ensure good combination of the ceramic repair welding material and the brick surface and carry out necessary cleaning on residues such as fire clay, graphite and the like on the furnace wall brick of the carbonization chamber before the ceramic repair welding begins each time, the vibration hammer disclosed by the department of China is adopted to clean the damaged furnace wall, so that the cleaning effect can be ensured.
9. After the surface of the furnace wall of the carbonization chamber is cleaned by the vibration hammer, the cleaned furnace wall is swept and cleaned by compressed air, and then ceramic welding repair of the deep vertical flame path is carried out. The compressed air can not sweep the furnace wall for a long time, so as to avoid secondary damage of the furnace wall caused by too fast local temperature reduction.
10. The ceramic repair welding overhaul furnace number must be cooled and controlled: (1) the overhaul furnace number is an empty furnace, and if the combustion chambers at the two sides of the overhaul furnace number burn blast furnace gas, the burn coke furnace gas is converted to burn coke furnace gas, so that the overhaul furnace number temperature is controlled conveniently; (2) and (3) erecting a flame path for stopping heating in the period of overhauling the combustion chambers at two sides of the overhauling furnace number, and controlling the temperature of the flame path erected at the furnace end at the machine coke side to be not lower than 900 ℃. If the temperature is lower than the target value, starting the cock and heating; (3) the adjacent carbonization chambers on two sides of the overhaul furnace number do not push coke during the overhaul period, the coking time is prolonged, and the temperature control of the vertical flame paths of the combustion chambers, which are alternated with the normal carbonization chambers, is determined by fire regulators according to comprehensive consideration of the overhaul, temperature, production organization and the like. The temperature of the furnace wall of the carbonization chamber is guaranteed to be maintained in the ceramic welding repair operation process: the furnace wall temperature of the repair area is more than or equal to 700 ℃, the furnace wall temperature of the non-repair area is more than or equal to 900 ℃, if the furnace wall temperature is too low, the temperature is firstly increased, and the furnace wall temperature reaches more than 700 ℃ before ceramic welding repair is carried out.
11. And (3) dismantling and taking out the heat-insulating iron cage after the furnace wall is repaired by ceramic welding.
12. And (3) after the furnace wall is welded and repaired by the ceramic, heating the furnace wall of the carbonization chamber, and periodically measuring and adjusting the spring pressure of the iron part of the furnace protection in the heating process.
13. And the coal can be charged after the temperature of the standard vertical flame path reaches the standard, the flaming and leakage situations of the vertical flame paths of the combustion chambers at two sides of the carbonization chamber after the coal is charged are observed, and if a problem exists, the problem is timely treated.
5. Effect
Aiming at the problem of leakage of a deep vertical flue in the process of transforming a coke oven, the ceramic welding repair technical method for the deep vertical flue of the company can thoroughly solve the problem and ensure the tight furnace wall of the deep vertical flue in a coking chamber of the coke oven. The material hanging and sealing time can reach 10-15 years.
In the description of the present invention, it should be noted that the terms "center", "top", "bottom", "left", "right", "vertical", "horizontal", "inner", "outer", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the device or element referred to must have a particular orientation, be constructed in a particular orientation, and be operated, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and the like are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
The principle and the implementation mode of the invention are explained by applying a specific example, and the description of the embodiment is only used for helping to understand the method and the core idea of the invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (8)
1. A method for ceramic welding repair of a furnace wall of a deep vertical flue of a coke oven carbonization chamber is characterized by comprising the following steps: the method comprises the following steps:
pushing out coke in a carbonization chamber to ensure that the coke is in an empty state before repair welding;
step two, manufacturing a heat preservation and insulation device which can be quickly pushed into the carbonization chamber and quickly taken out according to the specific situation of the width of the carbonization chamber of the coke oven;
thirdly, the furnace door frame on the upper part of the heat preservation and insulation device adopts a ceramic fiber blanket for heat preservation and insulation, the overhauled part and the exposed furnace wall are all preserved by adopting the ceramic fiber blanket, and the heat preservation thickness is 40-50mm;
opening a ventilation device of the heat preservation and insulation device, and allowing constructors to enter the heat preservation and insulation device to clean residues such as fire clay and graphite on the wall bricks of the carbonization chamber;
step five, blowing the cleaned furnace wall by using compressed air, then performing ceramic welding repair on the deep vertical flame path, wherein the temperature of the furnace wall of the carbonization chamber is guaranteed to be maintained in the ceramic welding repair operation process, the temperature of the furnace wall of a repair area is not less than 700 ℃, the temperature of the furnace wall of a non-repair area is not less than 900 ℃, if the temperature of the furnace wall is lower than a set temperature, the temperature is firstly increased, and the temperature of the furnace wall reaches over 700 ℃ and then the ceramic welding repair is performed;
step six, dismantling and taking out the heat preservation and insulation device after repairing the furnace wall by ceramic welding; after the furnace wall is welded and repaired by ceramic, the furnace wall of the carbonization chamber is heated, and the spring pressure of the iron part of the furnace protection is measured and adjusted periodically in the heating process; and (3) charging coal after the temperature of the standard vertical flame path reaches the standard, observing the flaming and leakage conditions of the vertical flame paths of the combustion chambers at two sides of the coking chamber after the coal is charged, and timely processing if problems exist.
2. The method for ceramic welding repair of the furnace wall of the deep vertical flue of the coke oven carbonization chamber as claimed in claim 1, characterized in that: in the second step, the heat preservation and insulation device comprises a plurality of iron cages with cubic structures, communication channels are arranged at the front and rear ends of each iron cage, stainless steel wire meshes cover the two sides and the top of each iron cage communication channel, and ceramic fiber blankets containing zirconium are fixedly wrapped outside the stainless steel wire meshes; the top of the iron cage is of a smooth arched surface structure.
3. The method for ceramic welding repair of the furnace wall of the deep vertical flue of the coke oven carbonization chamber as claimed in claim 2, characterized in that: in the fourth step, the ventilation device comprises a ventilation pipeline horizontally arranged in the iron cage, and the ventilation pipeline is positioned below the top of the iron cage; and the tail end of the ventilation pipeline is in threaded connection with an air nozzle close to the position of a constructor.
4. The method for ceramic welding repair of the furnace wall of the deep vertical flue of the coke oven carbonization chamber as claimed in claim 3, characterized in that: the air nozzle comprises an air inlet fixedly connected with the ventilation pipeline, the air inlet is far away from one end of the air pipeline is communicated with a nozzle body, one end of the nozzle body is connected with a nozzle, the other end of the nozzle body is connected with a rear cover in a sealing threaded manner, a flow deflector is fixedly arranged in the nozzle body, a plurality of flow guide holes are formed in the flow deflector, and the flow deflector is located between the nozzle and the air inlet.
5. The method for ceramic welding repair of the furnace wall of the deep vertical flue of the coke oven carbonization chamber as claimed in claim 4, characterized in that: the flow guide holes comprise six first flow guide holes uniformly arranged on the flow guide sheet in a surrounding manner and a second flow guide hole positioned at the center of the flow guide sheet; the second flow guide hole is of a vertical horn mouth-shaped structure, the diameter of the upper end of the second flow guide hole is 12mm, and the diameter of the lower end of the second flow guide hole is 7.5mm; first water conservancy diversion hole includes the upper portion passageway of horn mouth form and the lower part passageway that the slope set up, the degree of depth of upper portion passageway is 5mm, the top diameter of upper portion passageway is 12mm, and the bottom diameter of upper portion passageway is 7.5mm, upper portion passageway bottom with lower part passageway top intercommunication, the lower part passageway diameter is 7.5mm, just the lower part passageway is the inclined hole structure that degree of depth 10mm, gradient are 30 degrees.
6. The method for ceramic welding repair of the furnace wall of the deep vertical flue of the carbonization chamber of the coke furnace as claimed in claim 4, characterized in that: the flow deflector is arranged at the position of an air inlet at the top of the nozzle, the diameter of the maximum position of the air inlet at the upper part of the nozzle is 50mm, the upper part of the nozzle is of a bell-mouth-shaped structure with gradually reduced diameter, the narrowest part of the diameter of the upper part of the nozzle is 15mm, the diameter of the lower part of the nozzle is gradually enlarged, and the diameter of an air outlet at the lowest part of the lower part of the nozzle is 25mm.
7. The method for ceramic welding repair of the furnace wall of the deep vertical flue of the coke oven carbonization chamber as claimed in claim 1, characterized in that: the ceramic welding material for the deep vertical flame path welding material comprises the following components in percentage by weight: 45 to 58 parts of fused quartz with the granularity of 0.1 to 2mm, 16 to 22 parts of electrically fused white corundum with the granularity of 0.04 to 0.1mm, 20 to 32 parts of calcium-stabilized zirconia with the granularity of less than 100 meshes and 6 to 10 parts of metallic silicon powder with the granularity of 300 to 500 meshes.
8. The method for ceramic welding repair of the furnace wall of the deep vertical flue of the carbonization chamber of the coke furnace as claimed in claim 1, characterized in that: the discharging amount of a mixer used for the deep vertical flame path welding repair is 30 kilograms per hour; the pressure of oxygen is 0.15-0.2 MPa; the mixer comprises a mixing chamber mixing section, a mixing chamber contraction section and a mixing chamber expansion section which are sequentially communicated, wherein a discharge hole is formed in the tail end of the mixing chamber expansion section, a feed hole is formed in one side of the mixing section of the mixing chamber, and one end, far away from the discharge hole, of the mixing section of the mixing chamber is communicated with an oxygen nozzle; an overflow hole is formed in the mixing section of the mixing chamber; the diameter of the oxygen nozzle is 6mm; the total length of the mixer is 195mm, the diameter of the contraction section of the mixing chamber is 12mm, and the length is 115mm; the diameter of the outlet of the expansion section of the mixing chamber is 14mm and the length is 35mm.
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