JP7371668B2 - Furnace construction method - Google Patents

Description

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

Metallurgical coke used in steelmaking is produced by carbonizing coal in a room-fired coke oven. A room furnace type coke oven is constructed by arranging carbonization chambers and combustion chambers that supply heat to the carbonization chambers alternately in the width direction of the oven. Heat is supplied from the combustion chamber to the carbonization chamber via the regular refractory. Some indoor furnace coke ovens have more than 100 furnace chambers, and such indoor furnace coke ovens can be said to be huge brick structures with a total length of 100 m or more and a height of 10 m or more.

The standard refractories that make up coke ovens are different from bricks for general buildings, and have complex shapes such as rectangles, trapezoids, and L-shapes when viewed from above. Furthermore, the side, top, and bottom surfaces of these regular refractories are sometimes provided with fitting protrusions called dowels to prevent slippage, and fitting recesses called tenons to prevent slippage. Coke ovens are constructed by combining regular refractories with extremely complex shapes.

Due to the complexity of the shape of such regular refractories, the construction of coke ovens is currently carried out by hand construction work by furnace builders. When building a furnace by hand, it is necessary to repeatedly apply mortar to the position where the regular refractories are to be stacked using tools such as a trowel to achieve the specified joint thickness, and then stack the regular refractories on top of the mortar. There is. This requires an extremely high level of skill, as it is necessary to evenly apply mortar to the surface of a regular refractory with a complex shape, but there is always a shortage of skilled furnace builders with such skills. are doing. Furnace construction work, which involves applying mortar and stacking standard refractories by hand, can be said to be extremely hard work.

For the above reasons, there is a need to develop a method for stacking regular refractories efficiently with less manpower.

For example, in Patent Document 1, a module block is manufactured in advance at a location other than the construction site of a coke oven, in which a plurality of brick layers arranged horizontally are stacked vertically in multiple stages, and then transported to the construction site. A method of installation is proposed.

Japanese Patent Application Publication No. 2016-191064

In the method proposed in Patent Document 1, the module blocks are manufactured at a different location than the coke oven construction site where space is limited, so 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 regular refractories and the application of mortar using a robot or the like.

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

That is, since the regular refractories used in the construction of coke ovens are manufactured by firing, there are variations in dimensions. For example, commonly used standard refractories 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, even in module blocks obtained by stacking regular refractories, variations in shape occur from one module block to another.

In particular, in a coke oven, coal is inserted into a carbonization chamber and carbonized, and the obtained coke is extruded from the side and discharged, so that the walls of the carbonization chamber are required to have high flatness. Therefore, when manufacturing module blocks, it is conceivable to adjust the stacking method of regular refractories so that the wall surface of the carbonization chamber has the required flatness, but even in that case, the shape may vary in other parts. cannot be completely eliminated.

Due to this variation in the shape of the module blocks, there is a problem in that the accuracy and work efficiency of coke oven construction are reduced. For example, if the distance between the module blocks becomes too small due to variations in shape, the installation accuracy of the module blocks will decrease, and a sufficient thickness of mortar may not be ensured. In particular, when module blocks interfere with each other, it is not possible to stack the module blocks as they are, so it is necessary to modify the module blocks to prevent interference. However, since the module block installation work is usually performed while the module block is being held by a transportation jig, it is not possible to modify the module block as it is. Therefore, after removing the jig from the module block, it is necessary to shave off the regular refractories that make up the module block, or to disassemble at least a portion of the module block and reload the regular refractories. Such rework is extremely time-consuming work, and reworking module blocks at a coke oven construction site significantly reduces work efficiency. On the other hand, 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, so it is still difficult to carry out the work. Efficiency decreases.

Therefore, there is a need for a coke oven construction method using modular blocks that can efficiently construct a coke oven with even higher accuracy. Additionally, the construction method using modular blocks described above can be applied to the construction of furnaces other than coke ovens, but in that case as well, a method that can construct furnaces efficiently with even higher precision is required. .

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method for efficiently constructing a furnace with high precision by reducing the work required to modify module blocks at a furnace construction site.

The gist of the present invention is as follows.

1. A module block manufacturing process in which the module blocks are manufactured 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 the position where the module block is installed;
A furnace construction method, comprising a module block installation step of installing a module block transported in the module block transport step at a position where the mortar is applied,
The module block manufacturing process includes:
a stacking step of stacking a plurality of regular 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 the contour shape of the position where the module block is installed in the furnace to obtain the installation position contour shape;
A furnace construction method comprising: a determination step of comparing the module block contour shape and the installation position contour shape to determine whether the shape of the module block is acceptable.

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

3. 2. The furnace construction method according to item 1, wherein, when the shape of the module block is determined to be rejected in the determination step, the shape of the module block and/or the position where the module block is installed is corrected.

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

5. 5. The furnace construction method according to 3 or 4 above, wherein the modification of the shape is performed by replacing part or all of a regular refractory that constitutes the module block.

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

7. According to any one of 1 to 5 above, one or both of the measurement in the first measurement step and the measurement in the second measurement step is 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, a preliminary step of comparing the module block contour shape obtained in the first measurement step with an appropriate contour shape of the module block prepared in advance to determine whether the shape of the module block is acceptable or not. 8. The furnace construction method according to any one of 1 to 7 above, further comprising a target determination step.

According to the present invention, the rework work at the furnace construction site can be reduced and the furnace can be constructed efficiently with high precision.

1 is a flowchart showing a furnace construction method in an embodiment of the present invention. It is a flow chart showing a module block manufacturing process in one embodiment of the present invention. FIG. 2 is a top view schematically showing an example of the structure of a module block. FIG. 2 is a side view schematically showing an example of the structure of a module block. FIG. 2 is a top view schematically showing an example of a dowel and tenon structure between horizontally adjacent standard refractories. FIG. 2 is a side view schematically showing an example of a dowel and tenon structure between vertically adjacent standard refractories. It is a schematic diagram which shows the example of arrangement|positioning of the module block installed in the module block installation process, and the module block already installed. It is a flowchart which shows the module block manufacturing process in other embodiments of this invention.

Embodiments of the present invention will be specifically described below with reference to the drawings. Note that the following description exemplarily shows embodiments of the present invention, and the present invention is not limited to the following embodiments. In addition, in the following explanation, unless otherwise specified, standard refractories and module blocks manufactured by stacking the standard refractories will be referred to in the upper, lower, and horizontal directions based on the orientation when installed in a furnace. , vertical, and height.

In addition, "construction" of a furnace in the present invention includes not only the construction of a new furnace, but also the construction of a new part of an existing furnace (expansion), and the replacement of a part of an existing furnace. This also includes the case of constructing a new part (repair). In other words, "construction" in the present invention includes new construction, expansion, and repair. For example, when repairing a coke oven that is currently in operation, it is recommended to stop using some combustion chambers and carbonization chambers, and repair the remaining combustion chambers and carbonization chambers while they are still in operation (hot repair). This is commonly done. The present invention is also applicable to the hot repair described above.

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

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

[Module block manufacturing process]
In the module block manufacturing process, the module blocks are manufactured at a location other than the furnace construction site. In the present invention, since a coke oven is constructed by transporting and installing module blocks manufactured at a location other than the coke oven construction site, the furnace construction is carried out at a construction site where workability is poor, unlike in the past. This reduces the work of manually stacking standard refractories one by one, and greatly improves work efficiency at the construction site.

Although the present invention uses a modular block construction method, parts of the furnace, such as parts with complicated shapes, can also be fabricated by directly stacking regular refractories instead of modular blocks.

The above-mentioned "place other than the coke oven construction site" is not particularly limited, and may be any place that is different from the coke oven construction site and where modular blocks can be manufactured by stacking regular refractories. can be used. For example, a place adjacent to the coke oven construction site, such as land adjacent to a temporary shed set up at the location where the coke oven will be constructed; The stacking process can be carried out elsewhere, such as at other locations. Although it is possible to manufacture the module blocks at a remote location away from the coke oven construction site, it is preferable to manufacture the module blocks at a location adjacent to the coke oven construction site in consideration of transportation time and costs. Although it is desirable for efficiency to carry out the stacking process intensively at one location, it is also possible to carry out the stacking process at multiple locations and transport the module blocks manufactured at each location to a single coke oven construction site for use. You can also do it.

The module block manufacturing process in one embodiment of the present invention includes the following steps as shown in the flowchart of FIG.
・Stacking process ・First measurement process ・Second measurement process ・Judgment process

[Stacking process]
In the module block manufacturing process, first, a plurality of standard refractories are piled up to manufacture a module block (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 produce at least one of the module block that constitutes the heat storage chamber and the module block that constitutes the combustion chamber.

3 and 4 are schematic diagrams showing examples of the structure of a module block, and represent the structure of a module block that constitutes a combustion chamber of a coke oven. It should be noted that in the drawings including FIGS. 3 and 4, the shapes and combinations of the standard refractories are shown in a simplified manner for the purpose of explanation, and do not represent the actual exact structures.

The module block 1 is constructed by stacking a plurality of regular refractories 2, and the individual regular refractories 2 are joined with mortar (not shown) applied to the joints between the regular refractories 2. . As mentioned earlier, the regular refractory 2 for coke ovens has dowels 3 that are fitting projections and tenons 4 that are fitting recesses to prevent slippage, etc., as shown in FIGS. 5 and 6. is provided, and the dowel 3 and tenon 4 are joined with a mortar 5 interposed therebetween in a fitted state.

[[Standard refractories]]
The regular refractory for manufacturing the module block is not particularly limited, and any regular refractory such as bricks and precast blocks can be used. Among these, it is preferable to use regular regular refractories that are used when constructing coke ovens by hand. By using ordinary regular refractories, even when constructing a furnace using the method of the present invention, it is possible to design a furnace similar to the conventional one, and as a result, the performance of the furnace is guaranteed to be at least equivalent to that of the conventional one. It becomes possible to do so. In addition, when using large module bricks, if a crack occurs, there is a risk that the crack will spread throughout the entire module, but if regular regular refractories are used, even if the regular refractories crack, However, the propagation of cracks can be stopped within one standard refractory. Note that the regular regular refractories referred to here refer to all standard refractories that are hand-laid, not module bricks, and their dimensions are generally 10 to 15 cm in height and horizontal length. is 20 to 40 cm.

[[Stacking standard refractories by hand]]
The stacking of the above-mentioned regular refractories can be done manually. In the present invention, since module blocks are manufactured at a location other than the coke oven construction site, it is possible to secure sufficient work space, unlike when standard refractories are manually loaded at the coke oven construction site. . Therefore, the burden on the worker can be reduced even if the same is done by hand. In addition, when stacking regular refractories at a coke oven construction site, it is necessary to build scaffolding to match the height of the stacked regular refractories and work on it. Because the work involves loading standard refractories, there is no need to use scaffolding for work at heights, and the work can be carried out on the ground with good footing.

[[Stacking of standard refractories by robot]]
Moreover, the stacking of the above-mentioned regular refractories can also be performed using a robot. In this case, it is possible to automate part or all of the block manufacturing process, which reduces the number of workers involved in the heavy labor of manually stacking standard refractories, and also It becomes possible to automate part or all of the refractory stacking work using robots.

The robot used for stacking the regular refractories is not particularly limited and any robot can be used, but an arm-type robot with a movable arm capable of handling the regular refractories should be used. is preferred. An example of the arm-type robot is a vertical articulated robot, which is a type of industrial robot. Moreover, a module block can also be manufactured using an arm-type robot for stacking standard refractories and an arm-type robot for applying mortar.

[[Module block production line]]
Note that, regardless of whether the module blocks are stacked manually or by using a robot, the number of manufacturing lines for module blocks may be one or multiple. If modular blocks are manufactured by stacking regular refractories on multiple lines, the speed of supplying module blocks to the coke oven construction site can be increased, so from the perspective of work efficiency, the number of manufacturing lines for module blocks can be increased. is preferably 2 or more, more preferably 3 or more. On the other hand, there is no upper limit to the number of production lines, but even if the number of lines is increased more than necessary, the subsequent module block transportation process, mortar application process and module block installation process performed at the coke oven construction site will be the rate-limiting process. Therefore, it becomes difficult to further improve the construction speed of coke ovens, and cost effectiveness decreases. Therefore, the number of lines may 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 blocks is excessively high, it is necessary to set up a work floor by assembling scaffolding or other methods in order to stack standard refractories at high positions. For example, in Japan, Article 518 of the Industrial Safety and Health Regulations requires that a work floor be provided if work is performed at a height of 2 meters or more and there is a risk of falling. If the height of the module block is less than 2 m, even if the module block is manufactured by hand-laying regular refractories, there is no need to install scaffolding or the like to perform work at heights, 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 loaded is within the movable range of the arm of a general arm-type robot. It can be done. Therefore, module blocks can be manufactured simply by moving the robot in the horizontal direction, resulting in high work efficiency. Therefore, from the viewpoint of work efficiency, it is preferable that the height of the module block is less than 2 m. On the other hand, the lower limit of the height of the module block is not particularly limited either, but it is preferably two or more stages of regular refractories.

Further, the length in the longitudinal direction of the module block is not limited either, but from the viewpoint of work efficiency, it is preferably 1/8 or more of the length of the coke oven to be constructed. The length of the module block in the longitudinal direction may be 1/4 or more of the 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 length of the coke oven to be constructed.

Note that the "longitudinal length of the module block" here refers to the length in the longitudinal direction of the module block in the horizontal cross section, and the "height of the module block" refers to the length from the bottom surface to the top surface of the module block. refers to height. Note that the "longitudinal length of the module block" and "height of the module block" do not include irregularities such as dowels provided on the side, top, and bottom surfaces of the module block. Moreover, "the oven length of a coke oven" means the length in the longitudinal direction of each combustion chamber and carbonization chamber that constitute the coke oven. The length of the common coke oven currently in use is approximately 15 to 17 m.

[First measurement process]
Next, the contour shape of the module block obtained in the stacking step is measured to obtain the module block contour shape (first measurement 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 portion of the module block may be measured, or the contour shape of the entire module block may be measured.

The method for measuring the contour shape is not particularly limited, and any method can be used. As the measurement method, it is preferable to use a three-dimensional measurement method that measures three-dimensional contour shape data of the module block. In the three-dimensional measurement method, for example, the contour shape of a module block can be acquired 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. Acquire three-dimensional point cloud data of the contour shape of the module block by irradiating the module block with a laser and detecting the reflected light to measure the distance from the light source to each point on the surface of the module block. I can do it. Methods that can be used to measure distance using reflected light include, for example, a TOF (Time of Flight) method and a phase difference detection method, but are not limited to these and any other method can be used.

Further, 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, the three-dimensional coordinates of the same point in a plurality of images taken from different viewpoints can be determined using the principle of triangulation. Therefore, by determining the three-dimensional coordinates of many points in the image, three-dimensional point group data of the contour shape of the module block can be obtained.

Regardless of which measurement method is used, if the contour shapes of multiple surfaces of a module block are measured, the multiple measurement data obtained will be combined to generate data that includes the contour shapes of multiple surfaces. It is preferable.

Note that the dimensional tolerance of the regular refractories constituting the module block is generally about 1 to 2 mm. Further, the stacking accuracy of regular refractories in a coke oven is generally required to be about 1 to 2 mm. Therefore, the measurement accuracy of the measurement 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 group data and use the polygon model in subsequent steps.

In the first measuring step, there is no particular restriction on the part where the contour shape of the module block is measured, but it is preferable to measure at least the contour shape of the lower surface of the module block, and at least the contour shape of the lower surface and side surface of the module block. It is more preferable. The reason will be explained later.

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

Here, "the position where the module block is installed" refers to the position where the module block is planned to be installed in the module block installation process. "Contour shape of the position where the module block is installed (installation position contour shape)" refers to the contour shape of the part that will come into contact with the module block (via mortar) when the module block is installed. Point. The installation position contour typically includes the contour of the module block that has already been installed. Furthermore, as described above, in the present invention, parts of the furnace, such as parts with complicated shapes, can be manufactured by directly hand-laying regular refractories instead of modular blocks. Therefore, the installation position contour shape can also include the contour shape of the already installed regular refractories (other than the regular refractories that constitute the module block).

In the second measurement step, it is sufficient to measure the contour shape of at least a part of the position where the module block is installed. It is preferable to measure the contour shape of the face where the side faces of the block face each other.

The method for measuring the contour shape is not particularly limited, and any method can be used. As the measurement method, it is preferable to use a three-dimensional measurement method that measures data on a three-dimensional contour shape of the installation position. In the three-dimensional measurement method, for example, the contour shape of the installation position can be acquired as three-dimensional point group data.

As in the first measurement process described above, the measurement method in the second measurement process may be any arbitrary one, such as a three-dimensional measurement method using a laser or photogrammetry using images taken from multiple viewpoints. This can be done by any 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.

Regardless of the measurement method used, when the contour shapes of multiple surfaces at the installation position are measured, it is preferable to combine the multiple measurement data obtained to generate data including the contour shapes of the multiple surfaces.

Furthermore, for the same reason as stated in the first measurement step, the measurement accuracy of the measurement method used in measuring the contour shape of the installation position 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 group 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 to implement the second measurement step is not limited to this, and can be performed at any timing before the determination step. For example, the second measurement step may be performed before the first measurement step, or the second measurement step may be performed simultaneously with the second measurement step.

[Judgment process]
Next, the module block contour shape obtained in the first measurement step and the installation position contour shape obtained in the second measurement step are compared to determine whether the shape of the module block is acceptable (judgment step ). By comparing the module block contour shape and the installation position contour shape in this way, it is possible to check whether the shape of the module block matches the shape of the installation position when the module block is installed, during actual installation work. can be determined beforehand. As a result, it becomes possible to reduce the work required to modify module blocks at the furnace construction site and to efficiently construct the furnace with high precision.

The effects of the present invention will be explained in more detail with reference to the drawings. FIG. 7 is a schematic diagram showing an example of the arrangement of module blocks installed in the module block installation process and module blocks that have already been installed. In the example shown in FIG. 7, a plurality of module blocks constituting the furnace have already been installed at the furnace construction site. This module block that has already been installed is hereinafter referred to as an existing module block. The existing module blocks 11a, 11b, 11c are installed adjacent to each other in the horizontal direction, and the existing module block 11d is stacked on the upper stage of the existing module blocks 11b, 11c. Then, the module block 10 is installed above the existing module blocks 11a and 11b so as to be horizontally 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, etc. For example, the lower surface of the module block 10 comes into contact with the upper surface of the existing module blocks 11a and 11b. Therefore, if there is an unintended level difference on the top surface of the existing module blocks 11a and 11b, it will interfere with the bottom surface of the module block 10. Furthermore, even if there is no unintended level difference on the upper surfaces of the existing module blocks 11a and 11b, if the position of the existing module block 11 is shifted in the horizontal direction, the dowel on the lower surface of the module block 10 and the upper surface of the existing module block 11 may Interference may occur with the tenon.

According to the present invention, the presence or absence of interference between module blocks can be predicted in advance by making the above determination prior to the module block transportation process. As a result, it becomes possible to reduce the work required to modify module blocks at the furnace construction site and to efficiently construct the furnace with high precision.

There are no particular limitations on what to do when the shape of the module block is determined to be rejected in the determination step, but it is possible to take some measures to one or both of the module block and the installation position of the module block. preferable.

For example, in one embodiment of the present specification, when the shape of the module block is determined to be rejected in the determination step, a separately manufactured module block (second module block) is used in place of the module block. can be used. This makes it possible to avoid carrying module blocks that do not match the shape of the installation position to the furnace construction site and causing rework at the site.

Note that when using a 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 or not. . In this case, it is preferable to repeat the above process until a module block that passes the determination step is found.

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

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

For example, in one embodiment of the invention, the shape modification may be performed by machining. By performing 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. Furthermore, according to this method, only the portions with large errors in shape can be processed to have an appropriate shape.

Any machining means can be used for the machining without 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.

In another embodiment of the present invention, the shape can be modified by replacing part or all of the regular refractories that constitute the module block. When modifying the shape by replacing the regular refractories, for example, part or all of the module block may be once disassembled into regular refractories, and the disassembled portions of the regular refractories may be re-stacked. The regular refractories used in the disassembled parts may be reused or disposed of.

[Module block transportation process]
Next, the steps after the module block manufacturing process will be explained. The module blocks manufactured in the above module block manufacturing process are then transported to a coke oven construction site. The method of transporting module blocks in the module block transport process is not particularly limited, and depending on the distance between the module block manufacturing site and the coke oven construction site, trucks, transporters (self-propelled transport carts), cranes, etc. are used. Any method such as the above can be used alone or in combination. For example, if a temporary shed is set up at a coke oven construction site, transporters are used to transport module blocks from the place where they are manufactured or processed to the temporary shed, and an overhead crane and stage jack are installed inside the temporary shed. Can be used together to transport to the construction location. In addition, in the module block transportation process, module blocks can be directly transported from the module block manufacturing site to the construction site of the coke oven construction site, but first, they are transported to the module block storage site and temporarily stored. Depending on the progress of the furnace, the module blocks may be transported from the block storage location to the construction location at the coke oven construction location.

[Mortar application process]
Next, apply mortar to the locations where the module blocks will be installed. The method of applying mortar is not particularly limited, and as with the case of stacking standard refractories, apply mortar to the position where the bottom and side surfaces of the module blocks come into contact, in other words, to the top and side surfaces of the position where the module blocks will be installed. do it.

Spacers can also be installed on the surface coated with mortar that contacts the bottom surface of the module block to be installed, that is, the portion that will serve as a horizontal joint. Due to the load of the module block being applied to this part, it may not be possible to secure the desired joint thickness. Therefore, by installing a spacer and installing a module block from above, it becomes possible to easily ensure the joint thickness. The spacer preferably 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 may be lifted by a crane or the like and installed while adjusting the position on the surface coated with mortar. In this way, by constructing the module block by module block, the burden on the worker is reduced compared to the case where the standard refractories are manually stacked one by one, and the standard refractories can be piled up with high precision.

In addition, when installing the module blocks, it is preferable to install the module blocks so that they are staggered as shown in FIG. By stacking module blocks alternately, the strength of the furnace can be improved. Note that "staggered" here refers to the fact 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 using the above steps. Although the present invention has been explained so far by taking the construction of a coke oven as an example, the present invention is also applicable to the construction of furnaces other than coke ovens, as described above.

[Preliminary judgment process]
In another embodiment of the present invention, as shown in the flowchart of FIG. 8, the module block manufacturing process, prior to the determination process, uses the module block contour shape obtained in the first measurement process and a previously prepared The method may further include a preliminary determination step of comparing the shape of the module block with a proper contour shape of the module block to determine whether the shape of the module block is acceptable. In this way, by determining in advance whether or not the shape of the module block is appropriate, it becomes possible to construct the furnace more efficiently and accurately.

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

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

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

In the above preliminary judgment step, for example, the module block contour shape is compared with the appropriate contour shape of a module block prepared in advance, and if the error is within a certain range, no shape modification is necessary; otherwise, modification is necessary. It can be determined that

1 Module block 2 Standard refractory 3 Dowel 4 Tenon 5 Mortar 10 Module blocks 11a to d Existing module blocks

Claims (8)

A module block manufacturing process in which the module blocks are manufactured 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 the position where the module block is installed;
A furnace construction method, comprising a module block installation step of installing a module block transported in the module block transport step at a position where the mortar is applied,
The module block manufacturing process includes:
a stacking step of stacking a plurality of regular 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 the contour shape of the position where the module block is installed in the furnace to obtain the installation position contour shape;
A furnace construction method comprising: a determination step of comparing the module block contour shape and the installation position contour shape to determine whether the shape of the module block is acceptable. 2. The furnace construction method according to claim 1, wherein when the shape of the module block is determined to be rejected in the determination step, a separately manufactured module block is used in place of the module block. The furnace construction method according to claim 1, wherein when the shape of the module block is determined to be rejected 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 the modification of the shape is performed by machining. 5. The furnace construction method according to claim 3, wherein the modification of the shape is performed by replacing part or all of a regular refractory that constitutes the module block. The furnace according to any one of claims 1 to 5, wherein one or both of the measurements in the first measurement step and the measurements in the second measurement step are performed using a three-dimensional measurement method using a laser. Construction method. According to any one of claims 1 to 5, one or both of the measurement in the first measurement step and the measurement in the second measurement step is performed by photogrammetry using images taken from a plurality of viewpoints. Furnace construction method described. The module block manufacturing process includes:
Prior to the determination step, a preliminary step of comparing the module block contour shape obtained in the first measurement step with an appropriate contour shape of the module block prepared in advance to determine whether the shape of the module block is acceptable or not. The furnace construction method according to any one of claims 1 to 7, further comprising a target determination step.

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