JP2022191088A - Furnace construction method - Google Patents

Abstract

To provide a furnace construction method that can reduce the manual work of readjusting the installation of module blocks at construction sites and can install the module blocks efficiently with high accuracy.SOLUTION: A furnace construction method comprises: a module block production step of producing module blocks at a place other than a furnace construction site; a module block transporting step of transporting the module blocks to the furnace construction site; a mortar applying step of applying a mortar to locations where the module blocks are to be installed; and a module block installation step. The module block production step includes: a module block stacking step of stacking up multiple stereotyped refractory materials; a first measuring step of measuring contour shapes of the module blocks; a second measuring step of measuring contour shapes of locations where the module blocks are to be installed; and a determining step of comparing the contour shapes of the module blocks with the contour shapes of the installation locations to determine whether the shapes of the module blocks are acceptable or not.SELECTED DRAWING: Figure 1

Description

The present invention relates to a furnace construction method for constructing a furnace using module blocks.

Metallurgical coke used in iron making is produced by carbonizing coal in a chamber coke oven. The chamber-type coke oven is configured by alternately arranging a coking chamber and a combustion chamber for supplying heat to the coking chamber in the width direction of the furnace. Heat is supplied from the combustion chamber to the coking chamber through a shaped refractory. Some chamber-type coke ovens have a furnace chamber of 100 gates or more, and such a chamber-type coke oven can be said to be a huge brick structure with a total length of 100 m or more and a height of 10 m or more.

The shaped refractories that make up the coke oven have complex shapes such as rectangles, trapezoids, and L-shapes when viewed from above, unlike bricks for general buildings. Further, the side, top, and bottom surfaces of the standard refractories are sometimes provided with fitting protrusions called dowels for preventing slippage and fitting recesses called tenons for slippage prevention. A coke oven is constructed by combining shaped refractories having such extremely complicated shapes.

Due to the complexity of the shape of the standard refractories, the construction of coke ovens is currently carried out manually by furnace builders. In manual furnace construction, it is necessary to repeat the work of applying mortar to the position where the standard refractories are to be stacked using a tool such as a trowel to achieve a predetermined joint thickness, and then stacking the standard refractories on top of the mortar. There is In doing so, extremely advanced skills are required, such as the need to apply mortar evenly to the surface of a refractory with a complicated shape, but skilled furnace builders with such skills are always in short supply. doing. Furnace construction work, in which mortar is applied and standard refractories are piled up by hand, can be said to be extremely labor intensive.

For the above reasons, there is a demand for the development of a method for efficiently stacking standard refractories with less manpower.

For example, in Patent Document 1, a module block is manufactured by stacking a plurality of brick layers in which a plurality of bricks are horizontally arranged in a vertical direction in advance at a place other than the construction site of the coke oven, and transported to the construction site. Installation methods have been proposed.

JP 2016-191064 A

In the method proposed in Patent Document 1, since the module blocks are manufactured at a place other than the space-limited coke oven construction site, a sufficient work space can be secured. As a result, in addition to improving work efficiency, it is also easy to automate the stacking of standard refractories and the application of mortar using a robot or the like.

However, as a result of studies by the present inventors, it has been found that the conventional methods such as Patent Document 1 have room for further improvement as described below.

That is, since the shaped refractories used in the construction of coke ovens are manufactured by firing, there are variations in dimensions. For example, standard refractories generally used have a dimensional error of about 1 to 2 mm in diagonal distance in plan view or side view, and the dimensional error differs for each standard refractory. Therefore, module blocks obtained by piling up standard refractories also have variations in shape for each individual block.

In particular, in a coke oven, coal is introduced into a coking chamber for carbonization, and the obtained coke is pushed out from the side to be discharged, so the walls of the coking chamber are required to have a high degree of flatness. Therefore, when manufacturing module blocks, it is conceivable to adjust the stacking method of the standard refractories so that the walls of the coking chamber have the required flatness. cannot be completely eliminated.

Due to this variation in module block shape, there is a problem that the accuracy and work efficiency of coke oven construction are lowered. For example, if the distance between module blocks becomes too small due to variations in shape, the installation accuracy of the module blocks is lowered, and a sufficient thickness of mortar may not be ensured. In particular, when module blocks interfere with each other, the module blocks cannot be stacked as they are, so it is necessary to modify the module blocks so that the interference does not occur. However, since the module block installation work is usually performed while the module block is held by a jig for transportation, it cannot be repaired as it is. Therefore, it is necessary to first remove the jig from the module block, and then grind the standard refractories that make up the module block, or disassemble at least a part of the module block and restack the standard refractories. Such rework is very time-consuming work, and rework of the module block at the coke oven construction site significantly lowers work efficiency. Conversely, if the distance between the module blocks becomes too large, the installation accuracy may decrease and the gaps between the module blocks must be filled with a large amount of mortar. Less efficient.

Therefore, there is a demand for a method of constructing a coke oven using modular blocks, which can construct the coke oven efficiently with higher accuracy. In addition, the construction method using the above-mentioned module block can be applied to the construction of furnaces other than coke ovens, but even in that case, there is a demand for a method that can construct furnaces with even higher accuracy and efficiency. .

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method for efficiently constructing a furnace with high accuracy by reducing the work required for repairing module blocks at the furnace construction site.

The gist and configuration of the present invention are as follows.

1. a module block manufacturing process for manufacturing module blocks at a location other than the furnace construction site;
a module block transporting step of transporting the module blocks manufactured in the module block manufacturing step to the construction site of the furnace;
a mortar application step of applying mortar to a position where the module block is to be installed;
a module block installation step of installing the module blocks transported in the module block transportation step at the positions where the mortar has been applied, the furnace construction method comprising:
The module block manufacturing process includes:
a stacking step of stacking a plurality of standard refractories to manufacture the module block;
a first measuring step of obtaining a module block contour shape by measuring the contour shape of the module block obtained in the stacking step;
a second measuring step of measuring a contour shape of a position where the module block is installed in the furnace to obtain an installation position contour shape;
a determination step of comparing the contour shape of the module block with the contour shape of the installation position to determine whether the shape of the module block is acceptable.

2. 2. The furnace construction method according to 1 above, wherein when the shape of the module block is determined to be unacceptable in the determining step, a separately manufactured module block is used in place of the module block.

3. 2. The furnace construction method according to 1 above, wherein when the shape of the module block is determined to be unacceptable in the determining step, the shape of one or both of the module block and the position where the module block is installed is corrected.

4. 4. The furnace construction method according to 3 above, wherein the modification of the shape is performed by machining.

5. 5. The furnace construction method according to the above 3 or 4, wherein the modification of the shape is performed by replacing a part or all of the standard refractories constituting the module block.

6. Furnace construction according to any one of the above 1 to 5, wherein one or both of the measurement in the first measurement step and the measurement in the second measurement step are performed using a three-dimensional measurement method using a laser. Method.

7. 6. The measurement according to any one of 1 to 5 above, wherein one or both of the measurement in the first measurement step and the measurement in the second measurement step are performed by photogrammetry using images captured from a plurality of viewpoints. furnace construction method.

8. The module block manufacturing process includes:
Prior to the determination step, the contour shape of the module block obtained in the first measurement step is compared with an appropriate contour shape of the module block prepared in advance to determine whether the shape of the module block is acceptable. 8. The furnace construction method according to any one of the above 1 to 7, further comprising a target determination step.

ADVANTAGE OF THE INVENTION According to this invention, the repair work in the construction site of a furnace can be reduced, and a furnace can be built efficiently with high precision.

4 is a flow chart showing a furnace construction method in one embodiment of the present invention. 4 is a flow chart showing a module block manufacturing process in one embodiment of the present invention. FIG. 4 is a top view schematically showing an example of the structure of a module block; FIG. 3 is a side view schematically showing an example of the structure of a module block; FIG. 4 is a top view schematically showing an example of the structure of dowels and tenons between horizontally adjacent standard refractories. FIG. 4 is a side view schematically showing an example of a dowel and tenon structure between vertically adjacent standard refractories. FIG. 4 is a schematic diagram showing an example of arrangement of module blocks installed in a module block installation process and module blocks already installed. 4 is a flow chart showing a module block manufacturing process according to another embodiment of the present invention;

Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings. It should be noted that the following description exemplifies the embodiments of the present invention, and the present invention is not limited to the following embodiments. In the following description, unless otherwise specified, standard refractory materials and module blocks manufactured by stacking the standard refractory materials are oriented upward, downward, and horizontally, based on the direction in which they are assembled in a furnace. , vertical, and height.

In addition, the "construction" of the furnace in the present invention includes the case of constructing a new furnace, the case of additionally constructing a new part in an existing furnace (expansion), and the case of replacing a part of an existing furnace It also includes the case of constructing a new part (repair). In other words, "construction" in the present invention includes new installation, extension and repair. For example, in repairing coke ovens in operation, some combustion chambers and carbonization chambers are out of service, and other combustion chambers and carbonization chambers are repaired while they are in operation (hot repair). commonly practiced. The present invention is also applicable to the hot repair.

A furnace construction method in one embodiment of the present invention includes the following steps as shown in the flow chart of FIG.
・Module block manufacturing process ・Module block transportation process ・Mortar application process ・Module block installation process

Each of the above steps will be described below. In the following description, a method of constructing a coke oven will be described as an example, but the present invention is also applicable to construction of ovens other than coke ovens.

[Module block manufacturing process]
In the module block manufacturing process, module blocks are manufactured at a location other than the furnace construction site. In the present invention, since the module blocks manufactured at a place other than the coke oven construction site are transported and installed at the coke oven construction site to construct the coke oven, there is no need for a furnace construction worker at a construction site with poor workability as in the past. It is possible to reduce the work of manually loading the standard refractories one by one, and to significantly improve the work efficiency at the construction site.

Although the present invention uses the module block construction method, a part of the furnace, such as a part with a complicated shape, can be manufactured by directly stacking standard refractories instead of module blocks.

The above-mentioned "place other than the construction site of the coke oven" is not particularly limited as long as it is a place different from the construction site of the coke oven and where the standard refractories can be piled up to manufacture module blocks, and any place. can be used. For example, a place adjacent to a coke oven construction site such as land adjacent to a temporary shed provided at a site for constructing a coke oven, or if the coke oven is to be constructed within a steelworks, within the steelworks The build-up process can be performed elsewhere, such as in the In addition, although it is possible to manufacture the module blocks in a remote location away from the coke oven construction site, considering the time and cost required for transportation, it is preferable to manufacture the module blocks at a location adjacent to the coke oven construction site. Although it is desirable for efficiency to perform the stacking process intensively at one location, it is preferable to perform the stacking process at multiple locations and transport the module blocks manufactured at each location to a single coke oven construction site for use. can also

A module block manufacturing process in one embodiment of the present invention includes the following steps as shown in the flow chart of FIG.
・Accumulation process ・First measurement process ・Second measurement process ・Judgment process

[Stacking process]
In the module block manufacturing process, first, a module block is manufactured by stacking a plurality of standard refractories (stacking process). The module block can be a module block for configuring any part of the coke oven, but if a part with a relatively simple structure or a part with a repeated structure is made into a module block, work efficiency can be improved. Great effect. Therefore, in the stacking step, it is preferable to fabricate at least one of the module blocks that form the heat storage chamber and the module blocks that form the combustion chamber.

3 and 4 are schematic diagrams showing an example of the structure of the module block, showing the structure of the module block that constitutes the combustion chamber of the coke oven. In each drawing including FIGS. 3 and 4, for the sake of explanation, the shapes and combinations of standard refractories are shown in a simplified manner, and it should be noted that they do not show the actual accurate structure.

The module block 1 is configured by stacking a plurality of standard refractories 2, and the individual standard refractories 2 are joined by mortar (not shown) applied to joints between the standard refractories 2. . As described above, the standard refractory 2 for coke ovens has, as shown in FIGS. is provided, and the dowel 3 and the tenon 4 are joined in a fitted state via the mortar 5 .

[[Standard refractories]]
The standard refractories for manufacturing the module blocks are not particularly limited, and any standard refractories such as bricks and precast blocks can be used. Among them, it is preferable to use a normal shaped refractory that is used when constructing a coke oven by hand. By using ordinary standard refractories, it is possible to design the same furnace as the conventional one even when constructing the furnace by the method of the present invention. As a result, at least the same furnace performance as the conventional one is guaranteed. It becomes possible to Also, when using large module bricks, if cracks occur, the cracks may spread throughout the module. Also, the propagation of the crack can be stopped within one standard refractory. The standard refractory referred to here refers to all standard refractories for manual laying, which are not module bricks. is 20 to 40 cm.

[[Manual stacking of standard refractories]]
Stacking of the standard refractories can be performed manually. In the present invention, since module blocks are manufactured at a place other than the coke oven construction site, it is possible to secure a sufficient working space, unlike the case where standard refractories are manually loaded at the coke oven construction site. . Therefore, it is possible to reduce the burden on the worker even if the same manual loading is carried out. In addition, when stacking standard refractories at a coke oven construction site, it is necessary to build scaffolds according to the height of the stacked standard refractories and work on them. Since the work of stacking standard refractories is performed, there is no need to use scaffolding for high-place work, and work can be performed on the ground with good footing.

[[Stacking standard refractories by robot]]
Moreover, the stacking of the standard refractories can also be performed using a robot. In this case, part or all of the block manufacturing process can be automated. It becomes possible to automate part or all of the refractory stacking work by robots.

The robot used for stacking the standard refractories is not particularly limited, and any robot can be used. is preferred. An example of the arm-type robot is a vertical articulated robot, which is a type of industrial robot. Also, a module block can be manufactured using an arm-type robot for stacking standard refractories and an arm-type robot for applying mortar.

[[Module block production line]]
It should be noted that there may be one or more module block manufacturing lines, regardless of whether they are hand-loaded or robots are used. By stacking standard refractories on multiple lines to manufacture module blocks, it is possible to increase the supply speed of module blocks to the coke oven construction site. is preferably 2 or more, more preferably 3 or more. On the other hand, the upper limit of the number of production lines is not particularly limited, but even if the number of lines is increased more than necessary, the subsequent module block transportation process, the mortar coating process and the module block installation process at the coke oven construction site will be the rate-limiting processes. Therefore, it becomes difficult to further improve the construction speed of the coke oven, and the cost effectiveness decreases. Therefore, the number of lines should be determined in consideration of the scale of the coke oven, the work speed in each process, and the like.

[Module block size]
The size of the module block is not particularly limited and can be any size. However, when manufacturing module blocks by hand, if the height of the module block is too high, it is necessary to set up a work floor by assembling scaffolding or the like in order to stack the standard refractories at a high position. For example, in Japan, according to the provisions of Article 518 of the Ordinance on Industrial Safety and Health, it is required to provide a work floor when there is a risk of falling when working at a height of 2 m or more. If the height of the module block is less than 2 m, even when the standard refractories are manually stacked to manufacture the module block, there is no need to install a scaffold or the like to work in high places, resulting in high work efficiency. In addition, when manufacturing module blocks using a robot, if the height of the module block is less than 2 m, the height of the position where the standard refractory is stacked is within the movable range of the arm of a general arm-type robot. can be Therefore, since module blocks can be manufactured only by moving the robot in the horizontal direction, work efficiency is high. Therefore, from the viewpoint of work efficiency, it is preferable to set the height of the module block to less than 2 m. On the other hand, although the lower limit of the height of the module block is not particularly limited, it is preferable that the module block has two or more layers of standard refractories.

The length of the module block in the longitudinal direction is also not limited, but from the viewpoint of work efficiency, it is preferably 1/8 or more of the furnace length of the coke oven to be constructed. The longitudinal length of the module block may be 1/4 or more of the furnace length of the coke oven to be constructed. On the other hand, the length of the module block in the longitudinal direction is preferably 2/3 or less, more preferably 1/2 or less, of the furnace length of the coke oven to be constructed.

Here, "the length of the module block in the longitudinal direction" refers to the length in the longitudinal direction of the horizontal cross section of the module block, and "the height of the module block" refers to the height from the bottom surface to the top surface of the module block. refers to height. It should be noted that the "longitudinal length of the module block" and the "height of the module block" do not include irregularities such as dowels provided on the side, top and bottom surfaces of the module block. Further, the "furnace length of the coke oven" means the length in the longitudinal direction of each combustion chamber and carbonization chamber that constitute the coke oven. The furnace length of a general coke oven currently in use is about 15 to 17 m.

[First measurement step]
Next, the contour shape of the module block obtained in the stacking step is measured to obtain the module block contour shape (first measuring step). The measured module block contour shape is used in the determination process described later.

In the first measuring step, the contour shape of at least a part of the module block may be measured, or the contour shape of the entire module block may be measured.

A method for measuring the contour shape is not particularly limited, and any method can be used. As the measuring method, it is preferable to use a three-dimensional measuring method for measuring three-dimensional contour shape data of the module block. In the three-dimensional measurement method, for example, module block contour shapes can be obtained as three-dimensional point group data.

For example, in one embodiment of the present invention, the contour shape can be measured using a three-dimensional measurement method using a laser. Obtaining three-dimensional point cloud data of the contour shape of the module block by irradiating the module block with a laser and measuring the distance from the light source to each point on the surface of the module block by detecting the reflected light. can be done. Examples of methods that can be used to measure the distance using reflected light include a TOF (Time of Flight) method and a phase difference detection method, but are not limited to these and any method can be used.

In another embodiment of the present invention, the contour shape can be measured by photogrammetry using images of the module block taken from a plurality of viewpoints. That is, in photogrammetry, from a plurality of images taken from different viewpoints, the three-dimensional coordinates of the same point in the images can be obtained by the principle of triangulation. Therefore, by obtaining the three-dimensional coordinates of many points in the image, three-dimensional point cloud data of the contour shape of the module block can be obtained.

Regardless of which measurement method is used, when the contour shapes of multiple surfaces of the module block are measured, the obtained multiple measurement data are combined to generate data containing the contour shapes of the multiple surfaces. is preferred.

The dimensional tolerance of the standard refractories that constitute the module block is generally about 1 to 2 mm. Also, the stacking accuracy of the standard refractories in the coke oven is generally required to be about 1 to 2 mm. Therefore, the measurement accuracy of the measuring method used in measuring the contour shape is preferably 2 mm or less, more preferably 1 mm or less. It is also possible to create a three-dimensional polygon model from the obtained three-dimensional point cloud data and use the polygon model in subsequent steps.

In the first measuring step, the portion where the contour shape of the module block is measured is not particularly limited, but it is preferable to measure at least the contour shape of the lower surface of the module block, and at least the contour shapes of the lower surface and the side surface of the module block are measured. is more preferable. The reason for this will be described later.

[Second measurement step]
Also, the contour shape of the position where the module block is installed in the furnace is measured to obtain the installation position contour shape (second measuring step). The measured installation position contour shape is used in the determination step described later together with the module block contour shape obtained in the first measurement step.

Here, "the position where the module block is installed" refers to the position where the module block is to be installed in the module block installation process. The "contour shape of the position where the module block is installed (installation position contour shape)" refers to the contour shape of the part that comes into contact with the module block (via mortar) when the module block is installed. Point. The installation position contour shape typically includes the contour shape of the already installed module block. Further, as described above, in the present invention, a part of the furnace, such as a part having a complicated shape, can be manufactured by directly laying shaped refractories instead of module blocks. Therefore, the contour shape of the installation position can also include the contour shape of the standard refractories that have already been installed (those other than the standard refractory that constitutes the module block).

In the second measuring step, the contour shape of at least a part of the position where the module block is installed may be measured, but when the module block is installed, the surface of the module block facing the lower surface and the module. It is preferable to measure the contour shape of the faces facing the sides of the block.

A method for measuring the contour shape is not particularly limited, and any method can be used. As the measuring method, it is preferable to use a three-dimensional measuring method for measuring three-dimensional contour shape data of the installation position. In the three-dimensional measurement method, for example, an installation position contour shape can be obtained as three-dimensional point cloud data.

As the measurement method in the second measurement step, as in the first measurement step described above, any three-dimensional measurement method using a laser, photogrammetry using images taken from a plurality of viewpoints, etc. method. The measurement method used in the first measurement step and the measurement method used in the second measurement step may be the same or different.

Irrespective of the measurement method used, when the contours of multiple surfaces of the installation position are measured, it is preferable to combine the obtained measurement data to generate data containing the contours of the multiple surfaces.

For the same reason as described in the first measurement step, the measurement accuracy of the measurement method used in measuring the installation position contour shape is preferably 2 mm or less, more preferably 1 mm or less. . It is also possible to create a three-dimensional polygon model from the obtained three-dimensional point cloud data and use the polygon model in subsequent steps.

In addition, in the flowchart of FIG. 2, the case where the 2nd measurement process is performed after the 1st measurement process and before the determination process was shown as an example. However, in the present invention, the timing of performing the second measurement step is not limited to this, and can be performed at any timing as long as it precedes the determination step. For example, the second measurement process may be performed before the first measurement process, or the second measurement process may be performed simultaneously with the second measurement process.

[Determination process]
Next, the contour shape of the module block obtained in the first measuring step and the contour shape of the installation position obtained in the second measuring step are compared to determine whether the shape of the module block is acceptable (judgment step ). By comparing the contour shape of the module block and the contour shape of the installation position in this manner, it is possible to determine whether the shape of the module block matches the shape of the installation position when the module block is installed. can be determined in advance. As a result, it becomes possible to reduce the work of repairing the module blocks at the furnace construction site, and to construct the furnace efficiently with high accuracy.

The effects of the present invention will be described more specifically with reference to the drawings. FIG. 7 is a schematic diagram showing an example of arrangement of module blocks installed in the module block installation step and module blocks that have already been installed. In the example shown in FIG. 7, a plurality of module blocks constituting the furnace are already installed at the construction site of the furnace. This already installed module block is hereinafter referred to as an existing module block. The existing module blocks 11a, 11b, and 11c are installed adjacent to each other in the horizontal direction, and the existing module block 11d is stacked above the existing module blocks 11b and 11c. Then, the module block 10 is installed on the upper stage of the existing module blocks 11a and 11b so as to be laterally adjacent to the existing module block 11d.

However, the module block 10 and the existing module block 11 may interfere with each other due to variations in the shape of the module blocks, deviations in installation positions, installation angles, and the like. For example, the bottom surface of the module block 10 contacts the top surfaces of the existing module blocks 11a and 11b. Therefore, if there is an unintended step on the upper surface of the existing module blocks 11 a and 11 b in terms of design, it interferes with the lower surface of the module block 10 . Even if there is no unintended step on the upper surface of the existing module blocks 11a and 11b, if the position of the existing module block 11 is displaced in the horizontal direction, the dowels on the lower surface of the module block 10 and the upper surface of the existing module block 11 do not. Interference may occur between tenons.

According to the present invention, the presence or absence of interference between module blocks can be predicted in advance by performing the above determination prior to the module block transport step. As a result, it becomes possible to reduce the work of repairing the module blocks at the furnace construction site, and to construct the furnace efficiently with high accuracy.

Although there is no particular limitation on how to deal with the case where the shape of the module block is determined to be unacceptable in the determination step, some measures may be taken for one or both of the module block and the installation position of the module block. preferable.

For example, in one embodiment of the specification of the present application, when the shape of the module block is determined to be unacceptable in the determination step, a separately manufactured module block (second module block) is used instead of the module block. can be used. As a result, it is possible to prevent a module block that does not match the shape of the installation position from being brought into the construction site of the furnace and requiring rework at the site.

When using the second module block, it is preferable to perform the first measurement step and the determination step on the second module block to determine whether the shape of the second module block is acceptable. . In this case, the above process is preferably repeated until a module block is found that passes the judging step.

Further, in another embodiment of the present specification, when the shape of the module block is determined to be unacceptable in the determination step, the shape of one or both of the module block and the position where the module block is installed is changed. can be fixed. According to the present invention, since determination and shape correction can be performed in advance, it is possible to reduce the work of repairing module blocks at the construction site of the furnace, and to construct the furnace efficiently with high accuracy.

The shape correction method is not particularly limited, and any method can be used as long as it can correct the shape of one or both of the module block and the installation position.

For example, in one embodiment of the present invention, the shape modification can be performed by machining. By applying machining such as cutting, the contour shape of one or both of the module block and the installation position can be adjusted to eliminate interference. Moreover, according to this method, only the portion having a large shape error can be processed to obtain an appropriate shape.

Any processing means can be used for the machining without any particular limitation. As the processing means, for example, one or both of a laser processing machine and an end mill can be used. As the end mill, it is particularly preferable to use a ball end mill.

Further, in another embodiment of the present invention, the modification of the shape can be performed by replacing a part or all of the standard refractories constituting the module block. When the shape is corrected by exchanging the standard refractories, for example, part or all of the module block is once disassembled into standard refractories, and the decomposed standard refractories are restacked. The standard refractories used in the decomposed parts may be reused or discarded.

[Module block transportation process]
Next, processes after the module block manufacturing process will be described. The module blocks manufactured in the module block manufacturing process are then transported to a coke oven construction site. The method of transporting module blocks in the process of transporting module blocks is not particularly limited. Trucks, transporters (self-propelled trolleys), and cranes can be used depending on the distance between the module block manufacturing site and the coke oven construction site. etc. can be used singly or in combination. For example, if there is a temporary shed at the construction site of the coke oven, a transporter is used to transport the module blocks from the location where the module blocks were manufactured and processed to the temporary shed, and an overhead crane and stage jack are used inside the temporary shed. It can be used together and transported to the construction position. In the module block transportation process, the module blocks can be directly transported from the module block manufacturing site to the construction site of the coke oven construction site. According to the progress of the furnace, the module blocks may be transported from the block storage location to the construction position at the coke oven construction site.

[Mortar application process]
Next, mortar is applied to the position where the module block is to be installed. The method of applying mortar is not particularly limited, and mortar is applied to the positions where the bottoms and sides of the module blocks come into contact, in other words, the top and sides where the module blocks are installed, in the same way as when stacking standard refractories. do it.

A spacer can be installed on the mortar-coated surface that contacts the bottom surface of the module block to be installed, ie, the horizontal joint. In some cases, the desired joint thickness cannot be secured due to the load of the module block being applied to this portion. Therefore, by installing a spacer and installing a module block thereon, it becomes possible to easily secure the joint thickness. It is preferable that the spacer has the same height as the joint thickness.

[Module block installation process]
A module block is installed at a position where mortar is applied in the mortar application process. 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 placed on the surface coated with mortar while adjusting the position. In this way, by constructing in module block units, the burden on workers can be reduced and the standard refractories can be piled up with high accuracy, compared to the case of manually stacking standard refractories one by one.

When installing the module blocks, it is preferable to install the module blocks alternately as shown in FIG. By staggering the module blocks, the strength of the furnace can be improved. Here, "alternating" means that the joint positions between horizontally adjacent module blocks do not match between vertically adjacent stages.

A coke oven can be constructed by installing module blocks according to the above procedure. Although the present invention has been described by taking the construction of a coke oven as an example, as described above, the present invention is also applicable to the construction of ovens other than coke ovens.

[Preliminary judgment step]
In another embodiment of the present invention, as shown in the flow chart of FIG. 8, the module block manufacturing step includes the module block contour shape obtained in the first measuring step and the previously prepared module block shape prior to the determining step. It is possible to further include a preliminary judgment step of judging whether the shape of the module block is acceptable by comparing with the proper contour shape of the module block. By determining in advance whether or not the shape of the module block is appropriate in this way, it becomes possible to construct the furnace more efficiently and accurately.

Note that FIG. 8 shows, as an example, the case where the preliminary determination process is performed after the first measurement process and before the second measurement process. However, in the present invention, the timing of performing the preliminary determination step is not limited to this, and can be performed at any timing as long as it precedes the determination step. For example, the preliminary determination step may be performed after the second measurement step.

For example, design data (CAD data, etc.) of the module block can be used as the appropriate contour shape of the module block.

In the preliminary determination step, the outline shape of the entire module block can be used for determination, but the determination may be made using only the outline shape of a part of the module block. When the determination is made using only the contour shape of a part of the module block, it is preferable to use at least the contour shape of the dowel portion and tenon portion of the module block for the determination.

In the preliminary determination step, for example, the contour shape of the module block is compared with the appropriate contour shape of the module block prepared in advance. can be determined.

1 module block 2 standard refractory 3 dowel 4 tenon 5 mortar 10 module block 11a-d existing module block

Claims (8)

a module block manufacturing process for manufacturing module blocks at a location other than the furnace construction site;
a module block transporting step of transporting the module blocks manufactured in the module block manufacturing step to the construction site of the furnace;
a mortar application step of applying mortar to a position where the module block is to be installed;
a module block installation step of installing the module blocks transported in the module block transportation step at the positions where the mortar has been applied, the furnace construction method comprising:
The module block manufacturing process includes:
a stacking step of stacking a plurality of standard refractories to manufacture the module block;
a first measuring step of obtaining a module block contour shape by measuring the contour shape of the module block obtained in the stacking step;
a second measuring step of measuring a contour shape of a position where the module block is installed in the furnace to obtain an installation position contour shape;
a determination step of comparing the contour shape of the module block with the contour shape of the installation position to determine whether the shape of the module block is acceptable. 2. The reactor construction method according to claim 1, wherein when the shape of said module block is determined to be unacceptable in said determining step, a separately manufactured module block is used in place of said module block. 2. The furnace construction method according to claim 1, wherein when the shape of the module block is determined to be unacceptable in the determination step, the shape of one or both of the module block and the position where the module block is installed is corrected. . 4. The furnace construction method according to claim 3, wherein said modification of the shape is performed by machining. 5. The furnace construction method according to claim 3, wherein said modification of said shape is performed by replacing a part or all of the standard refractories constituting said module block. The furnace according to any one of claims 1 to 5, wherein one or both of the measurement in the first measurement step and the measurement in the second measurement step are performed using a three-dimensional measurement method using a laser. construction method. One or both of the measurement in the first measurement step and the measurement in the second measurement step are performed by photogrammetry using images captured from a plurality of viewpoints. Furnace construction method described. The module block manufacturing process includes:
Prior to the determination step, the contour shape of the module block obtained in the first measurement step is compared with an appropriate contour shape of the module block prepared in advance to determine whether the shape of the module block is acceptable. The furnace construction method according to any one of claims 1 to 7, further comprising a target determination step.

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