The refractory materials used in glass kiln regenerators mainly include lattice body, grate arch, regenerator top arch, side wall and middle partition wall. The temperature of the regenerator brick changes with time, the temperature fluctuation is large, and the gas is complex. It mainly bears losses from three aspects: thermal shock, chemical erosion and mechanical stress. Thermal shock can easily cause the brick body to melt, soften and generate thermal stress, resulting in cracking of the brick body, which mainly occurs in the upper part of the lattice brick. Chemical erosion is the erosion of the above-mentioned solid powder and gas and the contact reaction between lattice bricks of different properties, which will cause the brick body to melt into liquid phase, crystal transformation, structural cracking, peeling, etc., which mainly occurs in the middle and upper part of the regenerator. Mechanical stress is mass load. The total mass of the checker bricks in a regenerator is about 100t, so the load of the bottom checker bricks is relatively large. In addition, they have to withstand the alternating hot and cold effects of the reversing operation. Therefore, it is required to select dense, thermally shock-resistant and load-bearing refractory materials.
At present, there are two main options for the selection of checker bricks for regenerators:
- Alkaline brick scheme -
The top checker bricks of the regenerator in this scheme use directly bonded high-purity magnesia bricks, the upper layer uses ordinary fired magnesia bricks, the middle layer uses sulfate-resistant magnesia-chrome bricks or forsterite bricks, the lower layer uses low-porosity clay bricks, and the transition material between magnesia bricks and clay bricks uses anti-stripping high-alumina bricks.
- Fused zirconium brick scheme -
The entire lattice body of the regenerator uses the same cross-shaped fused zirconium corundum checker bricks (ER-1681). It is reported that recently, fused β-alumina materials have been selected as the top checker bricks.
The top arch of the regenerator is usually made of fused AZS bricks, directly bonded magnesia bricks or silica bricks. The upper layer of the side wall and the partition wall is made of magnesia bricks, the middle layer is made of magnesia bricks or low-porosity clay bricks, and the lower layer is made of low-porosity clay bricks. Low-porosity clay bricks are used for the grate arch.
After selecting a solution suitable for the kiln regenerator, the quality of its refractory materials, the construction quality of refractory bricks, and the subsequent furnace drying, maintenance, and daily operations are also the key to whether the kiln can operate safely. Therefore, these steps and processes must be completed according to the design requirements. Avoid economic losses caused by kiln problems.
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