Prefabricated furnace lining module, modular fast-assembly furnace lining system and furnace lining installation method

Abstract

The invention discloses prefabricated furnace lining modules, a modular fast-assembly type furnace lining system and a furnace lining installation method.According to the structural form of a furnace lining of a heating furnace, the modular structure of the furnace lining is decomposed into a furnace top module, a furnace wall module and a furnace door module correspondingly, and each prefabricated furnace lining module integrates a refractory layer, a heat insulation layer, an anchoring part and a connecting mechanism; the structural strength and the heat insulation performance are strictly inspected; each module is prefabricated and formed in a factory, during installation, only simple hoisting, positioning, splicing and locking are needed, installation of the furnace lining is rapidly completed like building blocks, the built splicing seams are filled with fireproof sealing materials, and the sealing performance and integrity of the seams are guaranteed. When the prefabricated furnace lining module is used for on-site furnace lining installation, the construction period can be shortened, the construction difficulty can be reduced, the uniformity of the construction quality can be guaranteed, after the furnace lining is damaged, only the damaged module needs to be dismantled and replaced with a new module, maintenance is easy, and the maintenance cost can be greatly reduced.

Description

Technical Field

[0001] This application relates to the field of metallurgical equipment technology, and in particular to metallurgical heating furnaces. Specifically, it relates to a prefabricated furnace lining module for a metallurgical heating furnace lining, a modular quick-installation furnace lining system built from the module, and a method for installing the module into the furnace lining. Background Technology

[0002] Heating furnaces are key thermal equipment in process industries such as metallurgy, petrochemicals, and ceramics. Their furnace lining structure directly affects the furnace's thermal efficiency, operational safety, energy consumption, and service life. Traditionally, heating furnace linings are constructed using on-site masonry methods, either by laying refractory bricks one by one or by casting refractory castables as a whole on-site.

[0003] For refractory bricklaying, the construction process heavily relies on the skill and experience of the workers. The quality of the masonry, such as the fullness, flatness, and verticality of the brick joints, directly affects the integrity and sealing of the furnace lining. The brick joints are the weakest point in the furnace lining; under long-term high temperatures, airflow erosion, and the thermal stress cycles of start-up and shutdown, they are highly susceptible to damage and spalling, leading to furnace shell red-hot, increased heat loss, and even safety accidents. Furthermore, refractory bricklaying has a long construction cycle, high labor intensity, and makes it difficult to achieve complex, irregular structures.

[0004] While on-site monolithic casting can achieve a seamless, integrated structure, it inherently suffers from the drawback of lengthy curing and baking times. Moisture in the castable must be slowly released through rigorous curing and prolonged low-temperature baking; otherwise, rapid evaporation during rapid heating can cause the furnace lining to crack and peel off. This process significantly extends the commissioning cycle of new heating furnaces or the downtime for maintenance of old furnaces, resulting in substantial production and economic losses for enterprises with continuous production.

[0005] Whether brick-built or cast-in-place, traditional furnace linings are extremely difficult to repair after localized damage. Repairs require manual chiseling and cleaning of the damaged area before rebuilding or casting, a process that is not only complex and time-consuming, but also often creates new weak points at the interface between the old and new materials, making it difficult to guarantee the repair's effectiveness. In many cases, because local replacement is not feasible, large areas or even the entire furnace lining must be dismantled and rebuilt, resulting in significant material waste and escalating maintenance costs.

[0006] In summary, traditional heating furnace linings suffer from the following systemic defects that urgently need to be addressed:

[0007] (1) Long construction period: There are many on-site operation procedures, which rely on manpower, and the casting material requires a long curing and baking time, which seriously affects the efficiency of equipment commissioning or resumption of production.

[0008] (2) Poor quality uniformity: The construction quality relies too much on the technical level of the workers, which is difficult to control precisely, resulting in unstable furnace lining performance and large fluctuations in lifespan.

[0009] (3) Difficult to repair and high cost: The repair technology for local damage is complicated and the effect is not good, often leading to "minor problems requiring major repairs" and high maintenance costs.

[0010] (4) Insufficient flexibility in structural design: It is difficult to efficiently and economically realize the furnace lining structure that integrates complex functions such as burners, thermocouples, and observation holes.

[0011] Therefore, there is an urgent need in this field for a new furnace lining technology that can fundamentally overcome the above-mentioned defects, so as to achieve rapid, high-quality, standardized installation and convenient maintenance of heating furnace linings. Summary of the Invention

[0012] This application provides a prefabricated furnace lining module, a modular quick-installation furnace lining system, and a furnace lining installation method to solve the problems of long construction period, poor quality uniformity, and difficult maintenance of existing heating furnace linings.

[0013] To achieve the above objectives, this application provides the following technical solution:

[0014] Firstly, this application provides a prefabricated furnace lining module, including a module body. The module body is an integrated composite structure, comprising a refractory layer, a heat insulation layer, and a backing layer stacked sequentially from the working surface to the back working surface, with each layer connected as a whole by pre-embedded anchors. The edge of the module body is provided with a standardized interface structure for adapting and splicing with adjacent module bodies to achieve mechanical interlocking. The standardized interface structure is a tenon and mortise structure opened at the edge of the module body. The module body is internally embedded with a module anchoring system for fixing the module body to the furnace shell of the heating furnace.

[0015] Furthermore, in the above technical solution, the standardized interface structure includes a male tenon and a female tenon that are adapted to each other in shape and size. The male tenon is set on the edge of the first module body, and the female tenon is set on the edge of the second module body adjacent to the first module body. When any two adjacent module bodies are spliced ​​together, the male tenon is adapted to be embedded in the female tenon to form a mechanical connection restricted in the three-dimensional direction.

[0016] Furthermore, the joint between the male tenon and the female tenon is filled with a fire-resistant sealant, which is any one or more combinations of fire-resistant mortar, fire-resistant fiber rope, or compressible fire-resistant ceramic plate.

[0017] Furthermore, the module anchoring system is a snap-on anchor or a bolt anchor.

[0018] Furthermore, the snap-on anchor includes a fixing part pre-embedded in the module body, and a snap-on part connected to one end of the fixing part, extending from the back working surface of the module body, and capable of being elastically snapped onto the pre-set hanging part of the furnace shell.

[0019] Furthermore, the bolt-type anchor includes a threaded sleeve pre-embedded in the module body, and a connecting bolt that passes through the furnace shell and is fastened to the threaded sleeve.

[0020] Furthermore, the refractory layer is a prefabricated working layer made of high-alumina refractory castable, with a thickness ranging from 100mm to 250mm; the heat insulation layer is a nanoporous heat insulation board adhered to the back working surface of the refractory layer, with a thickness ranging from 20mm to 50mm; and the backing layer is a ceramic fiber blanket adhered to the back working surface of the heat insulation layer, with a thickness ranging from 10mm to 30mm.

[0021] Furthermore, the anchor used to connect the fire-resistant layer, the heat insulation layer and the backing layer is made of heat-resistant steel. The anchor includes a "Y" or "V" shaped anchoring section embedded in the fire-resistant layer, and a fastening section that penetrates the heat insulation layer and the backing layer and presses each layer together.

[0022] Furthermore, when the module body serves as a furnace top module, it has an internally embedded reinforcing frame for enhancing hoisting strength. The reinforcing frame is welded from structural steel and is completely encased within the refractory layer material. Additionally, the module body has pre-drilled burner holes for installing burners.

[0023] Furthermore, when the module body serves as a furnace wall module, its bottom is integrally formed with a downwardly extending load-bearing base. The width of the load-bearing base is greater than the thickness of the module body to provide stable bottom support.

[0024] Furthermore, when the module body is used as a furnace door module, the module body is an irregularly shaped door frame module adapted to the shape of the furnace door. The inner contour of the irregularly shaped door frame module is adapted to the shape and size of the furnace door. The outer edge of the irregularly shaped door frame module and the edge of the adjacent furnace wall module are connected by a tenon and mortise structure.

[0025] Furthermore, the module body has one or more functional holes, including a temperature measuring hole for passing through a thermocouple, a pipeline hole for passing through a process pipeline, and an observation hole for maintenance.

[0026] Secondly, this application also provides a modular quick-installation furnace lining system, comprising multiple prefabricated furnace lining modules as described above. These prefabricated furnace lining modules are assembled and installed on-site within the furnace shell of a heating furnace to form the modular quick-installation furnace lining system. The modular quick-installation furnace lining system includes a furnace top module for forming the furnace top, a furnace wall module for forming the furnace wall, and a furnace door module for forming the furnace door. The furnace top module and furnace wall module are mechanically assembled using a mortise and tenon joint structure. The inner contour of the furnace door module is adapted to the shape and size of the furnace door. The furnace door module and furnace wall module are mechanically assembled using a mortise and tenon joint structure. The furnace top module, furnace wall module, and furnace door module are all fixedly connected to the furnace shell of the heating furnace through the module anchoring system.

[0027] Thirdly, this application also provides a furnace lining installation method, which uses the above-mentioned prefabricated furnace lining module. The furnace lining installation method includes the following steps:

[0028] S1: At the heating furnace site, mark the installation position of each prefabricated furnace lining module on the cleaned inner wall of the furnace shell;

[0029] S2: Using hoisting equipment, the prefabricated furnace lining modules are sequentially hoisted to the designated positions inside the furnace shell;

[0030] S3: Through the standardized interface structure at the edge of each prefabricated furnace lining module, adjacent modules are aligned and spliced ​​to form a mechanical interlock;

[0031] S4: Each prefabricated furnace lining module is fixed and locked to the furnace shell by a module anchoring system embedded in the prefabricated furnace lining module;

[0032] S5: Fill the joint between any two adjacent prefabricated furnace lining modules with refractory sealant to complete the sealing.

[0033] Furthermore, in the above technical solution, when local furnace lining repair is required, the following steps are included:

[0034] M1: Remove the refractory sealant from the joints of the precast furnace lining modules in the damaged area;

[0035] M2: Release the connection between the module anchoring system of the precast furnace lining module in the damaged area and the furnace shell;

[0036] M3: Separate and remove the damaged precast furnace lining module from the interface structure of the adjacent precast furnace lining module;

[0037] M4: Hoist the new precast furnace lining module to the target replacement position, and repeat steps S3 to S5 to complete the partial replacement.

[0038] Compared with the prior art, this application has at least the following beneficial effects:

[0039] 1. Based on further analysis and research of the problems in the prior art, this application recognizes that traditional heating furnace linings have long construction cycles, inconsistent quality, and are difficult to repair after damage. They also lack efficient and economical integration of functional components and structural flexibility. Therefore, this application provides a prefabricated furnace lining module, which prefabricates the refractory materials of the furnace top, furnace walls, and other parts into large, standardized modules in the factory. Through modular structural decomposition, the prefabrication of the structure is achieved. During installation, only simple hoisting, positioning, splicing, and locking are required, and the furnace lining can be installed quickly like "building blocks". This can shorten the construction cycle, reduce construction difficulty, and ensure the uniformity of construction quality. If the furnace lining is damaged, only the damaged module needs to be removed and replaced with a new module. The maintenance is simple and can significantly reduce maintenance costs.

[0040] 2. This application sets a standardized interface structure on each module body, and realizes mechanical interlocking between two adjacent module bodies through the tenon and mortise structure. The structure is simple, the connection is reliable, and the splicing is convenient.

[0041] 3. By filling the joint between the male tenon and the female tenon with refractory sealing material, all modules can be connected into an integral refractory sealing structure to meet the refractory sealing structure requirements of the furnace lining.

[0042] 4. This application uses snap-on or bolt-on anchors to connect the module body and the furnace shell, which is simple and reliable in structure, convenient to disassemble and assemble, and has high construction efficiency.

[0043] 5. This application uses anchors to connect the refractory layer, the heat insulation layer and the backing layer into one unit. This integrated composite multi-layer structure can not only meet the refractory and heat insulation requirements of the furnace lining, but also meet the structural strength requirements of the furnace lining.

[0044] 6. This application modularizes the furnace lining structure. These prefabricated furnace lining modules can be divided into regions based on the furnace lining structure, specifically into furnace top modules, furnace wall modules, and furnace door modules. The furnace top module has an internally embedded reinforcing frame, such as welded steel sections into a grid shape, which can achieve structural reinforcement. The furnace wall module has an integrally formed load-bearing base at the bottom, which can provide stable bottom support. The inner contour of the furnace door module is adapted to the shape and size of the furnace door. This irregularly shaped module can meet the structural shape of the furnace door. This module, which is divided according to the furnace lining structure region, can better adapt to the furnace shell and build a modular quick-installation prefabricated furnace lining system.

[0045] 7. This application provides one or more functional holes on the module body of the prefabricated furnace lining module. These functional holes can be pre-drilled in the factory during prefabrication. During on-site installation, functional components can be directly installed in the functional holes. Therefore, this modular quick-installation prefabricated furnace lining module is not only easy to construct and maintain, but also easy to integrate and install functional components, and has strong structural flexibility. Attached Figure Description

[0046] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the embodiments will be briefly described below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. It should be understood that the specific shapes and structures shown in the drawings should not generally be regarded as limiting conditions for implementing this application. For example, based on the technical concepts disclosed in this application and the exemplary drawings, those skilled in the art are able to easily make conventional adjustments or further optimizations to the addition / reduction / classification, specific shapes, positional relationships, connection methods, and size ratios of certain units (components).

[0047] Figure 1 This is a cross-sectional structural diagram of a prefabricated furnace lining module provided in this application in one embodiment, mainly showing the layer structure and interlayer anchors;

[0048] Figure 2 This is a schematic diagram showing the splicing state of a standardized interface structure between two adjacent prefabricated furnace lining modules in one embodiment.

[0049] Figure 3 This is a schematic diagram of the side connection structure of the prefabricated furnace lining module being fixed to the furnace shell using snap-on anchors in one embodiment.

[0050] Figure 4 This is a schematic diagram of the side connection structure in one embodiment where the prefabricated furnace lining module is fixed to the furnace shell using bolt-type anchors.

[0051] Figure 5 This is a schematic diagram of the front structure of the furnace top module in one embodiment, mainly showing the structural form of the reinforced skeleton covered by the refractory layer.

[0052] Explanation of reference numerals in the attached figures:

[0053] 1. Precast furnace lining module; 11. Refractory layer; 111. Reinforcing frame; 12. Insulation layer; 13. Backing layer; 14. Anchor; 141. Y-type anchoring section; 142. Screw; 143. Nut; 15. Male tenon; 16. Female tenon; 17. Snap-on anchor; 18. Threaded sleeve; 19. Refractory sealing material;

[0054] 2. Furnace shell; 21. L-shaped bracket; 22. Connecting bolts. Detailed Implementation

[0055] The present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0056] In the description of this application: unless otherwise stated, "a plurality of" means two or more. The terms "first," "second," etc., in this application are intended to distinguish the objects referred to and do not have any special meaning in terms of technical connotation (e.g., they should not be construed as an emphasis on importance or order). Expressions such as "including," "comprising," and "having" also mean "not limited to" (certain units, components, materials, steps, etc.).

[0057] The terms used in this application, such as "upper," "lower," "left," "right," and "middle," are generally used to facilitate intuitive understanding by referring to the accompanying drawings, and are not absolute limitations on the positional relationships in the actual product. Changes in these relative positional relationships, without departing from the technical concept disclosed in this application, should also be considered within the scope of this application.

[0058] To address the problems of long construction cycles, reliance on worker skills for quality, and difficult maintenance in traditional heating furnace lining construction, this application proposes a prefabricated furnace lining module, a modular quick-installation furnace lining system, and a furnace lining installation method based on the concept of modular structural decomposition for prefabrication. According to the furnace lining structure, the refractory materials for the furnace roof, furnace walls, and other parts are prefabricated into large, standardized modules in the factory. Each module integrates a refractory layer, insulation layer, anchors, and connecting mechanisms, and its structural strength and insulation performance have undergone rigorous testing. On-site, only simple hoisting, positioning, splicing, and locking are required, allowing for rapid furnace lining installation, much like "building blocks." This not only significantly shortens furnace downtime for maintenance and ensures the uniformity of furnace lining quality but also facilitates partial replacement, greatly reducing maintenance costs. The following detailed description, using specific embodiments, details the structure of the prefabricated furnace lining module, the modular quick-installation furnace lining system built using this prefabricated module, and the furnace lining installation method.

[0059] Example 1

[0060] See Figure 1 This embodiment provides a prefabricated furnace lining module, including a module body. The module body is an integrated composite structure, including a refractory layer 11, a heat insulation layer 12 and a backing layer 13 stacked sequentially from the working surface to the back working surface. The layers are connected as one unit by pre-embedded anchors 14.

[0061] Taking a standard furnace wall module as an example, it has a three-layer composite structure from the hot side (towards the furnace chamber) to the cold side (towards the furnace shell 2).

[0062] Refractory layer 11: Precast from high-alumina refractory castable with Al2O3 content ≥75% through vibration casting, curing, and baking, with a thickness of 150mm. This layer is in direct contact with high temperatures and is responsible for bearing the heat load and airflow scouring within the furnace.

[0063] Insulation layer 12: The cold side of the refractory layer 11 is in close contact with the insulation layer 11. It is made of nanoporous insulation board with a thickness of 30mm. This material has an extremely low thermal conductivity, which can effectively block heat transfer to the furnace shell 2 and significantly reduce heat loss.

[0064] Backing layer 13: Located on the outermost layer of the module body (i.e., the back working surface of the module body), it is made of 1260 type ceramic fiber blanket with a thickness of 20mm. This layer serves as an auxiliary heat insulation layer 12 on the one hand, and has a certain degree of flexibility on the other hand, which can absorb some thermal stress and improve the fit with the furnace shell 2.

[0065] The three layers of material are connected into a solid whole by heat-resistant steel anchors. The "Y"-shaped end (or V-shaped end) of the anchor is firmly embedded in the fire-resistant layer 11, and its screw part passes through the insulation layer 12 and the backing layer 13 in sequence, and is finally tightened by the nut 143 to ensure that the layers will not separate during transportation and installation.

[0066] To enable rapid and reliable assembly between modules, the edges of the module body are equipped with standardized interface structures for mechanical interlocking with adjacent module bodies. These standardized interface structures are tenon and mortise structures located at the edges of the module body. Figure 2 .

[0067] Specifically, the standardized interface structure between modules includes: taking the furnace wall module as an example, male tenon structures and female tenon groove structures are respectively set on the left and right edges of the furnace wall module. The cross-section of the male tenon 15 is trapezoidal (of course, it can also be other shapes, such as square, triangular, or arc-shaped), and the female tenon groove 16 is a matching trapezoidal groove. During installation, aligning the male tenon 15 of one module with the female tenon groove 16 of the adjacent module, and pushing it horizontally, achieves precise positioning and mechanical interlocking. Figure 2 This structure effectively prevents the modules from shifting perpendicular to the furnace wall. After assembly, the joints are filled with refractory sealant 19, such as by using a special refractory sealant (a high-viscosity refractory mortar) for grouting, ensuring the sealing and integrity of the joints. The refractory sealant can be any one or a combination of refractory mortar, refractory fiber rope, or compressible refractory ceramic plates.

[0068] In order to achieve a tight connection between the module body and the furnace shell 2, a module anchoring system is pre-embedded inside the module body to fix the module body to the furnace shell 2 of the heating furnace.

[0069] In one embodiment, the module anchoring system employs snap-fit ​​anchors 17. The fixing portion of this anchor is pre-embedded within the refractory layer 11, while the snap-fit ​​portion extends from the backing layer 13. An L-shaped bracket 21, matching the snap-fit ​​portion, is pre-welded onto the inner wall of the furnace shell 2. After the module is in place, a slight downward pressure allows the snap-fit ​​portion to elastically engage with the bracket, achieving quick and reliable fixing. Figure 3 .

[0070] In another embodiment, the modular anchoring system employs bolt-type anchors. The threaded sleeve 18 of this anchor is pre-embedded within the module body, and connecting bolts 22 are pre-embedded on the inner wall of the furnace shell 2. During installation, the threaded sleeve 18 and connecting bolts 22 on the module body are fitted together to achieve quick and reliable fixing. Figure 4 .

[0071] The prefabricated furnace lining modules provided in this application are standardized refractory material modules prefabricated in a factory and assembled on-site into the furnace shell 2 of the heating furnace. These prefabricated furnace lining modules can be categorized according to their installation location: furnace top modules for forming the furnace roof, furnace wall modules for forming the furnace walls, and furnace door modules for forming the furnace doors. Specifically, the furnace top module has a pre-embedded reinforcing frame 111 to enhance lifting strength. The reinforcing frame 111 is welded from structural steel and completely encased within the refractory layer 11. Furthermore, the furnace top module body has pre-drilled burner holes and lifting points for installing burners. The bottom of the furnace wall module has an integrally formed downward-extending load-bearing base. The width of the load-bearing base is greater than the thickness of the module body to provide stable bottom support. The main body of the furnace door module is an irregularly shaped door frame module that is adapted to the shape of the furnace door. The inner contour of the irregularly shaped door frame module is adapted to the shape and size of the furnace door. The outer edge of the irregularly shaped door frame module and the edge of the adjacent furnace wall module are connected by a tenon and mortise structure.

[0072] In this application, to withstand the lifting stress and gravity during operation, a "well"-shaped reinforcing frame 111 welded from Q235 steel is pre-embedded inside the refractory layer 11 of the prefabricated furnace lining module, which serves as the furnace top module. Simultaneously, burner holes with a diameter of 120mm are pre-reserved at corresponding locations according to the process layout.

[0073] In this application, a load-bearing base is designed at the bottom of the furnace wall module, which is integrally formed with the module body. The base is 50mm wider than the module body (or the size can be customized according to actual needs), which increases the stability of the module when it is placed upright.

[0074] In this application, all modules are pre-embedded with standardized functional holes according to the design drawings during prefabrication, such as Φ20mm holes for installing thermocouples, Φ80mm holes for threading process pipelines, and observation holes for maintenance. The number and type of functional holes on each module body can be designed according to requirements.

[0075] Example 2

[0076] This application also provides a modular quick-installation furnace lining system, which includes multiple prefabricated furnace lining modules as described above. The multiple prefabricated furnace lining modules are spliced ​​and installed in the furnace shell 2 of the heating furnace on site, thereby forming a modular quick-installation furnace lining system.

[0077] The modular quick-installation furnace lining system includes a furnace top module for forming the furnace top, a furnace wall module for forming the furnace wall, and a furnace door module for forming the furnace door. The furnace top module and furnace wall module are mechanically spliced ​​together by a tenon and mortise structure. The inner contour of the furnace door module is adapted to the shape and size of the furnace door. The furnace door module and furnace wall module are mechanically spliced ​​together by a tenon and mortise structure. The furnace top module, furnace wall module, and furnace door module are all fixedly connected to the furnace shell 2 of the heating furnace through a module anchoring system.

[0078] This application utilizes modular structural decomposition to achieve prefabrication of the structure. Large, standardized modules are prefabricated in the factory, requiring only simple hoisting, positioning, splicing, and locking during installation. The furnace lining installation is completed quickly, much like assembling building blocks, shortening the construction cycle, reducing construction difficulty, and ensuring uniform construction quality. Damage to the furnace lining can be easily repaired by removing the damaged module and replacing it with a new one, significantly reducing maintenance costs. Furthermore, functional holes can be pre-drilled in the factory, allowing functional components to be directly installed on-site. Therefore, this modular, quick-installation prefabricated furnace lining module not only facilitates construction and maintenance but also allows for easy integration and installation of functional components, offering high structural flexibility.

[0079] Example 3

[0080] This application also provides a furnace lining installation method, which uses the above-mentioned prefabricated furnace lining modules to construct the furnace lining of a heating furnace. The furnace lining installation method includes the following steps:

[0081] S1: In the factory, according to the design, refractory materials and heat insulation materials are prefabricated into composite modules that integrate refractory layer 11, heat insulation layer 12, backing layer 13, anchors, standardized interface structure and modular anchoring system.

[0082] S2: Conduct structural strength and thermal insulation performance tests on the prefabricated modules;

[0083] S3: At the heating furnace site, mark the installation position of each prefabricated furnace lining module on the cleaned inner wall of the furnace shell 2;

[0084] S4: Using hoisting equipment, the prefabricated furnace lining modules are sequentially hoisted to the designated positions inside the furnace shell 2;

[0085] S5: Through the standardized interface structure at the edge of each prefabricated furnace lining module, adjacent modules are aligned and spliced ​​to form a mechanical interlock;

[0086] S6: Each prefabricated furnace lining module is fixed and locked to the furnace shell 2 by means of a module anchoring system embedded in the prefabricated furnace lining module;

[0087] S7: Fill the joint between any two adjacent prefabricated furnace lining modules with refractory sealant to complete the sealing.

[0088] When localized furnace lining maintenance is required, the following steps are included:

[0089] M1: Remove the refractory sealant from the joints of the precast furnace lining modules in the damaged area;

[0090] M2: Release the connection between the module anchoring system of the precast furnace lining module in the damaged area and the furnace shell 2;

[0091] M3: Separate and remove the damaged precast furnace lining module from the interface structure of the adjacent precast furnace lining module;

[0092] M4: Hoist the new precast furnace lining module to the target replacement position, and repeat steps S5 to S7 to complete the partial replacement.

[0093] In summary, this application provides a prefabricated furnace lining module, a modular quick-installation furnace lining system, and a furnace lining installation method. Through modular structural decomposition, prefabrication of the structure is achieved. Refractory materials for the furnace roof, furnace walls, and other parts are prefabricated into large, standardized modules in the factory. During installation, only simple hoisting, positioning, splicing, and locking are required, allowing for rapid installation of the furnace lining like "building blocks." This shortens the construction cycle, reduces construction difficulty, and ensures uniformity of construction quality. If the furnace lining is damaged, only the damaged module needs to be removed and replaced with a new one, simplifying maintenance and significantly reducing maintenance costs. Furthermore, the structure is highly flexible, facilitating the integration and installation of functional components.

[0094] The technical features of the above embodiments can be combined in any way (as long as there is no contradiction in the combination of these technical features). For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described; these embodiments not explicitly written should also be considered to be within the scope of this specification.

[0095] The present application has been described in a relatively specific and detailed manner above through general descriptions and specific embodiments. It should be understood that, based on the technical concept of the present application, several conventional adjustments or further innovations can be made to these specific embodiments; however, as long as they do not depart from the technical concept of the present application, the technical solutions obtained by these conventional adjustments or further innovations also fall within the protection scope of the claims of the present application.

Claims

1. A pre-fabricated furnace lining module, characterized in that, The module body is an integrated composite structure, including a fire-resistant layer, a heat-insulating layer and a backing layer which are sequentially stacked from a working surface to a back working surface, and are connected as a whole through pre-embedded anchor members; The edge of the module body is provided with a standardized interface structure for fitting and splicing with adjacent module bodies to realize mechanical interlocking, and the standardized interface structure is a tenon-mortise structure provided at the edge of the module body; The module body is internally pre-embedded with a module anchoring system for fixing the module body to the furnace shell of a heating furnace.

2. The preformed lining module of claim 1, wherein, The standardized interface structure includes a male tenon and a female mortise which are mutually adapted in shape and size, the male tenon is arranged at the edge of a first module body, the female mortise is arranged at the edge of a second module body adjacent to the first module body, and when any two adjacent module bodies are spliced with each other, the male tenon is adapted to be embedded in the female mortise to form a mechanical connection which is limited in three-dimensional direction.

3. The preformed lining module of claim 2, wherein, The splicing joint of the male tenon and the female mortise is filled with a fire-resistant sealing material, and the fire-resistant sealing material is any one or a combination of fire-resistant mortar, fire-resistant fiber rope or compressible fire-resistant ceramic plate.

4. The preformed lining module of claim 1, wherein, The module anchoring system is a buckle type anchoring member or a bolt type anchoring member; The buckle type anchoring member includes a fixed part pre-embedded in the module body, and a buckle part connected at one end of the fixed part and extending from the back working surface of the module body and being capable of being elastically buckled on a pre-set hanging part of the furnace shell; The bolt type anchoring member includes a threaded sleeve pre-embedded in the module body, and a connecting bolt fastened with the threaded sleeve through the furnace shell.

5. The preformed lining module of claim 1, wherein, The fire-resistant layer is a working layer precast from high-aluminum refractory castable, and the thickness thereof ranges from 100 mm to 250 mm; The heat-insulating layer is a nano-microporous heat-insulating plate attached to the back working surface of the fire-resistant layer, and the thickness thereof ranges from 20 mm to 50 mm; The backing layer is a ceramic fiber blanket attached to the back working surface of the heat-insulating layer, and the thickness thereof ranges from 10 mm to 30 mm.

6. The preformed lining module of claim 1, wherein, The anchor member for connecting the fire-resistant layer, the heat-insulating layer and the backing layer is made of heat-resistant steel, and includes a "Y" type or "V" type anchoring section embedded in the fire-resistant layer, and a fastening section penetrating the heat-insulating layer and the backing layer and pressing the layers.

7. The preformed lining module of claim 1, wherein, When the module body is a furnace top module, an enhanced skeleton for enhancing hoisting strength is pre-embedded in the module body, the enhanced skeleton is welded from profile steel and is completely covered in the fire-resistant layer material, and a burner hole for installing a burner is reserved on the module body; When the module body is a furnace wall module, a downward extending load bearing base is integrally formed at the bottom of the module body, and the width of the load bearing base is greater than the thickness of the module body to provide stable bottom support; When the module body is a furnace door module, the module body is a special-shaped door frame module which is adapted to the shape of the furnace door part, the inner contour of the special-shaped door frame module is adapted to the shape and size of the furnace door, and the outer edge of the special-shaped door frame module and the edge of a furnace wall module adjacent thereto are connected through fitting and splicing of the tenon-mortise structure.

8. The preformed lining module of claim 1, wherein, The module body is provided with one or more functional holes, including a temperature measuring hole for penetrating a thermocouple, a pipeline hole for passing through a process pipeline, and an observation hole for maintenance.

9. A modular quick-fit lining system, characterized in that The modular quick-assembly furnace lining system comprises a furnace roof module for constituting a furnace roof, a furnace wall module for constituting a furnace wall, and a furnace door module for constituting a furnace door; the furnace roof module and the furnace wall module are mechanically spliced through a tenon and groove structure, the inner contour of the furnace door module is matched with the shape and size of the furnace door, the furnace door module and the furnace wall module are mechanically spliced through a tenon and groove structure, and the furnace roof module, the furnace wall module and the furnace door module are fixedly connected with the furnace shell of the heating furnace through the module anchoring system. The furnace lining installation method comprises the following steps:

10. A method of installing a furnace lining, characterised by, S1: demarcating the installation position of each prefabricated furnace lining module on the cleaned inner wall of the furnace shell at the site of the heating furnace; S2: using hoisting equipment to sequentially hoist the prefabricated furnace lining module to the designated position in the furnace shell; S3: aligning and splicing adjacent modules through the standardized interface structure at the edge of each prefabricated furnace lining module to form mechanical interlocking; S4: fixing and locking each prefabricated furnace lining module with the furnace shell through the module anchoring system embedded in the prefabricated furnace lining module; S5: filling refractory sealing material at the joint between any two adjacent prefabricated furnace lining modules to complete sealing. When local furnace lining needs to be repaired, the following steps are included:

11. The furnace lining installation method according to claim 10, characterized by, M1: removing the refractory sealing material at the joint of the prefabricated furnace lining module in the damaged area; M2: disconnecting the module anchoring system of the prefabricated furnace lining module in the damaged area from the furnace shell; M3: separating and removing the damaged prefabricated furnace lining module from the interface structure of the adjacent prefabricated furnace lining module; M4: hoisting a new prefabricated furnace lining module to the target replacement position, and repeating steps S3 to S5 to complete local replacement. ​

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