JP2021134338A - Construction method of coke oven and production method of module block - Google Patents

Abstract

To provide a construction method of a coke oven capable of reducing readjustment work of module block installation at a construction side of a coke oven, and efficiently installing a module block at high accuracy, and a production method of a module block.SOLUTION: A construction method of a coke oven comprises: a step for measuring a contour of a module block; a step for determining adequacy of the module block on the basis of the contour; and a step for preparing again, the module block for which it is determined to be rejected, in the step for determining adequacy. A production method of the module block comprises: a step for measuring a contour of the module block produced; a step for determining adequacy of the module block on the basis of the contour; and a step for preparing again, the module block for which it is determined to be rejected. The step for preparing again the module block includes piling again a plurality of regular refractory products for producing the module block again, or correcting an interference position in a virtual arrangement state.SELECTED DRAWING: Figure 7

Description

The present invention relates to a method for constructing a coke oven and a method for manufacturing a module block.

Metallurgical coke used for iron making is produced by carbonizing coal in a chamber-type coke oven. The chamber-type coke oven is configured by alternately arranging carbonization chambers and combustion chambers that supply heat to the carbonization chambers in the direction of the width of the furnace. Heat is supplied from the combustion chamber to the carbonization chamber via a standard fireproof material. Some chamber-type coke ovens are provided with 100 or more furnace chambers, and such a chamber-type coke oven can be said to be a huge brick structure having a total length of 100 m or more and a height of 10 m or more.

Unlike ordinary bricks for buildings, the standard refractories that make up a coke oven have complicated shapes such as rectangles, trapezoids, and L-shapes when viewed from above. Further, the side surface, the upper surface, and the bottom surface of the standard refractory may be provided with a fitting convex portion for preventing deviation called a dowel and a fitting concave portion for preventing deviation called a hozo. The coke oven is constructed by combining standard refractories having such extremely complicated shapes.

Due to the complexity of the shape of such standard refractories, the construction of coke ovens is currently carried out by hand-loading work by the builder. In the manual construction of a furnace, it is necessary to repeatedly apply mortar to the position where the standard refractory is to be loaded using a tool such as a trowel so that the joint thickness becomes a predetermined value, and then stack the standard refractory on the mortar. There is. In that case, extremely advanced skills are required, such as the need to evenly apply mortar to the surface of standard refractories with complicated shapes, but there is always a shortage of skilled furnace builders with such skills. doing. In addition, it can be said that the furnace construction work of manually applying mortar and stacking standard refractories is extremely hard work.
For the above reasons, it is required to develop a method for efficiently stacking standard refractories with a small amount of manpower.

For example, in Patent Document 1, a module block in which a plurality of brick layers arranged in a horizontal direction are laminated in a plurality of stages in a vertical direction is manufactured in advance at a place other than the construction site of a coke oven, and transported to the construction site. A method of installation has been proposed. In this method, by providing an appropriate spacer between the bricks on the other side when installing the module block, an appropriate mortar thickness can be secured and a coke oven can be constructed with high accuracy.

Japanese Unexamined Patent Publication No. 2016-191064

However, in the technique described in Patent Document 1, since refractory bricks generally used as standard refractory materials for coke ovens are made by firing, there is an error in the dimensions of each refractory brick (for example, in plan view). In the case of the diagonal distance in the side view, it is about 1 to 2 mm). Therefore, for example, even if the manufactured module blocks are adjusted in the horizontal direction and the flatness of the furnace wall on the carbonization chamber side where coke is extruded achieves the required accuracy, they are adjacent to each other when they are stacked at the time of installation. There are cases where the module blocks interfere with each other and mesh with each other because the thickness of the mortar cannot be secured, or the gaps that are more than necessary are filled with the mortar. Or, as a result, there is a problem that the installation cannot be performed accurately. This causes problems such as delay in construction period, cost for recovery by workers, and increase in workload.

The present invention has been made in view of the above circumstances, and is a coke oven capable of reducing the work of reworking the installation of the module block at the construction site of the coke oven and installing the module block with high accuracy and efficiency. It is an object of the present invention to provide a construction method and a method for manufacturing a module block.

The gist structure of the present invention is as follows.
(1) The method for constructing the coke oven of the present invention is as follows.
A module block manufacturing process in which a plurality of standard refractories are stacked in advance to manufacture a module block at a place other than the construction site of the coke oven.
A module block transportation process for transporting the module block to the construction site of the coke oven, and
A mortar application process in which the mortar is applied to the position where the transported module block is installed, and
A method for constructing a coke oven, which comprises a module block installation step of installing the transported module block at a position where the mortar is applied.
A module block shape measuring process for measuring the contour of the manufactured module block, and
A module block pass / fail determination step of determining the pass / fail of the module block based on the measured contour of the module block, and
Further including a module block re-preparation step of re-preparing the module block determined to be unacceptable in the module block pass / fail determination step.
The module block shape measuring step, the module block pass / fail determination step, and the module block repreparation step are performed after the module block manufacturing step and prior to the module block transporting step.

(2) In the above (1), in the module block shape measurement step, the contour is a distance from the laser irradiation device or the infrared irradiation device to the surface of the module block by using a laser irradiation device or an infrared irradiation device. It is preferable to measure by measuring.

(3) In the above (1), in the module block shape measurement step, the contour acquires a plurality of images obtained by capturing the module block from a plurality of viewpoints, and photogrammetry using the acquired plurality of images. It is preferable to measure by.

(4) In any of the above (1) to (3), it is preferable to measure the contour of the entire surface of the module block in the module block shape measuring step.

(5) In any of the above (1) to (4), it is preferable that the module block determined to be acceptable in the module block pass / fail determination step is subjected to the module block transport step.

(6) In any of the above (1) to (5), the pass / fail of the module block is determined by comparing the measured contour with the drawing shape prepared in advance in the module block pass / fail determination step. It is preferable to be done.

(7) In any of the above (1) to (6), in the module block pass / fail determination step, interference in a virtual arrangement state in which a plurality of the module blocks whose contours have been measured are virtually arranged on a computer. It is preferable that the pass / fail of the module block is determined by.

(8) In any of the above (1) to (7), in the module block repreparation step, it is preferable that the plurality of the standard refractories are re-stacked to remanufacture the module block.

(9) In any of the above (1) to (7), it is also preferable that the module block repreparation step modifies a part of the module block.

(10) In the above (9), the standard refractory of the module block has a fitting convex portion and a fitting concave portion.
In the module block repreparation step, the fitting convex portion of the standard fireproof material of the module block is scraped to reduce the fitting convex portion, and / or the portion for partitioning the fitting concave portion is scraped. It is preferable to modify a part of the module block by enlarging the fitting recess.

(11) In the above (7), in the module block shape measuring step, the contours of a plurality of the module blocks having the same shape are measured.
In the module block pass / fail determination step, interference in the virtual arrangement state is evaluated for the plurality of module blocks having the same shape whose contours have been measured.
In the module block repreparation step, it is preferable to replace the module block determined to be unacceptable in the module block pass / fail determination step with the module block determined to pass the interference evaluation result. ..

(12) In the above (11), the module block for which the evaluation result of the interference is optimal is the difference between the target mortar thickness and the joint thickness in the virtual arrangement state at one or more installation locations. It is preferable that the module block has the minimum integrated value of.
However, the integrated value at one installation location means the above difference at that location.

(13) In the above (7), the contours of a plurality of modules having the same shape are measured in the module block shape measuring step, and the contours are measured in the module block pass / fail determination step. For the module block of the above, the interference in the virtual arrangement state is evaluated, and the optimum overall arrangement is calculated.
In the module block re-preparation step, it is preferable to re-prepare only the module block whose interference evaluation result is unacceptable at the time of the optimum overall arrangement.

(14) In the above (13), in the optimum overall arrangement, the integrated value of the difference between the target mortar thickness and the joint thickness in the virtual arrangement state is minimized at one or more of the installation locations. It is preferable that the module blocks are arranged as a whole.

(15) The method for manufacturing a module block of the present invention is as follows.
A module block manufacturing method in which a plurality of standard refractories are stacked in advance to manufacture a module block for construction of a coke oven at a place other than the construction site of the coke oven.
A module block shape measuring process for measuring the contour of the manufactured module block, and
A module block pass / fail determination step of determining the pass / fail of the module block based on the measured contour of the module block, and
The module block re-preparation step of re-preparing the module block determined to be unacceptable in the module block pass / fail determination step is included.
The module block repreparation step includes re-stacking a plurality of the standard refractories to remanufacture the module block, or correcting an interference point of the module block in the virtual arrangement state. It is a feature.

According to the present invention, a method for constructing a coke oven and a method for manufacturing a module block, which can reduce the work of re-installing the module block at the construction site of the coke oven and can install the module block efficiently with high accuracy. Can be provided.

It is a schematic top view of an example of a module block in which standard refractories for a coke oven are stacked. It is a schematic side view of an example of a module block in which standard refractories for a coke oven are stacked. It is a schematic partial side view of an example of the furnace wall of a coke oven manufactured by installing module blocks in order. It is a figure which shows typically the state that the fitting convex part and the fitting concave part are fitted between the side surface of a brick. It is a figure which shows typically the state that the fitting convex part and the fitting concave part are fitted between the horizontal planes of a brick. It is a schematic side view which shows how the fitting convex part and the fitting concave part of a brick do not fit well in a part of a module block. It is a flowchart of the construction method of the coke oven which concerns on one Embodiment of this invention. It is a schematic diagram which shows the side surface of the 3D point cloud of a module block. It is a schematic diagram which shows the side surface of the 3D drawing shape of a module block. It is a side view which shows the state of the interference in the virtual arrangement state of a module block schematically. It is an enlarged view which shows the part of the interference of FIG. It is an enlarged view which shows typically the part which interfered when the fitting convex part of the interference part was cut and the module block was virtually arranged again. It is a conceptual diagram which shows how to select the module block of the optimum arrangement when a plurality of module blocks are virtually arranged. It is a side view which shows typically the arrangement of the module block before the module block repreparation in Example 1. FIG. It is a side view which shows typically the arrangement of the module block after the module block repreparation in Example 1. FIG. It is a side view which shows typically the arrangement of the module block before the module block repreparation in Example 2. FIG. It is a side view which shows typically the arrangement of the module block after the module block repreparation in Example 2. FIG. It is a figure which shows typically the state which three module blocks were installed in Example 3. FIG.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The following description illustrates the embodiments of the present invention, and the present invention is not limited to the following embodiments. Further, in the following description, unless otherwise specified, the standard refractory and the module block manufactured by stacking the standard refractories are referred to as above, below, and based on the orientation in the state of being incorporated in the coke oven. Use the terms horizontal, vertical, and height.

<Construction method of coke oven>
FIG. 1 is a schematic top view of an example of a module block in which standard refractories for a coke oven are stacked. FIG. 2 is a schematic side view of an example of a module block in which standard refractories for a coke oven are stacked. FIG. 3 is a schematic partial side view of an example of a furnace wall of a coke oven manufactured by installing module blocks in order.

As shown in FIGS. 1 to 3, the module block 1 is formed by stacking a standard refractory material (brick in this example) for a coke oven and mortar.

In the example shown in FIGS. 1 to 3, the brick is composed of a wall brick 2 forming a wall surface in the longitudinal direction of the coke oven and an inter-wall brick 3 connecting the wall bricks 2 in the lateral direction. As shown in FIG. 1, the flue 4 is partitioned by the wall brick 2 and the wall brick 3. In this example, the module block 1 used for the combustion chamber is illustrated, but the present invention can be similarly applied to the case of the module block 1 used for other parts of the coke oven such as a carbonization chamber. ..

As illustrated in FIG. 2, in general, the mortar between bricks is arranged so that the joints 5 are not arranged in a straight line in a side view. Therefore, as shown in FIG. 2, the end portion of the module block 1 is formed to protrude and retract without forming a straight line in this side view.

Further, as shown in FIG. 3, in this example, the center position in the longitudinal direction (horizontal direction in the drawing) of the wall surface of the coke oven of the odd-numbered module block 1 and the wall surface of the coke oven of the even-numbered module block 1 The module blocks 1 are stacked in a staggered manner so that the positions of the ends in the longitudinal direction are aligned when viewed in the vertical direction. As illustrated in FIG. 3, generally, when the module blocks 1 are stacked to manufacture a coke oven, the module blocks 1 are arranged so that the seams between the module blocks 1 do not line up in a straight line in a side view.

Here, although not shown in FIGS. 1 to 3, some or all of the bricks have a fitting convex portion 6 called a dowel on the lower surface or the side surface, and a fitting called a hozo on the upper surface or the side surface. It has a joint recess 7. As a result, when the bricks are piled up, the fitting recess 7 on the upper surface of the predetermined step and the fitting convex portion 6 on the lower surface of the next step are fitted, or the fitting convex is fitted between the bricks adjacent in the horizontal direction. The portion 6 and the fitting recess 7 are fitted to each other to increase the strength of the structure.

FIG. 4 is a diagram schematically showing how the fitting convex portion and the fitting concave portion are fitted between the side surfaces of the brick. FIG. 5 is a diagram schematically showing how the fitting convex portion and the fitting concave portion are fitted between the horizontal planes of the brick.
A large number of connections are formed between the side surfaces of the bricks of the module block 1 and between the horizontal planes, for example, the fitting protrusions 6 and the fitting recesses 7 as illustrated in FIGS. 4 and 5.

FIG. 6 is a schematic side view showing how the fitting convex portion and the fitting concave portion do not fit well in a part of the module block. As illustrated in FIG. 6, when the bricks in the module block 1 are connected, the fitting convex portion 6 and the fitting concave portion 7 may not fit well. That is, in the example shown in FIG. 6, the fitting convex portion 6 and the fitting concave portion 7 between the bricks cannot secure a predetermined joint thickness of the mortar, and there are places where they are in direct contact with each other.
Note that FIG. 6 shows a state in which the fitting convex portion 6 and the fitting concave portion 7 do not fit well between the horizontal planes of the bricks of the module block 1, but between the side surfaces of the bricks of the module block 1. The same may occur when the fitting convex portion 6 and the fitting concave portion 7 do not fit well.
Further, in FIG. 6, the fitting of the bricks in the module block 1 has been described, but similarly, the bricks are fitted with the fitting convex portion 6 between the horizontal planes and the side surfaces of the bricks between the adjacent module blocks 1. There may be cases where the recess 7 does not fit well.

In such a case, at the construction site of the coke oven, the work of repeatedly installing the bricks or scraping the fitting protrusions and fitting recesses to ensure proper fitting occurs at the site. Work efficiency may decrease. In addition, if the installation does not go well in the end, it may be necessary to switch to manual loading, which may significantly reduce the efficiency of the work process.

FIG. 7 is a flowchart of a method for constructing a coke oven according to an embodiment of the present invention.
As shown in FIG. 7, the method for constructing a coke oven of the present embodiment is a module block manufacturing process (step S101) in which a plurality of standard refractories are stacked in advance to manufacture a module block at a place other than the construction site of the coke furnace. ), The module block transporting step (step S105) of transporting the module block to the construction site of the coke furnace, the mortar coating step (step S106) of applying the mortar to the position where the transported module block is installed, and the mortar. The module block installation step (step S107) of installing the transported module block at the position where the above-mentioned material is applied is included.

Further, as shown in FIG. 7, the method for constructing the coke furnace of the present embodiment is a contour of the manufactured module block after the module block manufacturing step (step S101) and prior to the module block transporting step (step S105). The module block shape measurement step (step S102), the module block pass / fail determination step (step S103), and the module block pass / fail determination step of determining the pass / fail of the module block based on the measured contour of the module block. The module block re-preparation step (step S104) of re-preparing the module block determined to be unacceptable in the above process is further included.
Hereinafter, each step will be described in detail.

The module block manufacturing step (step S101) is a step of manufacturing the module block 1 by stacking a plurality of standard refractories in advance at a place other than the construction site of the coke oven.
Here, the "location other than the construction site of the coke oven" is not particularly limited as long as it is different from the construction site of the coke oven and the module block can be manufactured by stacking standard refractories. It can be anywhere. For example, in a place adjacent to a coke oven construction site such as land adjacent to a temporary roof provided in a place for constructing a coke oven, in the case of constructing the coke oven in a steel mill, in the steel mill. The module block manufacturing process can be performed in other places and the like. Further, although the module block can be manufactured in a remote place away from the coke oven construction site, it is preferable to manufacture the module block in a place adjacent to the coke oven construction site in consideration of the time and cost required for transportation. It is desirable for efficiency to carry out the module block manufacturing process centrally at one place, but it is carried out at multiple places, and the module blocks manufactured at each place are transported and carried into one coke oven construction site. It can also be used.
Further, as a standard refractory, brick can be exemplified. In addition, standard refractories can be stacked via mortar.
The bricks can be piled up by any known method, manually, or by a robot or the like.

Next, in the present embodiment, after the module block manufacturing step (step S101), the contour of the manufactured module block is measured prior to the module block transporting step (step S105) described later (module block shape measuring step: step). S102).
Here, the dimensional tolerance of the bricks constituting the module block is 1 to 2 mm, and the brick stacking accuracy is usually required to be 1 to 2 mm. Therefore, it is preferable that the contour of the module block 1 can be measured by about 1 mm. Therefore, in the present embodiment, in the module block shape measurement step (step S102), the contour is formed from the laser irradiation device or the infrared irradiation device to the surface of the module block by using the laser irradiation device infrared irradiation device. It is preferably measured by measuring the distance. As the laser irradiation device, for example, a laser scanner having a measurement accuracy of 30 μm can be used. As a result, a three-dimensional point cloud of the module block can be obtained by scanning the periphery of the module block. As the infrared irradiation device, for example, any known infrared irradiation device having a measurement accuracy of 1 mm can be used. Alternatively, in the present embodiment, in the module block shape measurement step (step S102), the above contour obtains a plurality of images obtained by capturing the module block from a plurality of viewpoints, and a photographer using the acquired plurality of images. It is also preferable to measure by metric. In photogrammetry, three-dimensional coordinates can be obtained from the principle of triangulation for the same point captured in two images taken from different viewpoints. By taking a plurality of (more preferably many) images from the periphery of the module block and using the above principle, a three-dimensional point cloud of the module block can be obtained.
Further, in the module block shape measuring step (step S102), it is preferable to measure the contour of the entire surface of the module block.
FIG. 8 is a schematic view showing a side surface of a three-dimensional point cloud of the module block. For example, as shown in FIG. 8, a three-dimensional point cloud of a module block can be obtained by a method using the above-mentioned laser irradiation device or a method using photogrammetry.

Returning to FIG. 7, following the module block shape measurement step (step S102), the pass / fail of the measured module block is determined (module block pass / fail determination step: step S103).
Here, FIG. 9 is a schematic view showing a side surface of the three-dimensional drawing shape of the module block. A drawing shape as shown in FIG. 9 is prepared in advance. In the present embodiment, in the module block pass / fail determination step (step S103), it is preferable that the pass / fail of the module block is determined by comparing the measured contour with the drawing shape prepared in advance. By comparing the measured contour with the drawing shape prepared in advance, the size of protrusion and recession from the drawing shape can be quantified. The three-dimensional point cloud may be handled in a polygonal shape from the point cloud. For example, if the size of the bulge or recess (for example, the maximum value of the bulge or recess in one module block) is less than or equal to a predetermined reference value, it is judged to be acceptable, while the bulge or retract is determined. When the size of the withdrawal is more than (or more than) a predetermined reference value, it can be determined that the product has failed. The above reference value is not particularly limited, and can be appropriately determined depending on the specifications of the coke oven (accuracy of flatness) and the like, and can be, for example, 2 mm.

As shown in FIG. 7, in the present embodiment, the module block determined to be acceptable in the module block pass / fail determination step (step S103) is subjected to the module block transport step (step S105).
On the other hand, as shown in FIG. 7, in the present embodiment, in the module block pass / fail determination step (step S103), the module block determined to be unacceptable is reprepared (module block repreparation step: step S104). ).
Here, in the module block re-preparation step (step S104), as an example, a plurality of standard refractories can be re-stacked to remanufacture the module block. In another example, the module block repreparation step (step S104) can also modify a part of the module block. In another example, the module block repreparation step (step S104) can also be replaced with another suitable module block.
Although not shown in FIG. 7, the remanufactured module block and the partially modified module block are again subjected to the module block shape measurement step (step S102) and the module block pass / fail determination step (step S103). If the result is passed, the module block can be transported to the module block transporting step (step S105). Further, when the module block determined to be unacceptable is replaced with another module block, the module block determined to be unacceptable is replaced with the module block determined to be acceptable through the same process, and the module block transportation step (step S105) is performed. ) Can be provided.

Next, in the module block transporting step (step S105), the module block is transported to the coke oven construction site after the drying is completed. The method for transporting the module block in the module block transport step (step S105) is not particularly limited, and a truck or a transporter (self-propelled transport) is used according to the distance between the module block manufacturing site and the coke furnace construction site. Any method such as a trolley) or a crane can be used alone or in combination of two or more. For example, if a temporary shed is installed at the coke oven construction site, it will be transported from the module block manufacturing site to the temporary shed by a transporter, and inside the temporary shed, an overhead crane and a stage jack will be used together to reach the construction position. Can be carried. Further, in the module block transportation step (step S105), the module block can be directly transported from the module block manufacturing site to the construction position of the coke oven construction site, but first, it is transported to the module block storage location temporarily. The module block may be stored and transported from the module block storage location to the construction location of the coke furnace construction site depending on the progress of the furnace construction.

Next, in the mortar application step (step S106), the mortar is applied to the position where the module block is installed. The method of applying the mortar is not particularly limited, and the mortar is applied to the position where the bottom surface and the side surface of the module block come into contact, in other words, the upper surface and the side surface of the position where the module block is installed, as in the case of loading a standard refractory. Just do it.

In the module block installation step (step S107), the module block is installed at a position where the mortar is applied in the mortar application step. The method of installing the module block is not particularly limited, but for example, the module block lifted by a crane or the like may be installed while adjusting the position on the surface coated with the mortar. In this way, by constructing in module block units, the burden on the operator can be reduced and the standard refractories can be stacked with high accuracy as compared with the case where the standard refractories are manually stacked one by one.

According to the method for constructing the coke furnace of the present embodiment, the pass / fail of the module block is determined prior to the module block transport process for transporting the module block, and for the module block that fails, before the module block is transported. It is possible to re-manufacture, modify a part, replace it with another module block, etc., and as a result, at the construction site, the module block that has been judged to have passed the module block pass / fail judgment process in advance can be used. It can be used to perform a mortar coating step and a module block installation step.
Therefore, according to the method for constructing the coke oven of the present embodiment, it is possible to reduce the work of re-installing the module block at the construction site of the coke oven, and to install the module block efficiently with high accuracy.

Here, even if the module block has a small shape error when viewed as a single module block and is judged to be acceptable in comparison with the drawing shape, etc., when the module block is installed vertically or horizontally. , Interference with adjacent module blocks (especially at fitting protrusions and fitting recesses) may occur.
FIG. 10 is a side view schematically showing the state of interference in the virtual arrangement state of the module blocks. FIG. 11 is an enlarged view showing the interference portion of FIG.
In the examples shown in FIGS. 10 and 11, the positions of the fitting convex portion 6 and the fitting concave portion 7 are displaced, the joint thickness of the mortar is not (almost), and the brick and the brick are (almost) in direct contact with each other. 8 has occurred.

Therefore, in the module block pass / fail determination step (step S103), the pass / fail of the module block may be determined by interference in a virtual arrangement state in which a plurality of module blocks whose contours have been measured are virtually arranged on a computer. preferable.
This pass / fail judgment can be performed, for example, in a form in which a further pass / fail judgment is performed as a secondary judgment for the module block that is firstly determined to be acceptable by comparison with the above drawing shape. Interference can be evaluated, for example, by the magnitude and / or number of interferences. For example, the maximum value of the magnitude of interference may be used as an index, or the value obtained by integrating the magnitude of interference by the number of interferences may be used as an index.
A predetermined reference value of the above index is set in advance, and if the interference is equal to or less than (less than) the reference value as a result of the interference evaluation, it is determined to be acceptable and the module block is subjected to the transport step (step S105). can do. On the other hand, as a result of the evaluation of the interference, if the interference exceeds the reference value (or less), it is determined that the interference has failed, and the module block is subjected to the module block re-preparation step (step S104). In this case, in the module block re-preparation step (step S104), it is preferable to modify a part of the module block, and it is more preferable to modify the interference portion 8. Specifically, the standard fireproof material (brick in this example) of the module block 1 has a fitting convex portion 6 and a fitting concave portion 7, and the module block repreparation step (step S104) is a standard fireproof material of the module block. A part of the module block by scraping the fitting convex portion 6 of the object to make the fitting convex portion 6 smaller, and / or scraping the portion that partitions the fitting concave portion 7 to make the fitting concave portion 7 larger. It is preferable to correct (more preferably, the interference portion 8).
FIG. 12 is an enlarged view schematically showing an interfering portion when the fitting convex portion of the interfering portion is cut off and the module block is virtually arranged again. In FIG. 12, the joint thickness of the mortar can be secured at various places above a certain level.
As a result, the interference between the module blocks is corrected in advance, so that the work of re-installing the module blocks at the construction site of the coke oven can be further reduced, and the module blocks can be installed with higher accuracy and more efficiently. can.
It should be noted that it is not preferable that the fitting convex portion becomes extremely small from the viewpoint of improving the strength of the coke oven. In such a case, it is preferable to increase the fitting concave portion at the same time.

In the above, in the module block repreparation step (step S104), it is also preferable to re-stack a plurality of standard refractories to remanufacture the module block. For example, when the magnitude of interference is large, it may be more appropriate to re-stack the standard refractories than to correct the interference points. This also corrects the interference between the module blocks in advance, so that the work of re-installing the module blocks at the construction site of the coke oven can be further reduced, and the module blocks can be installed with higher accuracy and more efficiently. Can be done.
In addition, for example, the case where the evaluation of interference is rejected is further classified into two degrees (for example, another reference value is set), and the case where the magnitude of interference is relatively large and fails is described above. If the magnitude of the interference is relatively small and the module block is rejected, the interference portion can be corrected.
Further, in the above example, when the pass / fail judgment of the module block is performed by the evaluation of interference in combination with the comparison with the above drawing shape (the primary judgment is made by comparison with the drawing shape, and the secondary judgment is made by the evaluation of interference. However, the pass / fail judgment of the module block by the evaluation of interference can be used as a single criterion in the module block pass / fail judgment step (step S103). Alternatively, another criterion may be added.

By the way, when the coke oven is renewed or newly installed, a large number of module blocks, for example, for 100 gates, will be manufactured. Therefore, it is also preferable to select a module block that has no modification or is minimized from a large number of module blocks.
FIG. 13 is a conceptual diagram showing a state in which a module block having an optimum arrangement is selected when a plurality of module blocks are virtually arranged.
In the present embodiment, the contours of a plurality of module blocks having the same shape are measured in the module block shape measurement step (step S102), and the contours of the plurality of modules having the same shape are measured in the module block pass / fail determination step (step S103). It is preferable to evaluate the interference of the module block in the virtual arrangement state. Then, in the present embodiment, in the module block repreparation step (step S104), the module block determined to be unacceptable in the module block pass / fail determination step (step S103) is determined to have passed the interference evaluation result. It is preferable to replace it with a module block that has been (more preferably optimal).
According to this, the module block suitable for the installation location can be arranged without remanufacturing or modifying the module block.

In the above case, various methods can be considered for quantifying the magnitude and number of interferences. For example, the joint thickness in the virtual placement state is calculated at one or more of the installation locations, and the difference between the target mortar thickness and the joint thickness in the virtual placement state (calculated by the absolute value | Δd |). The integrated value can be used as an index. Then, a module block whose integrated value is equal to or less than a predetermined reference value (more preferably the minimum) can be selected and replaced with the original module block determined to be rejected.
The above difference can be obtained by calculating | Δd | at, for example, 100 points on the installation surface between adjacent module blocks and using the integrated value as an index. It is preferable that the combination of the fitting convex portion and the fitting concave portion is included in the place where the | Δd | is calculated. Further, it is more preferable to calculate | Δd | at three or more locations for each combination of the fitting convex portion and the fitting concave portion.

By the way, it is also possible to first calculate the optimum overall arrangement of the module blocks.
That is, in the module block shape measuring step (step S102), the contours of a plurality of module blocks having the same shape are measured, and in the module block pass / fail determination step (step S103), the contours of the plurality of module blocks having the same shape are measured. It is also preferable to evaluate the interference in the virtual arrangement state and calculate the optimum overall arrangement. Various methods can be considered for this optimum overall arrangement. For example, the optimum overall arrangement can be such that the integrated value of the difference between the target mortar thickness and the joint thickness in the virtual arrangement state is minimized at one or more of the installation locations. In this case, it is preferable to calculate the above difference at at least one installation location between all the adjacent module blocks. Alternatively, the arrangement that minimizes the number of module blocks for which the evaluation result fails can be set as the optimum arrangement. Then, in the module block re-preparation step (step S104), only the module blocks whose interference evaluation results are unacceptable at the time of the optimum overall arrangement are re-prepared. Re-preparation can be remanufacturing or partial modification.
According to this, the number of module blocks to be remanufactured or partially modified can be reduced or minimized, so that a more efficient coke oven can be constructed.

<Manufacturing method of module block>
The method for manufacturing a module block according to an embodiment of the present invention is a method for manufacturing a module block for construction of a coke oven by stacking a plurality of standard refractories in advance at a place other than the construction site of the coke oven. The method includes a module block shape measuring step (step S201) for measuring the contour of a manufactured module block, and a module block pass / fail determination step for determining the pass / fail of the module block based on the measured contour of the module block. (Step S203) and a module block re-preparation step (step S204) for re-preparing the module block determined to be unacceptable in the module block pass / fail determination step (step S203).
Then, the module block re-preparation step (step S204) includes re-stacking a plurality of standard refractories to remanufacture the module block, or modifying a part of the module block.
The details of each step are the same as those described in steps S101 to S104 in the embodiment of the method for constructing a coke oven, and thus the description thereof will be omitted.
According to the method for manufacturing a module block of the present embodiment, it is possible to reduce the work of re-installing the module block at the construction site of the coke oven, and to install the module block with high accuracy and efficiency.

Hereinafter, preferred examples of the method for manufacturing the module block of the present invention will be described. The details are the same as those already described in the embodiment of the method for constructing a coke oven.
In the module block shape measuring step (step S201), the contour is preferably measured by measuring the distance from the laser irradiating device to the surface of the module block using a laser irradiating device.
Alternatively, in the module block shape measuring step (step S201), it is also preferable that the contour is measured by acquiring a plurality of images obtained by capturing the module block from a plurality of viewpoints and by photogrammetry using the acquired plurality of images. ..
Further, in the module block shape measuring step (step S201), it is preferable to measure the contour of the entire surface of the module block.
Further, in the module block pass / fail determination step (step S203), it is preferable to determine the pass / fail of the module block by comparing the measured contour with the drawing shape prepared in advance.
Further, in the module block pass / fail determination step (step S203), it is also preferable that the pass / fail of the module block is determined by interference in a virtual arrangement state in which a plurality of module blocks whose contours have been measured are virtually arranged on a computer. ..
Further, in the module block re-preparation step (step S204), it is preferable to re-stack a plurality of standard refractories to remanufacture the module block.
Alternatively, in the module block repreparation step (step S204), it is also preferable to modify a part of the module block.
In this case, the standard fireproof material of the module block has a fitting convex portion and a fitting concave portion, and in the module block re-preparation step (step S204), the fitting convex portion of the standard fireproof material of the module block is scraped and fitted. It is more preferable to modify a part of the module block by making the convex portion smaller and / or cutting the portion that partitions the fitting concave portion to make the fitting concave portion larger.

Hereinafter, examples of the present invention will be described, but the present invention is not limited to the following examples.

<Example 1>
As the first embodiment, first, four module blocks (module block 9, module block 10, module block 11, module block 12) in which six bricks in the horizontal direction and five bricks in the vertical direction are stacked were manufactured. The contour of the manufactured module block was measured using a laser scanner. This measurement was performed over the entire surface of the module block using a highly accurate handy type device with a measurement accuracy of 0.085 mm. The ideal module block shape was prepared in advance as 3D data of the drawing shape, and by comparing (taking a difference) with the measured scanner point cloud data, the collapse and unevenness of the module block were quantified. As a result, it was found that the module block 12 had a maximum unevenness of 3 mm on the lower surface, but the other module blocks 9 to 11 were below the reference value (2 mm or less). FIG. 14 is a side view schematically showing the arrangement of the module blocks before the module block re-preparation in the first embodiment. Each module block was arranged as shown in FIG. Spacers with a height of 4 mm were installed on each of the upper and lower joint surfaces as a substitute for mortar. In addition, the lower right part of the drawing is not an actual module block, but a gantry 14 is used instead. When the module block 12 was installed, it rose up at the mating surface with the module block 9 (interference point 13), and the module block did not fit correctly. Therefore, the spacer was adjusted within a height range of ± 2 mm, but the module block could not be accommodated correctly. Since the module block 12 does not meet the standard, the module block was reloaded and remanufactured so that the lower surface was within the unevenness of 2 mm or less. FIG. 15 is a side view schematically showing the arrangement of the module blocks after the module block is reprepared in the first embodiment. After the module block 12 was remanufactured into the module block 12', each module block was arranged again as shown in FIG. Spacers with a height of 4 mm were installed on each of the upper and lower joint surfaces as a substitute for mortar. As a result, the horizontality of the upper surface and the tilt of the side surface of the stacked module blocks 12'were within 2 mm, and the stacked module blocks 12'can be stacked within the allowable range of the standard.

<Example 2>
As the second embodiment, four module blocks (module block 15, module block 16, module block 17, module block 18) in which six bricks in the horizontal direction and five bricks in the vertical direction are stacked were manufactured. The contour of the manufactured module block was measured using a laser scanner. This measurement was performed over the entire surface of the module block using a highly accurate handy type device with a measurement accuracy of 0.085 mm. The ideal module block shape was prepared in advance as 3D data of the drawing shape, and by comparing (taking a difference) with the measured scanner point cloud data, the collapse and unevenness of the module block were quantified. As a result, it was confirmed that all the module blocks were below the reference value (2 mm or less). FIG. 16 is a side view schematically showing the arrangement of the module blocks before the module block re-preparation in the second embodiment. Each module block was arranged as shown in FIG. Spacers with a height of 4 mm were installed on each of the upper and lower joint surfaces as a substitute for mortar. In addition, the lower right part of the drawing is not an actual module block, but a gantry 14 is used instead. When the module block 18 is installed, interference points (19, 20) may occur at the dowel (fitting convex portion) and the hozo (fitting concave portion) on the mating surface with the module block 15 and the mating surface with the module block 17. all right. Next, when the module is virtually installed on the computer and the presence or absence of interference between the module blocks is confirmed, similarly, dowels (fitting convex portions) are formed on the mating surface with the module block 15 and the mating surface with the module block 17. ), It was found that interference points (19, 20) occur in the hozo (fitting recess). Therefore, the interference portion 19 is modified by scraping the dowel (fitting convex portion), and the interference portion 20 is modified by scraping the portion that partitions the hozo (fitting concave portion) to increase the hozo (fitting concave portion). The virtual installation on the computer was performed again and it was confirmed that the interference disappeared. FIG. 17 is a side view schematically showing the arrangement of the module blocks after the module block is reprepared in the second embodiment. Obtaining the results of the above re-virtual installation, each module block was repositioned as shown in FIG. Spacers with a height of 4 mm were installed on each of the upper and lower joint surfaces as a substitute for mortar. As a result, it was possible to stack the module blocks within the allowable range of the reference value without causing interference points.

<Example 3>
As Example 3, a plurality of module blocks in which 6 bricks in the horizontal direction and 5 bricks in the vertical direction were stacked were manufactured. FIG. 18 is a diagram schematically showing a state in which three module blocks are installed in the third embodiment. The three module blocks were installed within the range of the reference values in the arrangement shown in FIG. Ten such installation sets were produced. Then, 10 module blocks to be installed next were prepared. The contour of each module block was measured using a laser scanner. This measurement was performed over the entire surface of the module block using a highly accurate handy type device with a measurement accuracy of 0.085 mm. The ideal module block shape was prepared in advance as 3D data of the drawing shape, and by comparing (taking a difference) with the measured scanner point cloud data, the collapse and unevenness of the module block were quantified. As a result, it was confirmed that all the module blocks were below the reference value (2 mm or less). Next, all patterns of virtual installation were performed on the computer for the above 10 sets of installation sets and 10 module blocks. Then, in each pattern, the joint thickness when virtually installed was measured, and the absolute value | Δd | of the difference between the target joint thickness and the measured joint thickness was calculated. On the mounting surface, there were 56 mating points of dowels (fitting convex parts) and hozos (fitting concave parts). | Δd | was calculated at three locations for each dowel (fitting convex portion) and hozo (fitting concave portion) (total 56 × 3 = 168 locations), and the integrated values were calculated respectively. In the combination that minimizes the integrated value, there were 14 interference points of the dowel (fitting convex part) and the hozo (fitting concave part) for 10 sets of installation, and these were corrected. When the product was loaded again after the correction, the installation was completed below the standard value. On the other hand, in the combination that maximizes the above integrated value, there are 31 interference points of the dowel (fitting convex part) and hozo (fitting concave part) for 10 sets of installation, and the number of points to be corrected is doubled. That's all.

1: Module block,
2: Wall brick,
3: Brick between walls,
4: FuRyu,
5: Joint,
6: Fitting convex part,
7: Fitting recess,
8: Interference point,
9: Module block,
10: Module block,
11: Module block,
12: Module block,
13: Interference point,
14: Stand,
15: Module block,
16: Module block,
17: Module block,
18: Module block,
19: Interference point,
20: Interference point,
21: Module block,
22: Module block,
23: Module block

Claims (15)

A module block manufacturing process in which a plurality of standard refractories are stacked in advance to manufacture a module block at a place other than the construction site of the coke oven.
A module block transportation process for transporting the module block to the construction site of the coke oven, and
A mortar application process in which the mortar is applied to the position where the transported module block is installed, and
A method for constructing a coke oven, which comprises a module block installation step of installing the transported module block at a position where the mortar is applied.
A module block shape measuring process for measuring the contour of the manufactured module block, and
A module block pass / fail determination step of determining the pass / fail of the module block based on the measured contour of the module block, and
Further including a module block re-preparation step of re-preparing the module block determined to be unacceptable in the module block pass / fail determination step.
The coke oven, characterized in that the module block shape measuring step, the module block pass / fail determination step, and the module block repreparation step are performed after the module block manufacturing step and prior to the module block transporting step. Construction method. In the module block shape measuring step, the contour is measured by measuring the distance from the laser irradiation device or the infrared irradiation device to the surface of the module block using a laser irradiation device or an infrared irradiation device. The method for constructing coke according to claim 1. According to claim 1, in the module block shape measuring step, the contour is measured by acquiring a plurality of images obtained by capturing the module block from a plurality of viewpoints and by photogrammetry using the acquired plurality of images. The described coke construction method. The method for constructing a coke oven according to any one of claims 1 to 3, wherein in the module block shape measuring step, the contour of the entire surface of the module block is measured. The method for constructing a coke oven according to any one of claims 1 to 4, wherein the module block determined to be acceptable in the module block pass / fail determination step is subjected to the module block transportation step. The present invention according to any one of claims 1 to 5, wherein in the module block pass / fail determination step, the pass / fail of the module block is determined by comparing the measured contour with the drawing shape prepared in advance. How to build a coke oven. In the module block pass / fail determination step, the pass / fail of the module block is determined by interference in a virtual arrangement state in which a plurality of the module blocks whose contours have been measured are virtually arranged on a computer. The method for constructing a coke oven according to any one of 6. The method for constructing a coke oven according to any one of claims 1 to 7, wherein the module block repreparation step remanufactures the module block by re-stacking a plurality of the standard refractories. The method for constructing a coke oven according to any one of claims 1 to 7, wherein the module block repreparation step modifies a part of the module block. The standard refractory of the module block has a fitting protrusion and a fitting recess.
In the module block re-preparation step, the fitting convex portion of the standard refractory of the module block is scraped to reduce the fitting convex portion, and / or the portion for partitioning the fitting concave portion is scraped. The method for constructing a coke oven according to claim 9, wherein a part of the module block is modified by enlarging the fitting recess. In the module block shape measuring step, the contours of a plurality of module blocks having the same shape are measured.
In the module block pass / fail determination step, interference in the virtual arrangement state is evaluated for the plurality of module blocks having the same shape whose contours have been measured.
The module block repreparation step replaces the module block determined to be unacceptable in the module block pass / fail determination step with the module block determined to pass the evaluation result of the interference. 7. The method for constructing a coke furnace according to 7. In the module block for which the evaluation result of the interference is optimal, the integrated value of the difference between the target mortar thickness and the joint thickness in the virtual arrangement state is minimized at one or more of the installation locations. The method for constructing a coke oven according to claim 11, which is the module block. In the module block shape measuring step, the contours of a plurality of module blocks having the same shape are measured.
In the module block pass / fail determination step, interference in the virtual arrangement state is evaluated for the plurality of module blocks having the same shape whose contours have been measured, and the optimum overall arrangement is calculated.
The method for constructing a coke oven according to claim 7, wherein in the module block re-preparation step, only the module block whose interference evaluation result is unacceptable at the time of the optimum overall arrangement is re-prepared. The optimum overall arrangement is the overall arrangement of the module blocks so that the integrated value of the difference between the target mortar thickness and the joint thickness in the virtual arrangement state is minimized at one or more of the installation locations. The method for constructing a coke oven according to claim 13. A module block manufacturing method in which a plurality of standard refractories are stacked in advance to manufacture a module block for construction of a coke oven at a place other than the construction site of the coke oven.
A module block shape measuring process for measuring the contour of the manufactured module block, and
A module block pass / fail determination step of determining the pass / fail of the module block based on the measured contour of the module block, and
The module block re-preparation step of re-preparing the module block determined to be unacceptable in the module block pass / fail determination step is included.
The module block repreparation step includes re-stacking a plurality of the standard fireproof materials to remanufacture the module block, or correcting an interference point of the module block in the virtual arrangement state. A characteristic method for manufacturing module blocks.

Images