JP7136147B2 - Coke oven construction method and module block manufacturing method - Google Patents

Description

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

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. is 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. In this method, by providing an appropriate spacer between the mating bricks when installing the module block, an appropriate mortar thickness can be secured and the coke oven can be constructed with high accuracy.

JP 2016-191064 A

However, in the technique described in Patent Document 1, refractory bricks that are generally used as standard refractories for coke ovens are made by firing, so there are errors in the dimensions of individual refractory bricks (for example, when viewed from the top or In the case of the diagonal distance in side view, it is about 1 to 2 mm). Therefore, for example, even if the space between the manufactured module blocks is adjusted in the horizontal direction and the flatness of the oven wall on the side of the coking chamber from which coke is extruded has achieved the required accuracy, it will not be possible to stack adjacent blocks at the time of installation. Module blocks that are connected to each other interfere with each other, and there are cases where the thickness of the mortar cannot be secured and it meshes, and cases where the gaps are filled with mortar more than necessary. Or, as a result, there is a problem that the installation cannot be performed with high accuracy. This causes problems such as a delay in the construction period and an increase in costs and workload for workers to recover.

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

The gist and configuration of the present invention are as follows.
(1) The method for constructing a coke oven of the present invention comprises:
a module block manufacturing process for manufacturing a module block by stacking a plurality of standard refractories in advance at a location other than the construction site of the coke oven;
a module block transporting step of transporting the module blocks to a construction site of the coke oven;
a mortar application step of applying mortar to a position where the transported module block is to be installed;
a module block installation step of installing the transported module block at the position where the mortar is applied, the coke oven construction method comprising:
a module block shape measuring step of measuring the contour of the manufactured module block;
a module block acceptance/rejection determination step of determining acceptance/rejection of the module block based on the measured contour of the module block;
a module block re-preparation step of re-preparing the module block determined to be rejected in the module block pass/fail determination step;
The module block shape measurement process, the module block acceptance/rejection determination process, and the module block re-preparation process are performed after the module block manufacturing process and prior to the module block transport process.

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

(3) In the above (1), in the module block shape measuring step, the contour is obtained by obtaining a plurality of images obtained by imaging the module block from a plurality of viewpoints, and performing photogrammetry using the obtained plurality of images. is preferably measured by

(4) In any one of (1) to (3) above, preferably, in the module block shape measuring step, the contour of the entire surface of the module block is measured.

(5) In any one of (1) to (4) above, 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 one of the above (1) to (5), in the module block pass/fail judgment step, the pass/fail of the module block is judged by comparing the measured contour with a drawing shape prepared in advance. preferably.

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

(8) In any one of (1) to (7) above, preferably, in the module block re-preparing step, the module block is manufactured again by restacking a plurality of the standard refractories.

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

(10) In (9) above, the standard refractory of the module block has a fitting convex portion and a fitting concave portion,
In the module block re-preparing step, the fitting convex portion of the standard refractory of the module block is cut to reduce the size of the fitting convex portion, and/or the portion defining the fitting concave portion is cut to reduce the size of the fitting convex portion. It is preferable to modify a portion of the module block by enlarging the fitting recess.

(11) In the above (7), in the module block shape measuring step, contours of a plurality of the module blocks having the same shape are measured;
In the module block acceptance/rejection determination step, interference is evaluated in the virtual arrangement state for the plurality of module blocks having the same shape whose contours have been measured,
Preferably, in the module block re-preparation step, the module block determined to be unacceptable in the module block pass/fail determination step is replaced with the module block determined to be acceptable in the interference evaluation result. .

(12) In the above (11), the module block for which the interference evaluation result is optimal has a 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 is such that the integrated value of is minimized.
However, the integrated value at one installation location means the above difference at that location.

(13) In the above (7), in the module block shape measuring step, contours of the plurality of module blocks having the same shape are measured, and in the module block pass/fail judgment step, the plurality of the same shapes whose contours are measured. evaluating the interference in the virtual arrangement state for the module blocks of and calculating the optimum overall arrangement;
Preferably, the module block re-preparation step re-prepares only the module blocks for which the interference evaluation result fails during the optimal overall placement.

(14) In the above (13), the optimum overall arrangement minimizes the integrated value of 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 overall arrangement of the module blocks is as follows.

(15) The method for manufacturing a module block of the present invention comprises:
A module block manufacturing method for manufacturing a module block for construction of a coke oven by stacking a plurality of standard refractories in advance at a location other than the construction site of the coke oven,
a module block shape measuring step of measuring the contour of the manufactured module block;
a module block acceptance/rejection determination step of determining acceptance/rejection of the module block based on the measured contour of the module block;
a module block re-preparation step of re-preparing the module block determined to be rejected in the module block pass/fail determination step;
The module block re-preparation step includes re-manufacturing the module block by re-stacking the plurality of standard refractories, or correcting the interference part of the module block in the virtual arrangement state. Characterized by

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

FIG. 2 is a schematic top view of an example of a module block in which standard refractories for coke ovens are stacked. FIG. 3 is a schematic side view of an example of a module block in which standard refractories for coke ovens are stacked. FIG. 4 is a schematic partial side view of an example of a furnace wall of a coke oven manufactured by sequentially installing module blocks. It is a figure which shows typically a mode that the fitting convex part and fitting recessed part fitted between the side surfaces of the brick. It is a figure which shows typically a mode that the fitting convex part and the fitting recessed part were fitted between the horizontal surfaces of a brick. FIG. 4 is a schematic side view showing a state in which the convex fitting portion and the concave fitting portion of the brick are not properly fitted in a part of the module block. 1 is a flow chart of a coke oven construction method according to an embodiment of the present invention; It is a schematic diagram which shows the side surface of the three-dimensional point cloud of a module block. It is a schematic diagram which shows the side surface of the three-dimensional drawing shape of a module block. FIG. 11 is a side view schematically showing interference in a virtually arranged state of module blocks; FIG. 11 is an enlarged view showing the interference portion of FIG. 10; FIG. 10 is an enlarged view schematically showing an interfering portion when the mating convex portion of the interfering portion is removed and the module blocks are virtually arranged again. FIG. 10 is a conceptual diagram showing selection of an optimally arranged module block when a plurality of module blocks are virtually arranged; FIG. 4 is a side view schematically showing the arrangement of module blocks before re-preparation of module blocks in Example 1; FIG. 4 is a side view schematically showing the arrangement of module blocks after module block re-preparation in Example 1; FIG. 11 is a side view schematically showing the arrangement of module blocks before module block re-preparation in Example 2; FIG. 11 is a side view schematically showing the arrangement of module blocks after module block re-preparation in Example 2; FIG. 10 is a diagram schematically showing how three module blocks are installed in Example 3;

Embodiments of the present invention will be exemplified in detail below 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. Further, in the following description, unless otherwise specified, the standard refractory and the module block manufactured by stacking the standard refractory are based on the orientation in the state of being incorporated in the coke oven. The terms horizontal, vertical and height are used.

<Coke oven construction method>
FIG. 1 is a schematic top view of an example of a module block in which shaped refractories for a coke oven are stacked. FIG. 2 is a schematic side view of an example of a module block in which shaped 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 sequentially installing module blocks.

As shown in FIGS. 1 to 3, the module block 1 is formed by piling up standard refractories for coke ovens (bricks in this example) and mortar.

In the example shown in FIGS. 1 to 3, the bricks consist of wall bricks 2 that form the walls of the coke oven in the longitudinal direction, and inter-wall bricks 3 that connect the wall bricks 2 in the lateral direction. As shown in FIG. 1, wall bricks 2 and wall bricks 3 define flue 4 . In this example, the module block 1 used for the combustion chamber is exemplified, 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 the coking chamber. .

As illustrated in FIG. 2, mortar between bricks is generally arranged so that the joints 5 are not aligned in a straight line when viewed from the side. For this reason, as shown in FIG. 2, the ends of the module block 1 do not form a straight line when viewed from the side, but protrudes and recesses are formed.

In addition, as shown in FIG. 3, in this example, the center position of the odd-numbered module blocks 1 in the longitudinal direction (horizontal direction in the figure) of the wall surface of the coke oven, and the even-numbered module blocks 1 of the coke oven wall surface. The module blocks 1 are stacked in a zigzag manner so that the ends in the longitudinal direction are aligned when viewed in the vertical direction. As exemplified in FIG. 3, generally when module blocks 1 are stacked to manufacture a coke oven, the module blocks 1 are arranged so that the joints between the module blocks 1 are not aligned in a straight line when viewed from the side.

Here, although not shown in FIGS. 1 to 3, some or all of the bricks have fitting projections 6 called dowels on the bottom surface and side surfaces, and fitting projections 6 called tenons on the top surface and side surfaces. It has a joint recess 7 . As a result, when the bricks are stacked, the fitting concave portion 7 on the top surface of a given tier and the fitting convex portion 6 on the bottom surface of the next tier are fitted to each other, or the fitting protrusions are formed between horizontally adjacent bricks. 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 protrusion and the fitting recess are fitted between the side surfaces of the brick. FIG. 5 is a diagram schematically showing how the fitting protrusion and the fitting recess are fitted between the horizontal surfaces of the bricks.
Between the side surfaces and horizontal surfaces of the bricks of the module block 1, a large number of connections between the fitting protrusions 6 and the fitting recesses 7 are formed as illustrated in FIGS. 4 and 5, for example.

FIG. 6 is a schematic side view showing how the fitting protrusion and the fitting recess are not properly fitted in a part of the module block. As exemplified in FIG. 6, when connecting bricks in the module block 1, there may be a case where the fitting convex portion 6 and the fitting concave portion 7 do 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 are in direct contact with each other because the predetermined joint thickness of the mortar cannot be secured.
FIG. 6 shows that the fitting projections 6 and fitting recesses 7 between the horizontal surfaces of the bricks of the module block 1 are not properly fitted. A case where the fitting protrusion 6 and the fitting recess 7 are not properly fitted may also occur.
In FIG. 6, the fitting of the bricks within the module block 1 has been described. There may be a case where the concave portion 7 does not fit well.

In such a case, at the construction site of the coke oven, it is necessary to repeat the installation of the bricks, or to scrape the fitting protrusions and fitting recesses so that they fit well. 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 lead to a significant decrease in efficiency of the work process.

FIG. 7 is a flow chart of a coke oven construction method according to an embodiment of the present invention.
As shown in FIG. 7, the coke oven construction method of the present embodiment includes a module block manufacturing process (step S101 ), a module block transportation step (step S105) of transporting the module blocks to the construction site of the coke oven, a mortar application step (step S106) of applying mortar to the position where the transported module blocks are to be installed, and mortar and a module block installation step (step S107) of installing the transported module block at the position where is applied.

Further, as shown in FIG. 7, in the coke oven construction method of the present embodiment, after the module block manufacturing process (step S101) and prior to the module block transporting process (step S105), the outline of the manufactured module block a module block shape measuring step (step S102) for measuring the module block shape measurement step (step S102); a module block pass/fail judgment step (step S103) for judging pass/fail of the module block based on the measured contour of the module block; and a module block re-preparation step (step S104) of re-preparing the module block determined to be rejected in .
Each step will be described in detail below.

The module block manufacturing step (step S101) is a step of stacking a plurality of standard refractories in advance to manufacture the module block 1 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 a location different from the construction site of the coke oven and where modular refractories can be stacked to manufacture module blocks. It can be any location. 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 module block manufacturing process can be performed at other locations such as 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. It is desirable for efficiency that the module block manufacturing process be performed intensively at one location, but it is performed at multiple locations, and the module blocks manufactured at each location are transported and carried to one coke oven construction site. can also be used.
Moreover, a brick can be illustrated as a fixed form refractory. Also, the fixed refractories can be piled up through mortar.
The laying of the bricks can be done by any known technique and can be done manually, or can be done by robots or the like.

Next, in this embodiment, after the module block manufacturing process (step S101) and prior to the module block transporting process (step S105) described later, the contour of the manufactured module block is measured (module block shape measuring process: 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. For this reason, it is preferable that the measurement of the contour of the module block 1 can discriminate on the order of 1 mm. Therefore, in the present embodiment, in the module block shape measurement step (step S102), the above contour is measured using a laser irradiation device or an infrared irradiation device from the laser irradiation device or the infrared irradiation device to the surface of the module block. It is preferably measured by measuring the distance. For example, a laser scanner with a measurement accuracy of 30 μm can be used as the laser irradiation device. As a result, a three-dimensional point cloud of the module block can be obtained by scanning the periphery of the module block. Any known infrared irradiation device with a specification of, for example, a measurement accuracy of 1 mm can be used as the infrared irradiation device. Alternatively, in the present embodiment, in the module block shape measurement step (step S102), the above contour is obtained by acquiring a plurality of images of the module block taken from a plurality of viewpoints, and photographing using the acquired plurality of images. It is also preferably measured by metric. In photogrammetry, three-dimensional coordinates can be obtained from the principle of triangulation for the same point in two images taken from different viewpoints. A three-dimensional point cloud of the module block can be obtained by taking a plurality (more preferably a large number) of images around the module block and using the above principle.
Moreover, 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 diagram showing a side view of the three-dimensional point cloud of the module block. For example, a three-dimensional point cloud of the module block can be obtained as shown in FIG. 8 by the method using the laser irradiation device or the method using photogrammetry.

Returning to FIG. 7, following the module block shape measurement step (step S102), the acceptance/rejection of the measured module block is determined (module block acceptance/rejection determination step: step S103).
Here, FIG. 9 is a schematic diagram showing a side view 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 acceptance/rejection determination step (step S103), the acceptance/rejection of the module block is preferably determined by comparing the measured contour with a drawing shape prepared in advance. By comparing the measured contour with a drawing shape prepared in advance, it is possible to quantify the magnitudes of protrusions and recesses from the drawing shape. Note that the three-dimensional point group may be treated as a polygonal shape from the point group. For example, when the magnitude of this protrusion or recession (for example, the maximum value of protrusions and recessions in one module block) is equal to or less than (less than) a predetermined reference value, it is determined to be acceptable. A reject can be determined if the magnitude of the retraction is greater than (or greater than) a predetermined reference value. The above reference value is not particularly limited, and can be appropriately determined according to the specifications of the coke oven (accuracy of flatness) and the like, and can be set to 2 mm, for example.

As shown in FIG. 7, in the present embodiment, module blocks determined to be acceptable in the module block acceptance/rejection determination step (step S103) are subjected to the module block transportation step (step S105).
On the other hand, as shown in FIG. 7, in the present embodiment, in the module block pass/fail judgment step (step S103), the module blocks judged to be rejected are prepared again (module block re-preparation step: step S104). ).
Here, in the module block re-preparation step (step S104), for example, a plurality of standard refractories can be restacked to manufacture the module block again. In another example, the module block re-preparation step (step S104) can also modify a portion of the module block. In another example, the module block repriming step (step S104) may be replaced with another suitable module block.
Although not shown in FIG. 7, the remanufactured module block and the partially corrected module block are again subjected to the module block shape measurement step (step S102) and the module block acceptance/rejection determination step (step S103). , and if it passes the module block transporting step (step S105). When replacing a module block that has been determined to be unacceptable with another module block, the module block is replaced with a module block that has been determined to be acceptable through the same steps, and the module block transporting step (step S105) is performed. ).

Next, in the module block transportation step (step S105), the module blocks are transported to the coke oven construction site after the drying is completed. The method of transporting the module blocks in the module block transport step (step S105) is not particularly limited. trolley), crane, etc. can be used singly or in combination. For example, if there is a temporary shed at the coke oven construction site, transport from the module block manufacturing location to the temporary shed will be carried by a transporter, and in the temporary shed, overhead cranes and stage jacks will be used together to reach the construction location. can be transported. In the module block transportation step (step S105), the module blocks can be directly transported from the module block manufacturing site to the construction position at the coke oven construction site. The module blocks may be stored and transported from the module block storage location to the construction position at the coke oven construction location according to the progress of furnace construction.

Next, in the mortar application step (step S106), mortar is applied to the positions where the module blocks are 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.

In the module block installation step (step S107), module blocks are installed at the positions where the mortar was 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 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 precision, compared to the case of manually stacking standard refractories one by one.

According to the coke oven construction method of the present embodiment, prior to the module block transporting step of transporting the module blocks, the acceptance/rejection of the module blocks is determined, and for unacceptable module blocks, before the module blocks are transported, It is possible to re-manufacture, partially modify, replace with another module block, etc., and re-preparation can be performed. A mortar application process and a module block installation process can be performed by using the mortar coating process.
Therefore, according to the coke oven construction method of the present embodiment, it is possible to reduce the repair work of installing the module blocks at the construction site of the coke oven, and to install the module blocks efficiently with high accuracy.

Here, even in the case of a module block that has a small error in shape 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 may occur between adjacent module blocks (particularly at fitting projections and fitting recesses).
FIG. 10 is a side view schematically showing interference in a virtually arranged state of module blocks. FIG. 11 is an enlarged view showing an interference location in FIG. 10. 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 (almost) absent, and the bricks are (almost) directly in contact with each other. 8 has occurred.

Therefore, in the module block acceptance/rejection determination step (step S103), the acceptance/rejection of a 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 acceptance/rejection determination can be performed, for example, by performing a second acceptance/rejection determination on a module block that has been primarily 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 a quantified value obtained by integrating the magnitudes of interference by the number of interferences may be used as an index.
A predetermined reference value for the index is set in advance, and as a result of the interference evaluation, if the interference is equal to or less than the reference value (less than), it is determined to be acceptable, and the module block transporting step (step S105) is performed. can do. On the other hand, as a result of the interference evaluation, if the interference is greater than (or less than) the reference value, it is determined to be unsatisfactory and subjected to the module block re-preparation step (step S104). In this case, the module block re-preparation step (step S104) preferably corrects a part of the module block, and more preferably corrects the interfering portion 8 described above. Specifically, the standard refractories (bricks in this example) of the module block 1 have fitting protrusions 6 and fitting recesses 7, and the module block re-preparation step (step S104) is performed by A part of a module block by cutting the fitting convex portion 6 of the object to reduce the fitting convex portion 6 and/or cutting the portion defining the fitting concave portion 7 to enlarge the fitting concave portion 7 It is preferable to correct (more preferably, the interference point 8).
FIG. 12 is an enlarged view schematically showing an interfering portion when the mating convex portion of the interfering portion is removed and the module blocks are virtually arranged again. In FIG. 12, the joint thickness of the mortar can be ensured at various locations above a certain level.
As a result, the interference between the module blocks is also corrected in advance, so that it is possible to further reduce the reworking work of installing the module blocks at the coke oven construction site, and to install the module blocks more efficiently with higher accuracy. can.
In addition, since it is not preferable from the viewpoint of improving the strength of the coke oven that the fitting convex portion becomes extremely small, it is preferable to enlarge the fitting concave portion in such a case as well.

In the above, it is also preferable that the module block re-preparation step (step S104) re-stacks a plurality of standard refractories to manufacture the module block again. For example, if the size of the interference is large, it may be more appropriate to restack the standard refractories rather than correcting the location of the interference. This also corrects the interference between the module blocks in advance, so that it is possible to further reduce the repair work of installing the module blocks at the construction site of the coke oven, and to install the module blocks more efficiently with higher accuracy. 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 if the magnitude of interference is relatively large and is rejected, the above If the module block is manufactured again and the size of the interference is relatively small and the block is rejected, it is also possible to correct the location of the interference.
In the above example, when judging whether a module block is acceptable or not by evaluating interference in combination with the comparison with the drawing shape (primary judgment is made by comparison with the drawing shape, and secondary judgment is made by interference evaluation). However, the pass/fail judgment of the module block based on the evaluation of the interference can also be used as an independent criterion in the module block pass/fail judgment step (step S103). Alternatively, another criterion may be added.

By the way, when renewing or installing a new coke oven, a large number of module blocks, for example, 100 gates, are manufactured. Therefore, it is also preferable to select a module block with no or minimal modification from a large number of module blocks.
FIG. 13 is a conceptual diagram showing selection of an optimally arranged module block when a plurality of module blocks are virtually arranged.
In this embodiment, in the module block shape measurement step (step S102), the contours of a plurality of module blocks having the same shape are measured, and in the module block acceptance/rejection determination step (step S103), the contours of the plurality of the same shape whose contours are measured are measured. For module blocks, interference is preferably evaluated in a virtual arrangement. Then, in the present embodiment, the module block re-preparation step (step S104) determines that the module block determined to be unacceptable in the module block acceptance/rejection determination step (step S103) is accepted by the interference evaluation result. It is preferable to replace with a modified (more preferably optimal) module block.
According to this, a module block suitable for the installation location can be arranged without remanufacturing or modifying the module block.

In the above case, various methods are conceivable for quantifying the magnitude and number of interferences. For example, at one or more installation locations, the joint thickness is calculated in the virtual arrangement state, and the difference between the target mortar thickness and the joint thickness in the virtual arrangement state (calculated by the absolute value |Δd|) An integrated value can be used as an index. Then, it is possible to select a module block whose integrated value is equal to or less than a predetermined reference value (more preferably the minimum), and replace the module block that was originally determined to be rejected.
The above difference can be obtained by calculating |Δd| at, for example, 100 locations on the mounting surfaces of adjacent module blocks and using the integrated value as an index. It is preferable to include a combination of the fitting convex portion and the fitting concave portion as the location for calculating |Δd|. Further, it is more preferable to calculate |Δd| at three or more locations for one combination of the fitting convex portion and the fitting concave portion.

By the way, it is also possible to first calculate the optimum overall layout of the module blocks.
That is, in the module block shape measurement step (step S102), the contours of a plurality of module blocks having the same shape are measured, and in the module block pass/fail judgment step (step S103), the contours of the plurality of module blocks having the measured contours are measured. , it is also preferable to evaluate the interference in the virtual arrangement state and calculate the optimum overall arrangement. Various methods are conceivable for this optimal 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 installation locations. In this case, the difference is preferably calculated in at least one installation point between all adjacent module blocks. Alternatively, the optimum layout may be the layout that minimizes the number of module blocks that fail the evaluation. Then, the module block re-preparation step (step S104) re-prepares only the module blocks for which the evaluation result of interference is rejected during the optimum overall layout. Repreparation 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.

<Method for manufacturing module block>
A 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) of measuring the contour of the manufactured module block, and a module block pass/fail judgment step of judging 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 rejected in the module block acceptance/rejection determination step (step S203).
Then, the module block re-preparation step (step S204) includes re-stacking a plurality of standard refractories to manufacture the module block again or modifying a portion of the module block.
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, so description thereof will be omitted.
According to the module block manufacturing method of the present embodiment, it is possible to reduce the repair work for installing the module blocks at the construction site of the coke oven, and to install the module blocks efficiently with high accuracy.

Preferred examples of the method for manufacturing the module block of the present invention are described below. The details are the same as those already explained in the embodiment of the coke oven construction method.
In the module block shape measuring step (step S201), the contour is preferably measured by using a laser irradiation device and measuring the distance from the laser irradiation device to the surface of the module block.
Alternatively, in the module block shape measurement step (step S201), the contour is preferably measured by photogrammetry using a plurality of images obtained by capturing a plurality of images of the module block from a plurality of viewpoints. .
Also, in the module block shape measuring step (step S201), it is preferable to measure the contour of the entire surface of the module block.
Furthermore, in the module block acceptance/rejection determination step (step S203), the acceptance/rejection of the module block is preferably determined by comparing the measured contour with a drawing shape prepared in advance.
Further, in the module block acceptance/rejection determination step (step S203), it is also preferable that the acceptance/rejection 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. .
In addition, in the module block re-preparation step (step S204), it is preferable to re-manufacture the module block by re-stacking a plurality of standard refractories.
Alternatively, the module block re-preparation step (step S204) preferably modifies a portion of the module block.
In this case, the standard refractory of the module block has a fitting projection and a fitting recess, and in the module block re-preparing step (step S204), the fitting projection of the standard refractory of the module block is shaved to fit. It is more preferable to modify a part of the module block by reducing the size of the projection and/or cutting away the portion defining the fitting recess to enlarge the fitting recess.

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

<Example 1>
As Example 1, first, four module blocks (module block 9, module block 10, module block 11, and module block 12) were manufactured by stacking bricks for six levels in the horizontal direction and five levels in the vertical direction. The profile 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 instrument 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 compared with the measured scanner point cloud data (taking the difference), the inclination and unevenness of the module block were digitized. 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 less than the reference value (2 mm or less). FIG. 14 is a side view schematically showing the arrangement of module blocks before re-preparation of module blocks according to the first embodiment. Each module block was arranged as shown in FIG. A spacer with a height of 4 mm was 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 replaced by the frame 14 instead of the actual module block. When the module block 12 was installed, the mating surface with the module block 9 protruded (interference point 13), and the module block did not fit properly. Therefore, the spacers were adjusted within a range of ±2 mm in height, but the module block could not be properly accommodated. Since the module block 12 did not satisfy the standard, it was remanufactured by restacking the module blocks so that the unevenness of the lower surface was 2 mm or less. FIG. 15 is a side view schematically showing the arrangement of module blocks after module block re-preparation in the first embodiment. After remanufacturing the module block 12 into a module block 12', each module block was again arranged as shown in FIG. A spacer with a height of 4 mm was 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 inclination of the side surface of the stacked module blocks 12' were within 2 mm, and stacking was possible within the standard allowable range.

<Example 2>
As Example 2, four module blocks (module block 15, module block 16, module block 17, and module block 18) were manufactured by laminating six bricks horizontally and five bricks vertically. The profile 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 instrument 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 compared with the measured scanner point cloud data (taking the difference), the inclination and unevenness of the module block were digitized. As a result, it was confirmed that all the module blocks were equal to or less than the reference value (2 mm or less). FIG. 16 is a side view schematically showing the arrangement of module blocks before re-preparation of module blocks in the second embodiment. Each module block was arranged as shown in FIG. A spacer with a height of 4 mm was 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 replaced by the frame 14 instead of the actual module block. When the module block 18 is installed, interference points (19, 20) may occur at the mating surfaces of the module block 15 and the module block 17 at the dowels (fitting projections) and tenons (fitting recesses). all right. Next, a virtual installation was performed on the computer, and the presence or absence of interference between the module blocks was confirmed. ), and interference points (19, 20) were found to occur at the tenons (fitting concave portions). Therefore, for the interference location 19, the dowel (fitting convex portion) is cut, and for the interference location 20, the portion that defines the tenon (fitting recess) is cut to enlarge the tenon (fitting recess). A virtual installation on the computer was performed again to confirm that the interference disappeared. FIG. 17 is a side view schematically showing the arrangement of module blocks after module block re-preparation in the second embodiment. Having obtained the results of the above re-virtual installation, each module block was again arranged as shown in FIG. A spacer with a height of 4 mm was 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 standard values without any interference.

<Example 3>
As Example 3, a plurality of module blocks were manufactured by stacking bricks for 6 levels in the horizontal direction and 5 levels in the vertical direction. FIG. 18 is a diagram schematically showing how three module blocks are installed in the third embodiment. Three module blocks were arranged as shown in FIG. 18 and installed within the range of standard values. Ten such installation sets were produced. Then, 10 module blocks to be installed next were prepared. Contour measurements were performed on each module block using a laser scanner. This measurement was performed over the entire surface of the module block using a highly accurate handy type instrument 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 compared with the measured scanner point cloud data (taking the difference), the inclination and unevenness of the module block were digitized. As a result, it was confirmed that all the module blocks were equal to or less than the reference value (2 mm or less). Next, all patterns of virtual installation were performed on the computer for the above 10 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. There were 56 dowels (fitting projections) and tenons (fitting recesses) on the installation surface. |Δd| was calculated at three points (56×3=168 points in total) for each dowel (fitting projection) and tenon (fitting recess), and the integrated value was calculated for each. In the combination with the smallest integrated value, there were 14 points of interference between dowels (fitting projections) and tenons (fitting recesses) for 10 sets of installations, and these were corrected. After re-loading after the correction, the installation was completed at below the standard value. On the other hand, in the combination that maximizes the integrated value, there are 31 points of interference between dowels (fitting protrusions) and tenons (fitting recesses) for 10 sets of installations, and the number of points to be corrected is doubled. That's it.

1: module block,
2: wall bricks,
3: inter-wall bricks,
4: Flue,
5: Joints,
6: fitting projection,
7: fitting recess,
8: interference location,
9: module block,
10: module block,
11: module block,
12: module block,
13: interference point,
14: mount,
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 for manufacturing a module block by stacking a plurality of standard refractories in advance at a location other than the construction site of the coke oven;
a module block transporting step of transporting the module blocks to a construction site of the coke oven;
a mortar application step of applying mortar to a position where the transported module block is to be installed;
a module block installation step of installing the transported module block at the position where the mortar is applied, the coke oven construction method comprising:
a module block shape measuring step of measuring the contour of the manufactured module block;
a module block acceptance/rejection determination step of determining acceptance/rejection of the module block based on the measured contour of the module block;
a module block re-preparation step of re-preparing the module block determined to be rejected in the module block pass/fail determination step;
The module block shape measurement step, the module block acceptance/rejection determination step, and the module block re-preparation step are performed after the module block manufacturing step and prior to the module block transportation step. construction method. In the module block shape measuring step, the contour is measured by using a laser irradiation device or an infrared irradiation device and measuring the distance from the laser irradiation device or the infrared irradiation device to the surface of the module block. The coke construction method according to claim 1. 2. The method according to claim 1, wherein in said module block shape measuring step, said contour is measured by photogrammetry using said plurality of acquired images obtained by acquiring a plurality of images of said module block taken from a plurality of viewpoints. Method of construction of coke described. The coke oven construction method according to any one of claims 1 to 3, wherein in said module block shape measuring step, the contour of the entire surface of said module block is measured. The coke oven construction method according to any one of claims 1 to 4, wherein the module block determined to be acceptable in the module block acceptance/rejection determination step is supplied to the module block transportation step. 6. The module block acceptance/rejection determination process according to any one of claims 1 to 5, wherein acceptance/rejection of the module block is determined by comparing the measured contour with a drawing shape prepared in advance in the module block acceptance/rejection determination step. How to build a coke oven. 2. In the module block acceptance/rejection determination step, acceptance/rejection of the module block is determined by interference in a virtual arrangement state in which the plurality of module blocks whose contours have been measured are virtually arranged on a computer. 7. The method for constructing a coke oven according to any one of 6. The coke oven construction method according to any one of claims 1 to 7, wherein said module block re-preparation step re-stacks a plurality of said standard refractories to manufacture said module block again. The coke oven construction method according to any one of claims 1 to 7, wherein said module block re-preparation step modifies a part of said module block. The standard refractory of the module block has a fitting convex portion and a fitting concave portion,
In the module block re-preparing step, the fitting convex portion of the standard refractory of the module block is cut to reduce the size of the fitting convex portion, and/or the portion defining the fitting concave portion is cut to reduce the size of the fitting convex portion. 10. The coke oven construction method according to claim 9, wherein a portion of the module block is modified by enlarging the fitting recess. measuring contours of a plurality of module blocks having the same shape in the module block shape measuring step;
In the module block acceptance/rejection determination step, interference is evaluated in the virtual arrangement state for the plurality of module blocks having the same shape whose contours have been measured,
3. The module block re-preparation step replaces the module block determined to be unacceptable in the module block acceptance/rejection determination step with the module block determined to be acceptable in the interference evaluation result. 7. The method for constructing a coke oven according to 7. The module block for which the interference evaluation result is optimal is 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 installation locations. The construction method of coke oven according to claim 11, wherein the module block. measuring contours of a plurality of module blocks having the same shape in the module block shape measuring step;
In the module block acceptance/rejection determination step, for the plurality of module blocks of the same shape whose contours have been measured, interference in the virtual arrangement state is evaluated to calculate an optimum overall arrangement,
8. The coke oven construction method according to claim 7, wherein said module block re-preparation step re-prepares only said module blocks for which said interference evaluation result fails during said optimal overall arrangement. The optimal overall layout is the overall layout of the module blocks such that the integrated value of the difference between the target mortar thickness and the joint thickness in the virtual layout state is minimized at one or more installation locations. The coke oven construction method according to claim 13, wherein A module block manufacturing method for manufacturing a module block for construction of a coke oven by stacking a plurality of standard refractories in advance at a location other than the construction site of the coke oven,
a module block shape measuring step of measuring the contour of the manufactured module block;
a module block acceptance/rejection determination step of determining acceptance/rejection of the module block based on the measured contour of the module block;
a module block re-preparation step of re-preparing the module block determined to be rejected in the module block pass/fail determination step;
The module block re-preparation step includes re-manufacturing the module block by re-stacking the plurality of standard refractories, or correcting the interference part of the module block in the virtual arrangement state. A method of manufacturing a modular block, characterized in that:

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