At present, most float glass manufacturers adopt the "double high heat load" melting operation system, increase the temperature of 1 to 2 small furnaces, and correspondingly increase the temperature of the feeding pool, resulting in a relatively "active" root of the pile. Due to the melting operation, the temperature of the pool walls on both sides is lower than the temperature in the middle of the melting furnace. The lateral convection of the glass liquid will lead the pile to the pool wall during the forward process. In addition, large float glass melting furnaces mostly use two blanket feeders, and each stock cannot adjust the direction of the stock separately. The longer the time, the easier it is to form an "inverted eight-shaped" pile that is biased to the pool walls on both sides.
The biased pile directly adheres to the pool wall bricks of the small furnace in the material zone and gradually melts, which has a greater scouring effect on the pool wall, accelerating the scouring and erosion speed of the pool wall bricks in the small furnace in the material zone.
When encountering biased glass kilns, how to prevent and protect the pool wall becomes the key. The following are the remedial measures for preventing material deviation and protecting the pool wall of the glass furnace summarized in the actual production process, for reference!
PART.01
Middle solid material water pipe
Install a 76mm, 7-8m long cooling water pipe in the center of the melting furnace (i.e. between the two feeders) close to the material surface, about to the position of the 2nd small furnace, and use the heat absorption and cooling effect of the cooling water bag to attract the material piles on both sides to move close to the solid material water bag, so that the material piles are not close to the pool wall, and the glass liquid temperature at the pool wall on both sides increases. When the temperature difference between the glass liquid in the middle of the melting furnace and on both sides is reduced, and the horizontal convection reaches a balance, the material pile can be guaranteed to be stable and not deflected, which has a good effect on preventing material deviation, reducing pool wall erosion and improving glass quality.
PART.02
Both sides of the pool wall baffle
Due to the "inverted eight-shaped" material pile caused by the specific reasons of the melting furnace, if the melting operation is not easy to correct, a 76mm, 7-8m long baffle can be installed on both sides of the feeding pool, close to the glass liquid surface, and its placement angle is slightly tilted toward the center of the melting furnace. The deflected material pile is forcibly blocked within the effective length of the baffle, the tilting movement direction of the material pile is changed, and the degree to which the material pile is close to the wall of the small furnace pool in the material-making area is reduced, which has a certain effect on reducing the scouring of the pool wall by the material pile.
PART.03
Water hook for cooling pool wall
Due to the continuous erosion of the pool wall, when the thickness of the pool wall brick in the material zone is thin (about 100mm) after the operation of the melting furnace for a certain period, some manufacturers install cooling water hooks from the lower gap bricks. Generally, 2 to 3 cooling water hooks are installed on the pool wall of a small furnace. The water hook is L-shaped and the length is 800 to 1000. The cooling water hook is close to the inner side of the pool wall and extends into the material layer to a depth of 60 to 70mm (determined by the height of the lower gap brick). The cooling water hook supports the deflected material pile so that it does not stick to the pool wall, and can also reduce the viscosity of the glass liquid at this place, reduce the erosion rate of the material pile on the pool wall, and play a role in protecting the pool wall. However, the cooling water hook of the pool wall is a double-edged sword, with advantages and disadvantages. Due to the cooling effect of the cooling water hook of the pool wall, the temperature difference between the middle and the two sides of the melting furnace is increased, making it easier for the material pile to produce deflected material.
PART.04
Brick binding of pool wall
Brick binding of pool wall can be adopted in the middle and late stages of the melting furnace when the thickness of the pool wall is very small. Use 33 or 36 oxidation method non-shrinkage zirconium corundum bricks with specifications of 300mm×400mm×100mm, and tie them from the 1st small furnace to the pool wall at the hot spot small furnace. Each time the bricks are tied, the pool wall air volume is appropriately increased. Generally, the bricks can be safely used for about 2 years, and the bricks can be tied twice in one kiln period.
The technical remedial measures taken to prevent material deviation, protect the pool wall and extend the service life of the pool wall are mostly forced. Among them, the technical measures of using material blocking water bags and cooling water hooks are double-edged swords, with advantages and disadvantages. On the one hand, they play a role in preventing material deviation and protecting the pool wall, but on the other hand, they will also affect the melting condition, increase the temperature difference between the middle and both sides of the melting furnace, increase the difficulty of material pile control, and increase fuel consumption accordingly. The cooling water hook of the pool wall can be used in combination with the material blocking water bag, which not only reduces the viscosity of the glass liquid at the pool wall and reduces the erosion of the pool wall, but also forces the material pile to change direction, overcomes the tendency of the cooling water hook to deviate from the material, so that the material pile does not cling to the pool wall, and can play a better role in protecting the pool wall.
The use of the middle solid material water pipe and the pool wall binding brick is currently a technical measure for domestic glass manufacturers to prevent material deviation and protect the pool wall. The use of solid material water bags in large float glass melting furnaces is conducive to the control of the material pile, which can make the material piles on both sides close to the solid material water bag and not close to the pool wall, and prevent the material pile from directly eroding the pool wall; the use of pool wall binding bricks will not affect the melting condition. After the bricks are tied, the thickness of the pool wall is directly increased, and the cooling air volume of the pool wall is increased, which also has an effective cooling effect, which has the effect of extending the service life of the melting furnace pool wall.
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