6S flat-layer masonry method for large coke oven body

Abstract

The present invention discloses a 6S flat-layer masonry method for a large coke oven body, comprising the following steps: constructing a three-dimensional control network for the body masonry, and building a refractory brick receiving platform on the coke side or the machine side; based on the three-dimensional control network and the refractory brick receiving platform, marking the masonry position of each layer of refractory bricks, arranging the refractory bricks required for each layer of masonry, laying the refractory bricks layer by layer according to the marking and arrangement, grouting the refractory bricks after masonry is completed layer by layer, cleaning the refractory bricks after grouting, and inspecting the cleaned refractory bricks layer by layer. Based on the three-dimensional control network and the refractory brick receiving platform, the present invention controls the quality of the coke oven body masonry from a holistic perspective in six dimensions, maximizing the quality and precision of large coke oven masonry, and effectively reducing the difficulty of masonry technology and the degree of dependence on highly skilled furnace builders, achieving high-precision and rapid masonry, making the coke oven body neat, clean, and unobstructed, and effectively extending the service life of the coke oven.

Description

Technical Field

[0001] The invention belongs to a large coke oven body masonry technology, and in particular relates to a large coke oven body 6S flat layer masonry method. Background Art

[0002] Coke ovens are the core equipment of coking plants. Large coke ovens generally refer to top-loading coke ovens taller than 7 meters and ramming coke ovens taller than 5.5 meters. They offer larger capacity, higher energy efficiency, and lower unit emissions. Large coke ovens can reduce pollutant emissions, lower production capital costs, improve production efficiency, reduce labor requirements, extend oven life, and enhance product quality. However, the complex structure and cumbersome construction of large coke ovens present new challenges for their construction technology.

[0003] The body of a large coke oven primarily consists of a furnace roof, carbonization and combustion chambers, inclined flues, and regenerators. Its complex structure directly impacts the performance of the coke oven after commissioning. A single large coke oven body utilizes over 10 types of refractory materials and over 1,000 different brick types, weighing approximately 30,000 tons. The masonry process is complex and the workload is enormous. Traditional coke oven body construction utilizes a staggered-layer construction method controlled by the burner head. This method prioritizes the construction of each burner head to control the accuracy of the coke oven wall. This makes masonry quality and efficiency highly dependent on highly skilled construction personnel. Furthermore, because each wall in the body is individually precision-controlled based on the burner head being constructed first, effective control of overall accuracy and quality is difficult. Furthermore, in this burner head-first construction method, refractory bricks are directly stacked on the newly constructed walls within the oven, leading to chaotic refractory material management on the construction site. This exposes the refractory materials and newly constructed walls to contamination from masonry slurry, making it difficult to ensure the cleanliness of the coke oven body. Summary of the Invention

[0004] The purpose of the present invention is to provide a 6S flat-layer masonry method for a large coke oven body, which solves the problems of great difficulty in masonry construction and difficulty in effectively controlling quality of traditional coke ovens.

[0005] The object of the present invention is achieved through the following technical solutions:

[0006] A 6S flat-layer masonry method for a large coke oven body comprises the following steps:

[0007] Step S1, carrying out acceptance inspection of the coke oven foundation platform;

[0008] Step S2: constructing a three-dimensional control network for the furnace body and building a refractory brick receiving platform on the coke side or the machine side;

[0009] Step S3: Marking the laying position of each layer of refractory bricks based on the three-dimensional control network;

[0010] Step S4: Arrange the refractory bricks required for each layer of masonry layer by layer based on the refractory brick receiving platform;

[0011] Step S5: Laying refractory bricks layer by layer according to marking and arrangement based on the three-dimensional control network;

[0012] Step S6, grouting the refractory bricks after the masonry is completed layer by layer;

[0013] Step S7, cleaning the refractory bricks layer by layer after the grouting is completed;

[0014] Step S8: Based on the three-dimensional control network, the refractory bricks after cleaning are inspected layer by layer.

[0015] Furthermore, in step S2, constructing the three-dimensional control network for the furnace body includes: step S2.1, staking out the baseline of the coke oven foundation platform; step S2.2, installing and fixing the furnace columns or vertical poles; step S2.3, installing the horizontal poles; step S2.4, laying out the masonry control lines;

[0016] The wall layer height line on the furnace column, the wall center line on the horizontal benchmark and the wall width line are used to form the height control line of each wall width of the entire furnace body and each layer of refractory bricks; the longitudinal center line of the coke oven and the longitudinal control edge lines of the coke oven on both sides of the machine coke are used to control the length of each wall in the furnace and form the control line of the entire wall length.

[0017] Furthermore, in step S2.1, the baseline of the coke oven foundation platform is laid out as follows: using the measurement control points of the coke oven foundation platform, the longitudinal center line of the coke oven, the longitudinal control edge line of the coke oven and the center line of the carbonization chamber at the end of the oven are laid out on the coke oven foundation platform that has passed the quality acceptance and the resistance walls at both ends.

[0018] Furthermore, in step S2.2, the furnace column or vertical pole is installed and fixed as follows:

[0019] When the coke oven construction process is to erect the furnace columns first and then build the furnace body, the furnace columns are installed first to build the three-dimensional control network. The furnace columns will be installed on the calves of the top plate side beams of the coke oven foundation platform. Before installation, the elevation of the calves is measured to ensure that its elevation is within the set range.

[0020] The center line of each combustion chamber of the coke oven is placed on the calf at the corresponding position through the control point, and is checked according to the baseline set out on the coke oven foundation platform to ensure the accuracy of the center line of each combustion chamber;

[0021] The furnace column is hoisted. After the furnace column is erected, the center should be adjusted so that the center of the furnace column coincides with the center of the combustion chamber placed on the calf, and the horizontal deviation value is within the set range;

[0022] After the center is adjusted, the furnace columns are temporarily fixed. At the top of the furnace columns, the entire row of furnace columns are connected and fixed using horizontal fixing rods.

[0023] Control the column spacing deviation and overall deviation of the furnace column within the set range;

[0024] By adjusting the adjusting pad between the bottom of the furnace column and the coke oven foundation platform and the adjusting inclined iron between the side of the furnace column and the coke oven foundation platform, the elevation, verticality and horizontal position of the furnace column can be fine-tuned;

[0025] After checking the position and verticality of the furnace column, the center lines of the combustion chambers on the calf are placed on the furnace column, and the height lines of the furnace wall are placed on the furnace column;

[0026] When the coke oven construction process is to build the furnace body first and then erect the furnace columns, first temporarily install vertical benchmarks to construct a three-dimensional control network. The height of the vertical benchmark is determined according to the coke oven masonry height. After adjusting the verticality and horizontal position of the vertical benchmark to meet the requirements, the center lines of each combustion chamber on the calf are laid out on the vertical benchmark, and the wall height lines of the furnace body are laid out on the vertical benchmark. The lower part of the vertical benchmark is fixed to the calf with anchor bolts or embedded parts.

[0027] Furthermore, in step S2.2, a lower horizontal brace is provided between the lower end of the furnace column and the coke oven foundation platform, an adjusting sleeve is sleeved on the lower horizontal brace, and an adjusting bolt for pressing the adjusting sleeve is connected to the lower horizontal brace, and the adjusting sleeve temporarily presses the furnace column and the coke oven foundation platform.

[0028] Furthermore, in step S2.3, the horizontal marker is installed as follows: the horizontal marker is horizontally arranged between two furnace columns on the side of the coke oven, and the horizontal marker is temporarily fixed to the furnace column using a temporary fixing fixture. After the temporary fixing fixture is loosened, the horizontal marker can be vertically moved along the furnace column. After the temporary fixing fixture is tightened, the horizontal marker is temporarily fixed to the furnace column.

[0029] When laying each layer of refractory bricks, adjust the horizontal benchmark to align with the elevation line on the furnace column of that layer, and mark out the center line and width line of the wall to be built on the horizontal benchmark to provide precision control for the laying of refractory bricks of that layer;

[0030] Furthermore, in step S2.4, the setting of the masonry control line is as follows: the center line and the width line of the heat storage chamber wall, the inclined flue wall, the carbonization chamber and the combustion chamber wall or the furnace top wall in the furnace body are drawn on the horizontal benchmark, and the center line and the width line of the wall are set according to the drawn lines during the masonry, so as to dynamically control the masonry accuracy in real time during the masonry process.

[0031] Furthermore, in step S2, building a refractory brick receiving platform on the coke side or the machine side includes: in order to realize the fixed-point and layer-by-layer arrangement of refractory bricks, a refractory brick receiving platform should be set up on the machine side or the coke side according to the receiving situation of the refractory bricks laid in the coke oven; fixed loading points are set up in the length direction of the coke oven according to the number of furnace holes, which serve as the designated positions for vertical transportation of the coke oven greenhouse crane; after the refractory bricks sent from the warehouse are transported to the site, they are transported to the refractory brick receiving platform, and after the previous process is completed, the inspected refractory bricks are placed one by one at the designated positions of the furnace wall in the furnace through the receiving scaffolding; at the same time, the refractory brick receiving platform should be set up synchronously with the increasing number of steps as the height of the wall masonry in the furnace increases.

[0032] Furthermore, step S3, based on the three-dimensional control network, marks the laying position of each layer of refractory bricks layer by layer: make a refractory brick laying-out ruler rod, and mark the size line of the refractory bricks of the furnace wall on the refractory brick laying-out ruler rod, and the refractory brick laying-out ruler rod needs to be marked for the walls of different parts of the furnace; after the previous layer of refractory bricks of the coke oven wall is completed, before the current layer of refractory bricks is laid, the refractory brick laying-out ruler rod is used to mark the position line of each refractory brick in this layer on both sides of the completed wall; for each layer of refractory bricks, the refractory brick laying-out ruler rod must be used to mark the laying position of each refractory brick in the furnace wall in advance, and it must be reviewed through the three-dimensional control network to achieve layer-by-layer marking.

[0033] Furthermore, in step S4, based on the refractory brick receiving platform, the refractory bricks required for each layer of masonry are arranged layer by layer: after each layer of refractory bricks of the coke oven is marked, the refractory bricks required for masonry of this layer are first transported to the refractory brick receiving platform in whole boxes for unpacking and inspection, and then the corresponding refractory bricks are transported horizontally according to the masonry drawings, and the refractory bricks are fixedly arranged in the marked positions of each layer of the wall, and the refractory bricks of the entire layer of the furnace body are fully arranged, so that the refractory bricks of the furnace body are arranged layer by layer.

[0034] Furthermore, in step S5, based on the three-dimensional control network, the refractory bricks are laid layer by layer according to the marking and arrangement: after all the refractory bricks of each layer of the coke oven are arranged, the furnace construction workers lay the refractory bricks of this layer of the furnace body as a whole, so that the coke oven body is laid in a flat layer as a whole, and the furnace body is laid layer by layer; during the laying process, the laying accuracy should be dynamically controlled in real time according to the constructed three-dimensional control network to ensure the laying accuracy and quality, and the laying operation should complete the laying of the entire layer of refractory bricks at the same time.

[0035] Furthermore, step S6, grouting the completed refractory bricks layer by layer is as follows: after each layer of refractory bricks of the coke oven is completed and before the mud solidifies, the furnace builder checks and adjusts the refractory brick wall of the layer. After passing the inspection, all the refractory brick joints of the layer are compacted and grouting is performed. The grouting chute is used to press the grouting mud into the refractory brick joints, and the grouting is applied evenly and densely to achieve grouting of each layer of the furnace body.

[0036] Furthermore, step S7, after the grouting is completed, the refractory bricks are cleaned layer by layer: after each layer of refractory bricks in the coke oven is completely laid and grouted, the furnace builders clean the wall surface and wall body of the laid layer of refractory bricks, so that the entire coke oven is clean, tidy and unobstructed, and the furnace body is cleaned layer by layer.

[0037] Furthermore, in step S8, based on the three-dimensional control network, the refractory bricks after cleaning are inspected layer by layer: after each layer of refractory bricks in the coke oven is cleaned, the refractory bricks are inspected according to the constructed three-dimensional control network, and the error should be controlled within the set range. By inspecting and controlling the quality of each layer of masonry, the overall masonry accuracy and quality of the coke oven are ensured, and the masonry of the furnace body is inspected layer by layer.

[0038] Beneficial effects of the present invention:

[0039] 1. The three-dimensional control network for leveling masonry, established using furnace columns (vertical benchmarks), horizontal benchmarks, baselines, and control wires, can fundamentally and effectively control the accuracy of refractory brick masonry within the furnace, achieving high-precision control of refractory brick masonry from the overall to the local level. This is reflected in the high-precision control of the "layer-by-layer marking," "layer-by-layer masonry," and "layer-by-layer acceptance" processes of 6S leveling masonry, providing the necessary guarantee for achieving 6S leveling masonry and solving the problem of precision control of leveling masonry in large coke ovens. The accuracy of furnace masonry can be reduced to within ±1mm, greatly reducing the rework rate and extending the service life of the coke oven. In addition, the three-dimensional control network realizes three-dimensional dynamic control of the 6S leveling masonry process of the furnace body and real-time deviation correction during the masonry process, raising the qualified rate of furnace refractory brick masonry to over 98%.

[0040] 2. The use of a refractory brick receiving platform fundamentally solves the problem of traditional staggered-layer masonry techniques, where refractory bricks are directly stacked on the newly constructed furnace body, resulting in a chaotic masonry environment, poor cleanliness, and even damage to the newly constructed walls. Furthermore, combined with the "layer-by-layer arrangement" of the 6S flat-layer masonry process, this allows for orderly and efficient coke oven body construction, effectively ensuring the industrialization, process-based, and standardized nature of coke oven body construction. Furnace body cleanliness is also greatly enhanced, and the refractory brick receiving platform allows refractory bricks to be arranged in designated locations, reducing the loss of refractory bricks during handling during traditional masonry techniques.

[0041] 3. The 6S flat-layer masonry process for large coke ovens innovatively utilizes an overall flat-layer construction method, breaking away from the traditional staggered-layer masonry method that relies on precision control of the furnace head. Traditional furnace masonry techniques suffer from inherent flaws such as the ability to control the precision of each furnace wall individually, low cleanliness, and slow efficiency. The 6S flat-layer masonry process fundamentally addresses the challenges of large masonry errors, low efficiency, and poor furnace cleanliness caused by traditional staggered-layer masonry methods. It achieves fast, clean, and flat construction of the entire coke oven body, reduces material loss, and shortens construction time.

[0042] 4. The "6S" furnace body flat masonry technology, featuring "layer-by-layer marking, layer-by-layer arrangement, layer-by-layer masonry, layer-by-layer jointing, layer-by-layer cleaning, and layer-by-layer inspection," ensures comprehensive and comprehensive control of the coke oven body masonry quality across six technical quality dimensions. This also industrializes, streamlines, and standardizes the coke oven body masonry method, significantly reducing the technical difficulty and the reliance on highly skilled labor. The coke oven body is constructed layer by layer from the bottom up, including the regenerator, inclined flue, carbonization chamber, combustion chamber, and furnace roof. This maximizes the accuracy, quality, efficiency, and cleanliness of the furnace body, effectively extending the coke oven's service life.

[0043] The aforementioned main solution of the present invention and its further options can be freely combined to form multiple solutions, all of which are solutions that can be adopted and protected by the present invention; and the (non-conflicting options) of the present invention can also be freely combined with each other and with other options. After understanding the solutions of the present invention, those skilled in the art will understand that there are many combinations based on existing technology and common knowledge, all of which are technical solutions to be protected by the present invention, and these are not exhaustive here. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 It is a schematic flow diagram of the present invention.

[0045] Figure 2 It is a schematic diagram of the arrangement of five horizontal and vertical reference lines of the present invention.

[0046] Figure 3 It is a schematic diagram of the position of the calf and the center line of the combustion chamber of the present invention.

[0047] Figure 4 It is a structural schematic diagram of the installation and fixation of the furnace column of the present invention.

[0048] Figure 5 It is a top view of the structure of a horizontal bar of a furnace column clamp of the present invention.

[0049] Figure 6 It is a top view of the structure of a horizontal bar of another furnace column clamp of the present invention.

[0050] Figure 7 It is a schematic diagram of the arrangement of the furnace columns, horizontal benchmarks and masonry control lines of the present invention.

[0051] Figure 8 It is a structural schematic diagram of the three-dimensional control network of the furnace body of the present invention.

[0052] Figure 9 It is a schematic diagram of the arrangement of the refractory brick receiving platform of the present invention.

[0053] Figure 10This is a structural front view of the refractory brick receiving platform of the assembled steel structure of the present invention.

[0054] In the figure: 1-coke oven foundation platform, 2-resistance wall, 3-coke oven longitudinal center line, 4-coke oven longitudinal control edge line, 5-furnace end carbonization chamber center line, 6-coke side edge line, 7-machine side edge line, 8-combustion chamber center line, 9-top plate side beam, 10-calf, 11-furnace column, 12-adjustment pad, 13-sliding layer, 14-anchor bolt, 15-adjustment inclined iron, 16-lower horizontal brace, 17-adjustment sleeve, 18-adjustment bolt, 1 9-horizontal benchmark, 20-pressed splint, 21-spring, 22-clamped bolt, 23-clamped nut, 24-buckled splint, 25-wall floor height line, 26-wall width line, 27-wall center line, 28-masonry control line, 29-furnace wall, 30-horizontal fixed rod, 31-coke oven body, 32-refractory brick receiving platform, 33-fixed loading point, 34-receiving scaffolding, 35-column, 36-flat rod, 37-cambered. DETAILED DESCRIPTION

[0055] The following non-limiting examples illustrate the present invention.

[0056] Example 1:

[0057] refer to Figures 1 to 10 As shown, a 6S flat-layer masonry method for a large coke oven body includes the following steps:

[0058] Step S1, carrying out acceptance inspection of the coke oven foundation platform;

[0059] Step S2: constructing a three-dimensional control network for the furnace body and building a refractory brick receiving platform on the coke side or the machine side;

[0060] Step S3: Marking the laying position of each layer of refractory bricks based on the three-dimensional control network;

[0061] Step S4: Arrange the refractory bricks required for each layer of masonry layer by layer based on the refractory brick receiving platform;

[0062] Step S5: Laying refractory bricks layer by layer according to marking and arrangement based on the three-dimensional control network;

[0063] Step S6, grouting the refractory bricks after the masonry is completed layer by layer;

[0064] Step S7, cleaning the refractory bricks layer by layer after the grouting is completed;

[0065] Step S8: Based on the three-dimensional control network, the refractory bricks after cleaning are inspected layer by layer.

[0066] The flat-layer masonry process of the coke oven body is based on a three-dimensional control network and a refractory brick receiving platform, and the "6S" process - "marking, arranging, laying, grouting, cleaning, and inspecting layer by layer" should be strictly implemented to ensure the accuracy and quality of each layer and achieve high-precision and rapid masonry.

[0067] The time interval for each layer of coke oven body construction should be ≥2 hours. The order of 6S flat layer construction of the coke oven body from bottom to top is: heat storage chamber, inclined flue, carbonization chamber and combustion chamber, and coke oven top according to the coke oven body structure.

[0068] In step S1, the acceptance of the coke oven foundation platform is as follows: the coke oven foundation platform 1 is constructed and the sliding plate is laid. Only after the acceptance is qualified can the 6S leveling masonry construction of the furnace body be carried out.

[0069] In step S2, constructing the three-dimensional control network for the furnace body includes: S2.1, staking out the baseline of the coke oven foundation platform 1; S2.2, installing and fixing the furnace columns 11 or vertical benchmarks; S2.3, installing the horizontal benchmarks 19; S2.4, laying out the masonry control lines 28.

[0070] refer to Figure 2 As shown in S2.1, the baseline layout of the coke oven foundation platform 1 is as follows: using the measurement control points of the coke oven foundation platform 1, the coke oven longitudinal center line 3, the coke oven longitudinal control edge line 4 and the center line 5 of the oven end carbonization chamber are laid out on the coke oven foundation platform 1 that has passed the quality acceptance and the resistance walls 2 at both ends.

[0071] refer to Figures 2 to 4 As shown in S2.2, the installation and fixation of the furnace column 11 or the vertical benchmark are as follows: According to the design process requirements, the coke oven furnace column can be divided into two categories: first erecting the furnace column and then building the furnace body; and first building the furnace body and then erecting the furnace column.

[0072] When the coke oven construction process involves erecting the furnace columns first and then building the furnace body, the furnace columns 11 are installed first to construct the three-dimensional control network. The furnace columns 11 will be installed on the calves 10 of the top plate side beams 9 of the coke oven foundation platform. Before installation, the elevation of the calves 10 should be measured to ensure that it is within the range of ±3mm. The elevation deviation value of ±1mm can be adjusted using steel plates of the same thickness as the deviation value (thin shims are not allowed).

[0073] The center lines 8 of each combustion chamber of the coke oven are placed on the calves 10 at the corresponding positions through the control points, and are checked according to the baseline laid out on the coke oven foundation platform 1 to ensure that the center lines 8 of each combustion chamber are positioned accurately.

[0074] The furnace column 11 is hoisted by a crane or a traveling crane. After the furnace column 11 is erected, the center should be adjusted so that the center of the furnace column coincides with the center of the combustion chamber placed on the calf 10, and the horizontal deviation value is within the range of ±3mm.

[0075] After centering, the oven column 11 is temporarily fixed. A lower cross brace 16 is positioned between the lower end of the oven column 11 and the coke oven foundation platform 1. An adjustment sleeve 17 is sleeved on the lower cross brace 16. An adjustment bolt 18, which presses the adjustment sleeve 17, is connected to the lower cross brace 16. The adjustment sleeve 17 temporarily presses the oven column 11 against the coke oven foundation platform 1. When the coke oven spring is to be installed, the adjustment sleeve on the lower cross brace is removed and replaced with the coke oven spring.

[0076] At the top of the furnace columns 11, 1 to 2 meters apart, bolt horizontal fixing rods 30 (28-inch channel steel) to secure the entire row of furnace columns 11. Both ends of the horizontal fixing rods extend to the supporting wall for securement. Depending on the actual site conditions, one or two additional horizontal fixing rods 30 (vertically spaced 1 to 3 meters apart) may be added to stabilize the furnace columns 11.

[0077] The column spacing deviation D is controlled within the range of ±3mm, and the overall deviation of every 5 consecutive columns should be less than ±3mm. The sliding layer 13 between the bottom of the column and the pad should be coated with yellow dry oil to facilitate sliding caused by the expansion of the furnace body.

[0078] To control the verticality of the furnace column and the distance between the furnace column and the center of the furnace, the lower cross brace is spring-loaded with an adjustable sleeve. The length of the adjustable sleeve is calculated based on actual conditions. Fine adjustments to the elevation, verticality, and horizontal position of the furnace column 11 are made by adjusting the adjusting pad 12 between the bottom of the furnace column 11 and the coke oven foundation platform 1, as well as the adjusting wedge 15 between the side of the furnace column 11 and the coke oven foundation platform 1. The gap δ between the lower part of the furnace column 11 and the calf shank 10 should be controlled within a range of 10-20 mm. Exposed threads inside and outside are protected with plastic sleeves.

[0079] After checking the position and verticality of the furnace columns, the center lines 8 of the combustion chambers on the calves 10 are set out on the furnace columns 11, and the wall height lines 25 of the furnace body are set out on the furnace columns 11.

[0080] When the coke oven construction process involves building the furnace body first and then erecting the furnace columns, temporary vertical rods are installed to construct a three-dimensional control network, replacing the furnace columns. The vertical rods are made of 120×60mm rectangular steel pipes. The height of the vertical rods is determined according to the height of the coke oven. After the verticality and horizontal position of the vertical rods are adjusted to meet the requirements, the center lines of each combustion chamber on the calf are set onto the vertical rods. The height lines of the furnace wall are also set onto the vertical rods. The lower portion of the vertical rods is fixed to the calf 10 with anchor bolts 14 or embedded parts. The upper portion uses a 100×50mm aluminum alloy rectangular pipe as a horizontal fixing rod 30.

[0081] refer to Figure 5 and Figure 6As shown in S2.3, the installation of the horizontal mark rod 19 is as follows: the horizontal mark rod 19 is made of 3000×100×25mm aluminum alloy rectangular tube, and the horizontal mark rod 19 is horizontally arranged between the two furnace columns 11 on the side of the coke oven (coke side or machine side). The horizontal mark rod 19 is temporarily fixed to the furnace column 11 by using a temporary fixing fixture. After loosening the temporary fixing fixture, the horizontal mark rod 19 can be vertically displaced along the furnace column 11. After tightening the temporary fixing fixture, the horizontal mark rod 19 is temporarily fixed to the furnace column 11.

[0082] As each layer of refractory bricks is laid, the horizontal bar 19 is adjusted to align with the wall height line 25 on the furnace column 11 of that layer. The wall center line 27 and wall width line 26 of the wall to be built are also set out on the horizontal bar 19 to provide precision control for the laying of the refractory bricks in that layer. The horizontal bar 19 moves upwards with each layer of bricks laid.

[0083] The temporary fixing fixture includes two structural forms, one includes a pressing clamp 20 that presses the furnace column 11 from both sides, and the other includes a buckling clamp 24 that is integrally buckled on the furnace column 11.

[0084] refer to Figure 5 As shown, the pressing plate 20 is a bent plate structure. One end of the pressing plate 20 is welded to the horizontal mark 19, and the other end of the pressing plate 20 is pressed onto the furnace column 11. A clamping bolt 22 is passed through the other end of the pressing plate 20 and the horizontal mark 19. A spring 21 is provided between the screw head of the clamping bolt 22 and the pressing plate 20. A clamping nut 23 is provided on the screw rod of the clamping bolt 22. By loosening or tightening the clamping nut 23, the elastic force of the spring 21 can be adjusted. The elastic force of the spring 21 acts on the pressing plate 20, and the pressing plates 20 on both sides press the furnace column 11, tightening or loosening the furnace column 11 and the horizontal mark 19.

[0085] refer to Figure 6 As shown, the clamping plate 24 is a plate-like structure with a U-shaped groove. The furnace column 11 is just buckled into the U-shaped groove. Clamping bolts 22 are passed through both ends of the clamping plate 24 and the horizontal mark 19. A spring 21 is provided between the screw head of the clamping bolt 22 and the pressing plate 20. The screw of the clamping bolt 22 is provided with a clamping nut 23. By loosening or tightening the clamping nut 23, the elastic force of the spring 21 can be adjusted. The elastic force of the spring 21 acts on the clamping plate 24, and the entire clamping plate 24 presses the furnace column 11, tightening or loosening the furnace column 11 and the horizontal mark 19.

[0086] The clamp's clamping plate is made of 5mm steel sheet. The spring-loaded clamp not only effectively secures the horizontal bar but also controls the clamping force through the spring's deformation. This prevents deformation of the horizontal bar caused by excessive clamping force or inconsistent clamping force at both ends, which can affect the accuracy of the three-dimensional control network. The use of the spring clamp effectively improves the control accuracy of the three-dimensional control network. A temporary clamp should be installed for every furnace column, ensuring that each horizontal bar has at least two fixing points to the furnace column.

[0087] refer to Figure 7 As shown, S2.4, the setting of the masonry control line 28 is as follows: the center line and the wall width line of the heat storage chamber wall, the inclined flue wall, the carbonization chamber and the combustion chamber wall or the furnace top wall in the furnace body are drawn on the horizontal mark rod 19, and the wall center line 27 and the wall width line 26 are drawn according to the drawn lines during the masonry process to dynamically control the masonry accuracy in real time during the masonry process.

[0088] refer to Figure 8 As shown, a three-dimensional control network for furnace masonry is constructed through S2.1 to S2.4:

[0089] The wall height line 25 on the furnace column 11, the wall center line 27 on the horizontal marker 19, and the wall width line 26 form the control lines for the width of each wall and the height of each layer of refractory bricks in the entire furnace. The longitudinal center line 3 of the coke oven and the longitudinal control lines 4 on both sides of the coke oven control the length of each wall in the furnace, forming the control line for the entire wall length (furnace width).

[0090] Based on the wall height lines 25 on the oven columns 11, the wall center lines 27 and width lines 26 on the horizontal markers 19, the coke oven longitudinal center line 3, and the coke oven longitudinal control edge lines 4, the length, width, and height of the wall masonry in each part of the coke oven body can be effectively controlled in three dimensions. Furthermore, because the three-dimensional control network is established based on the entire coke oven body, the spatial positional relationships between the walls within the three-dimensional control network are also fundamentally and effectively controlled, enabling real-time dynamic control of the masonry process.

[0091] The three-dimensional control network for coke oven body leveling must maintain a precision of ±0.5mm for each marking to ensure the quality of the final construction. The three-dimensional control network is an independent system, and its columns 11 and horizontal bars 19 must be securely fixed to ensure effective precision control.

[0092] In step S2, building a refractory brick receiving platform on the coke side or the machine side includes: in order to realize the fixed-point layered arrangement of refractory bricks, a refractory brick receiving platform 32 should be set up on the machine side or the coke side according to the receiving conditions of the refractory bricks laid in the coke oven to meet the construction requirements.

[0093] refer to Figure 9 and 10As shown, the receiving platform is constructed using a reusable, easily assembled and disassembled prefabricated steel structure. It is connected by columns 35, horizontal bars 36, and inclined braces 37. The platform's design load should be ≥1.5t / m². The platform structure should be ≥3m wide, with scaffolding laid on top. The height should be ≤2m per step. Fixed loading points 33 are located at 20-30 oven openings along the length of the coke oven, serving as designated locations for vertical transportation of the coke oven greenhouse crane.

[0094] After the refractory bricks are shipped from the warehouse to the site, they are hoisted to the refractory brick receiving platform 32 by a crane. After the previous process is completed, the inspected refractory bricks are placed one by one in the designated positions of the furnace wall through the receiving scaffolding 34. At the same time, the refractory brick receiving platform 32 should be built upwards in increasing steps as the height of the furnace wall increases.

[0095] The refractory brick receiving platform 32 on the machine or coke side can also be constructed using a steel pipe scaffolding platform with a step distance ≤ 1.8m, a platform structure width ≥ 3m, and meeting the load requirements.

[0096] Step S3, based on the three-dimensional control network, the masonry position of each layer of refractory bricks is marked layer by layer: a 50×50㎜ wooden square with a length of 1 / 2 of the length of the furnace wall (the width of the coke oven body) is used to make a refractory brick laying-out ruler rod, and the size line of the refractory bricks in the furnace wall (including the mortar joint size) is marked on the refractory brick laying-out ruler rod. For the walls of different parts of the furnace, the refractory brick laying-out ruler rod needs to be marked.

[0097] After the previous layer of refractory bricks is completed in the coke oven wall, before the current layer of refractory bricks is laid, the position of each refractory brick in this layer should be marked on both sides of the completed wall using a refractory brick marking rod. For each layer of refractory bricks laid, the position of each refractory brick in the furnace wall must be marked in advance using a refractory brick marking rod, and the marking is verified using a three-dimensional control network to ensure that the marking is accurate layer by layer.

[0098] Step S4, based on the refractory brick receiving platform, the refractory bricks required for each layer of masonry are arranged layer by layer as follows: after the refractory bricks of each layer of the coke oven are marked, the refractory bricks required for masonry of this layer are first transported in boxes to the refractory brick receiving platform 32, unpacked and inspected on the receiving platform, and then the corresponding refractory bricks are transported horizontally according to the masonry drawings, and the refractory bricks are fixedly arranged in the marked positions of each wall layer, and the refractory bricks of the entire layer of the furnace body are fully arranged, so that the refractory bricks of the furnace body are arranged layer by layer.

[0099] Step S5: Based on the 3D control network, refractory bricks are laid layer by layer according to the marking and arrangement. After each layer of refractory bricks is fully arranged, the furnace builders lay the refractory bricks of that layer as a whole, ensuring the coke oven body is laid flat and layer by layer. During the laying process, the 3D control network is used to dynamically control the laying accuracy in real time to ensure both accuracy and quality. During laying, the mortar fill rate between bricks should be ≥95%, and the entire layer of refractory bricks should be laid simultaneously.

[0100] Step S6, grouting the completed refractory bricks layer by layer: after each layer of refractory bricks of the coke oven is completed and before the mud solidifies, the furnace builder checks and adjusts the refractory brick wall of the layer. After passing the inspection, all the refractory brick joints of the layer are compacted and grouted. The grouting chute is used to press the grouting mud into the refractory brick joints, and the grouting is applied evenly and densely to achieve grouting of each layer of the furnace body.

[0101] Step S7, cleaning the refractory bricks layer by layer after grouting is completed: after each layer of refractory bricks in the coke oven is completely laid and grouted, the furnace builder cleans the wall surface and wall body of the laid layer of refractory bricks, so that the entire coke oven is clean, tidy and unobstructed, and the furnace body is cleaned layer by layer.

[0102] Step S8, based on the three-dimensional control network, the refractory bricks after cleaning are inspected layer by layer: after each layer of refractory bricks in the coke oven is cleaned, the refractory bricks are inspected according to the constructed three-dimensional control network, and the error should be controlled within the range of ±2mm. By inspecting and controlling the quality of each layer of masonry, the overall masonry accuracy and quality of the coke oven are ensured, and the masonry of the furnace body is inspected layer by layer.

[0103] The aforementioned basic examples and their further alternatives can be freely combined to form multiple embodiments, all of which are applicable and claimed embodiments of the present invention. In the scheme of the present invention, each alternative can be arbitrarily combined with any other basic examples and alternatives.

[0104] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A 6S flat-layer masonry method for a large coke oven body, characterized in that: The steps include: Step S1, carrying out acceptance inspection of the coke oven foundation platform; Step S2: constructing a three-dimensional control network for the furnace body and building a refractory brick receiving platform on the coke side or the machine side; Step S3: Marking the laying position of each layer of refractory bricks based on the three-dimensional control network; Step S4: Arrange the refractory bricks required for each layer of masonry layer by layer based on the refractory brick receiving platform; Step S5: Laying refractory bricks layer by layer according to marking and arrangement based on the three-dimensional control network; Step S6, grouting the refractory bricks after the masonry is completed layer by layer; Step S7, cleaning the refractory bricks layer by layer after the grouting is completed; Step S8: Based on the three-dimensional control network, the refractory bricks after cleaning are inspected layer by layer; In step S2, the construction of the three-dimensional control network for the furnace body includes: step S2.1, staking out the reference line of the coke oven foundation platform (1); step S2.2, installing and fixing the furnace column (11) or vertical benchmark; step S2.3, installing the horizontal benchmark (19); step S2.4, laying out the masonry control line (28); The wall layer height line (25) on the furnace column (11), the wall center line (27) on the horizontal mark (19) and the wall width line (26) form the width control line of each wall of the entire furnace body and the height control line of each layer of refractory bricks; the coke oven longitudinal center line (3) and the coke oven longitudinal control edge lines (4) on both sides of the machine coke are used to control the length of each wall in the furnace and form the control line of the entire wall length; Step S2.1, the baseline of the coke oven foundation platform (1) is laid out as follows: using the measurement control points of the coke oven foundation platform (1), the coke oven longitudinal center line (3), the coke oven longitudinal control edge line (4) and the center line (5) of the coke oven end carbonization chamber are laid out on the coke oven foundation platform (1) and the resistance walls (2) at both ends that have passed the quality inspection; Step S2.3, the installation of the horizontal mark rod (19) is as follows: the horizontal mark rod (19) is horizontally arranged between the two furnace columns (11) on the side of the coke oven, and the horizontal mark rod (19) and the furnace column (11) are temporarily fixed by using a temporary fixing fixture. After the temporary fixing fixture is loosened, the horizontal mark rod (19) can be vertically displaced along the furnace column (11). After the temporary fixing fixture is tightened, the horizontal mark rod (19) and the furnace column (11) are temporarily fixed. When laying each layer of refractory bricks, adjust the horizontal bar (19) to align with the elevation line on the furnace column (11) of that layer, and mark out the center line (27) and the wall width line (26) of the wall to be built on the horizontal bar (19) to provide precision control for the laying of the refractory bricks of that layer; Step S2.4, the setting of the masonry control line (28) is as follows: the center line and the wall width line of the heat storage chamber wall, the inclined flue wall, the carbonization chamber and the combustion chamber wall or the furnace top wall in the furnace body are drawn on the horizontal mark bar (19), and the wall center line (27) and the wall width line (26) are set according to the drawn lines during the masonry process, so as to dynamically control the masonry accuracy in real time during the masonry process.

2. The 6S flat-layer masonry method for a large coke oven body according to claim 1, characterized in that: Step S2.2, installation and fixing of furnace column (11) or vertical pole is as follows: When the coke oven construction process is to first erect the furnace column and then build the furnace body, the furnace column (11) is first installed to construct a three-dimensional control network. The furnace column (11) will be installed on the calf (10) of the top plate side beam (9) of the coke oven foundation platform. Before installation, the elevation of the calf (10) is measured to ensure that its elevation is within the set range; The center line (8) of each combustion chamber of the coke oven is placed on the calf (10) at the corresponding position through the control point, and is checked according to the baseline laid out on the coke oven foundation platform (1) to ensure that the position of the center line (8) of each combustion chamber is accurate; The furnace column (11) is hoisted. After the furnace column (11) is erected, the center should be adjusted so that the center of the furnace column coincides with the center of the combustion chamber placed on the calf (10), and the horizontal deviation value is within the set range; After the center is adjusted, the furnace column (11) is temporarily fixed, and the entire row of furnace columns (11) is connected and fixed using a horizontal fixing rod (30) at the top position of the furnace column (11); Controlling the column spacing deviation and the overall deviation of the column (11) to be within a set range; By adjusting the adjusting pad (12) between the bottom of the furnace column (11) and the coke oven base platform (1) and the adjusting inclined iron (15) between the side of the furnace column (11) and the coke oven base platform (1), the elevation, verticality and horizontal position of the furnace column (11) are finely adjusted; After checking the position and verticality of the furnace column, the center lines (8) of the combustion chambers on the calf (10) are placed on the furnace column (11), and the wall height lines (25) of the furnace body are placed on the furnace column (11); When the coke oven construction process is to first build the furnace body and then erect the furnace columns, first temporarily install vertical benchmarks to construct a three-dimensional control network. The height of the vertical benchmark is determined according to the coke oven masonry height. After the verticality and horizontal position of the vertical benchmark are adjusted to meet the requirements, the center lines of the combustion chambers on the calf (10) are placed on the vertical benchmark, and the wall height lines of the furnace body are placed on the vertical benchmark. The lower part of the vertical benchmark is fixed to the calf (10) by anchor bolts (14) or embedded parts.

3. The 6S flat-layer masonry method for a large coke oven body according to claim 2, characterized in that: In step S2.2, a lower cross brace (16) is provided between the lower end of the furnace column (11) and the coke oven base platform (1), an adjusting sleeve (17) is sleeved on the lower cross brace (16), and an adjusting bolt (18) for pressing the adjusting sleeve (17) is connected to the lower cross brace (16), and the adjusting sleeve (17) temporarily presses the furnace column (11) and the coke oven base platform (1).

4. The 6S flat-layer masonry method for a large coke oven body according to claim 1, characterized in that: In step S2, the construction of the refractory brick receiving platform on the coke side or the machine side includes: in order to realize the fixed-point layered arrangement of refractory bricks, a refractory brick receiving platform (32) should be set up on the machine side or the coke side according to the receiving situation of the refractory bricks in the coke oven; a fixed loading point (33) is set in the length direction of the coke oven according to the number of furnace holes, which serves as the designated position for the vertical transportation of the coke oven shed crane; after the refractory bricks sent from the warehouse are transported to the site, they are transported to the refractory brick receiving platform (32), and after the previous process is completed, the refractory bricks that have been inspected are arranged one by one at the designated position of the furnace wall in the furnace through the receiving scaffolding (34); at the same time, the refractory brick receiving platform (32) should be built upward with increasing steps as the height of the wall in the furnace increases.

5. The 6S leveling masonry method for a large coke oven body according to claim 1 is characterized in that: Step S3, based on the three-dimensional control network, the laying position of each layer of refractory bricks is marked layer by layer as follows: a refractory brick laying-out ruler rod is made, and the size line of the refractory bricks of the furnace wall is marked on the refractory brick laying-out ruler rod. For the walls of different parts of the furnace, the refractory brick laying-out ruler rod needs to be marked with lines; after the previous layer of refractory bricks of the coke oven wall is completed, before the current layer of refractory bricks is laid, the refractory brick laying-out ruler rod is used to mark the position line of each refractory brick in this layer on both sides of the completed wall; for each layer of refractory bricks, the refractory brick laying-out ruler rod must be used to mark the laying position of each refractory brick in the furnace wall in advance, and the 3D control network is used to review it to achieve layer-by-layer marking.

6. The method for laying 6S flat layers of a large coke oven body according to claim 1, characterized in that: Step S4, based on the refractory brick receiving platform, the refractory bricks required for each layer of masonry are arranged layer by layer as follows: after the refractory bricks of each layer of the coke oven are marked, the refractory bricks required for masonry of this layer are first transported in boxes to the refractory brick receiving platform (32), unpacked and inspected, and then the corresponding refractory bricks are transported horizontally according to the masonry drawings, and the refractory bricks are fixedly arranged in the marked positions of each layer of the wall, and the refractory bricks of the entire layer of the furnace body are fully arranged, so that the refractory bricks of the furnace body are arranged layer by layer; Step S5: Based on the three-dimensional control network, refractory bricks are laid layer by layer according to the marking and arrangement. After all the refractory bricks of each layer of the coke oven are arranged, the furnace builders lay the refractory bricks of this layer as a whole, so that the coke oven body is laid in a flat layer, and the furnace body is laid layer by layer. During the laying process, the laying accuracy should be dynamically controlled in real time based on the constructed three-dimensional control network to ensure the laying accuracy and quality. The laying operation should complete the laying of the entire layer of refractory bricks at the same time. Step S6, grouting the refractory bricks after the masonry is completed layer by layer: after the masonry of each layer of refractory bricks is completed and before the slurry solidifies, the furnace builder inspects and adjusts the refractory brick wall of the layer. If it is qualified, the grouting slurry is compacted and grouted on all the refractory bricks of the layer. The grouting slurry is pressed into the refractory brick joints using a grouting chute, and the grouting is applied evenly and densely to achieve the grouting of the furnace body layer by layer; Step S7, cleaning the refractory bricks layer by layer after the grouting is completed: after all the refractory bricks of each layer of the coke oven are laid and grouting is completed, the furnace builder cleans the wall surface and wall body of the refractory bricks of the layer, so that the entire coke oven is cleaned, tidy and unobstructed, and the furnace body is cleaned layer by layer; Step S8, based on the three-dimensional control network, the refractory bricks after cleaning are inspected layer by layer: after each layer of refractory bricks in the coke oven is cleaned, the refractory bricks are inspected according to the constructed three-dimensional control network. The error should be controlled within the set range. By inspecting and controlling the quality of each layer of masonry, the overall masonry accuracy and quality of the coke oven are ensured, and the masonry of the furnace body is inspected layer by layer.

Images