1. Glass melting furnace nozzle failure
In the glass melting process, the nozzle is a key component, and its performance directly affects the combustion efficiency of the melting furnace and the quality of glass. However, after a period of use, the nozzle often has various faults, including internal and external coking, concentricity deviation, nozzle wear, change in outlet area, and nozzle angle movement. These faults will seriously affect the atomization and combustion conditions, and then affect the stability of the entire melting process and the quality of glass.
① Coking problem
Coking is mainly caused by the incomplete combustion of heavy oil at high temperature, especially the cracking residue formed when the combustion air is insufficient. When the atomization effect is good and the combustion air is sufficient, the incompletely burned coarse oil droplets will precipitate free carbon particles, which will aggregate to form coking, usually appearing on the nozzle mouth and nozzle brick. In addition, the residual oil in the nozzle is cracked by heat or the nozzle is too small and the concentricity is deviated, which can easily lead to the formation of coking.
② Concentricity deviation
The concentricity deviation in the nozzle will lead to uneven atomization, resulting in incomplete combustion and smoke in the dense oil mist area. In this case, the flame brightness is uneven, and in severe cases, the flame state will become unstable, deflected, or even lose directionality.
③ Nozzle wear
The nozzle is washed by high-temperature oil and gas jets for a long time, which can easily lead to a gradual expansion of the caliber, thereby affecting the oil flow, atomization and combustion effect. In order to maintain a good atomization effect, it is necessary to adjust parameters such as oil pressure and air pressure in time, and even replace a new nozzle when necessary.
④ Changes in the annular area of the air outlet and the distance from the nozzle to the nozzle
The distance d from the nozzle to the nozzle has an important influence on the atomization conditions and diffusion angle. Generally speaking, when the d value is large, the atomization conditions are better and the diffusion angle is smaller; when the d value is small, the atomization effect is poor and the diffusion angle is larger. However, the d value should not be too large, otherwise the high-speed airflow will block the oil flow, resulting in insufficient oil supply. Therefore, this distance needs to be checked and adjusted frequently during operation.
⑤ Movement of the nozzle angle
The change in the nozzle installation angle will directly lead to a change in the flame direction. In order to ensure the correct flame direction and avoid direct impact on the crown to cause local melting, the nozzle angle must be checked and adjusted frequently. At the same time, the flame should be kept as close to the glass liquid surface as possible and have a large coverage area to improve thermal efficiency.
2. Hot repair of glass kiln nozzle bricks:
Nozzle bricks, as the core components of fuel-fired melting furnaces, play an important role in the mixing channel of atomized heavy oil and combustion-supporting air. Because they are located at the nozzle port where the flame directly impacts, nozzle bricks are easily eroded by high-temperature flames and require regular professional hot repairs.
When a burnt gap appears at the nozzle port of the nozzle brick, it needs to be replaced. The replacement process requires delicate operation: first remove the spray gun, open the gap above the nozzle brick, and remove the damaged nozzle brick. Then, place the new nozzle brick that has been preheated or heated to more than 900°C as required, ensure that the gap is filled and flat, reinstall the spray gun, and restore its normal function. At this point, the hot repair process is completed.
The traditional hot repair operation environment is harsh and requires high labor intensity. Although the use of advanced refractory materials has alleviated this problem, it is still heavy and has a certain interference with the production process. With technological advances, hot repair and hot oxygen spraying technologies have been gradually applied, which has greatly improved hot repair conditions and improved operational safety and efficiency.
Hot repair technology is mainly used to reinforce the refractory materials or seal holes in the late stage of melting furnace, but attention should be paid to the possible glass liquid pollution and problems affecting the operation of melting furnace. The hot oxygen gunning technology is to spray refractory powder at high temperature to achieve self-melting welding of materials and complete the rapid and safe repair of refractory materials. This technology is not only suitable for conventional corrosion repair, but also efficient for complex situations such as displacement and breakage, which significantly improves the maintenance efficiency and working performance of melting furnace.
In short,
Regular inspection and maintenance are equally important. Don't wait until the problem occurs before thinking about solving it, but through daily inspection, timely discover and deal with potential problems. For example, regularly check the wear of the kiln pool wall, heat storage chamber and nozzle. Once abnormalities are found, measures should be taken immediately to repair them.
Although hot repair work seems difficult and challenging, as long as we master the correct methods and techniques, and always stay vigilant and focused, we will be able to overcome these difficulties. I hope my sharing can help you, and you are also welcome to leave a message in the comment area to share your own experiences and problems.
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