The kiln is the core equipment of the glass factory. Generally, it is cold repaired once every few years. Under normal circumstances, the reasons for cold repair are as follows.
A. The refractory material at the contact part of the molten glass is seriously damaged, there is a danger of material leakage, and it is difficult to repair locally.
B. The refractory material of the upper structure is damaged, the fire leakage is serious, and the glass cannot be melted normally, and various hot repair measures are invalid.
C. The regenerator is seriously blocked, so that the fuel consumption increases and the glass melting capacity is reduced, so that the cost is significantly increased, and it is not economical to replace the checker bricks.
Of course, there are also various special circumstances that cause the kiln to be shut down for cold repair. Such as improper design that can not be produced normally; wrong selection of refractory materials caused a large number of stones and streaks; due to various reasons, serious material leakage in the kiln, etc.
The simplest cold repair only replaces the liquid hole, pool wall bricks and regenerator checker bricks. For medium-scale cold repairs, the bottom of the pool, small furnaces and large turrets must be rebuilt. For large-scale cold repairs, all except the foundation and flue must be dismantled and repaired. Generally, cold repairs are not simply repairs as they are, but must be combined with technical transformations.
Preparation before cold repair
a. Design and material preparation Before cold repair, according to the production plan of the new kiln and the use experience of the old kiln, put forward the parts that need to be cold repaired and the technical transformation plan, and then carry out theoretical calculations and structural design, and put forward the materials required for cold repair according to the structural design plan.
b. The materials used for brick preparation (mainly refractory materials) should be carefully inspected after arriving at the factory. The bricks to be processed should be ground and cut, and special parts should be pre-laid.
c. Before planning and arranging the cold repair, list the project schedule in detail, so that the specific construction personnel can clarify the operation method and quality requirements, and do a good job in the arrangement and training of the personnel.
D. Review of drawings and check all drawings in detail before drawing lines, and correct them immediately if any errors are found. Before construction, the masonry location must be determined on the site according to the drawings and the line should be drawn. The most important thing in the line is to determine the center line, the drip center and the liquid surface level.
e. In order to ensure the accuracy of the masonry dimensions when building standard lines and templates, there must be standard lines or templates. The standard line is generally used to mark the vertical and horizontal lines of each part with a rope line, and the model is measured by a standard shape made of steel or wood. Before masonry, the standard line must be drawn and the model must be prepared.
f. Prepare masonry tools such as bricklaying, brick cutting, concrete and other tools.
Discharging the molten glass in the furnace is an important part of the cold repair work. The requirement for unwinding work is thorough safety. At present, there are two methods for discharging the float glass melting furnace: one is to use the glass discharging pool to discharge; the other is to discharge the water by the water quenching method. Taking the use of a glass discharging pool as an example, the preparation and operation steps for discharging are described as follows.
initial preparation work
a. Glass discharge pool, one week before discharge, drain the water in the pool, remove all the sundries in the pool, and rinse the bottom and wall sludge. Lay a layer of broken glass ballast at the bottom of the pool with a thickness of about 100mm to prevent the released glass from sticking to the bottom of the pool. Spread more broken glass ballast near the discharge ditch, and then put in clean water to a sufficient depth, and be ready to add water Pipes and related tools and equipment.
b. Discharging hole, the day before discharging, remove the iron parts and air ducts at the corresponding parts outside the discharging hole, open and remove the two layers of bricks outside the hole bricks, and prepare to hit the big iron of the third layer of hole bricks. Kong.
c. Discharging ditch. One week before discharging, clean the discharging ditch and rebuild it. Spread quartz sand with a thickness of about 20mm on the bottom of the ditch, and then pave wood sticks with a thickness of about 100mm to avoid glass liquid. Condensation is difficult to flow.
d. Prepare a diesel spray gun and the corresponding fuel supply system and barreled diesel at the exit of the discharge tunnel and the tail of the discharge ditch to prepare for preheating the discharge ditch and heating the exit of the discharge ditch.
e. Contact the power supply, steam and water supply units to ensure normal and stable power supply, steam and water supply during the furnace discharge period.
f. Check all oil, gas, and gas systems, prepare various tools and instruments, and make preparations for purging the oil system after the fire ceases. And prepare large pipe wrenches and afterburner steel pipes for the purpose of tightening the strips.
g. One day before discharging, add kerosene or engine oil to lubricate the screws of each brace of the melting furnace, so that the brace can be easily tightened when the kiln ceases fire and cold kiln is dismantled.
h. Check the fire-fighting facilities around the furnace, and the fire-fighting truck should store water on standby.
i. Arrange the division of labor, safety education and tool preparation for furnace discharge operations.
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