A semi-flameproof high-efficiency energy-saving roller kiln

Abstract

This invention discloses a semi-insulated, high-efficiency, energy-saving roller kiln, comprising a roller kiln body with a kiln cavity and multiple transport rollers arranged front-to-back within the kiln cavity. The roller kiln body includes a flue gas zone, a preheating zone, and a firing zone arranged sequentially from front to back. In the preheating zone, first burners are provided on both the upper and lower sides of the transport rollers, located within the kiln cavity of the preheating zone. In the firing zone, flame-insulating plate assemblies and second burners are provided on both the upper and lower sides of the transport rollers, located within the kiln cavity of the firing zone. The surface of the flame-insulating plate assembly facing away from the transport rollers, together with the wall of the kiln cavity, defines a fire channel. The front end of the fire channel has an open structure and sequentially connects to the kiln cavity of the firing zone and the kiln cavity of the flue gas zone. The second burners are located on the side of the flame-insulating plate away from the transport rollers. This invention simultaneously utilizes the advantages of high heating efficiency with open flame and the absence of waste gas contact with the product in flame-insulated kilns, effectively solving the problems of low heating efficiency and large temperature differences in electric kilns and fully flame-insulated gas kilns.

Description

Technical Field

[0001] This invention relates to the field of kiln technology, and in particular to a semi-insulated, high-efficiency, energy-saving roller kiln. Background Technology

[0002] Everyday ceramics such as plates, dishes, bowls, teacups, teapots, and vases typically undergo decorative processes during production. These include adding pigments directly to the glaze to create a uniform color throughout, or applying decals and gilding to fired white porcelain. After firing at different temperatures, the colorants develop vibrant colors, enhancing the aesthetics of the ceramics. The colorants in these pigments are primarily metal ions. When fired using fuels such as natural gas, the sulfides in the combustion exhaust at high temperatures react chemically with the colorants, causing discoloration and crystallization. Incomplete combustion can also lead to the reduction of metal ions by CO and C, resulting in darker or lighter colors that fail to meet the user's desired hue. This increases the defect rate and undoubtedly raises the operating costs for ceramic manufacturers.

[0003] The industry generally uses electric kilns or gas kilns with flame-insulated combustion to avoid color defects in daily-use porcelain. However, electric kilns and fully flame-insulated gas kilns mainly rely on radiant heat transfer, which has a relatively low heating efficiency. The temperature is high in the area of ​​the product close to the heating wire (rod) or flame-insulating plate, while the temperature is low in the area farther away from the heating wire (rod) or flame-insulating plate. Excessive temperature difference can cause abnormalities such as color difference. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention aims to provide a semi-flame-proof, high-efficiency, energy-saving roller kiln. Based on the characteristic that colorants require specific high temperatures to undergo chemical reactions, the kiln directly heats the colorant with fuel gas while it remains in a stable valence state (e.g., chromium has +6, +3, and +2 valences, iron has +3 and +2 valences, etc.). Convection stirring improves heat transfer efficiency and reduces temperature differences. Flame-proof heating is employed in the firing zone, and heat preservation further minimizes internal temperature differences, while simultaneously preventing the impact of combustion exhaust gases on the coloring. This invention leverages the advantages of high open-flame heating efficiency and the absence of exhaust gases contacting the product in a flame-proof environment, comprehensively solving the aforementioned problems with a semi-flame-proof, high-efficiency, energy-saving roller kiln.

[0005] The technical solution adopted to solve the above-mentioned technical problems is as follows:

[0006] This invention provides a semi-flame-proof, high-efficiency, energy-saving roller kiln, comprising a roller kiln body having a kiln cavity and multiple transport rollers arranged front-to-back within the kiln cavity. The roller kiln body includes a flue gas exhaust zone, a preheating zone, and a firing zone arranged sequentially from front to back. Within the preheating zone, a first burner is provided on both the upper and lower sides of each transport roller, located within the kiln cavity of the preheating zone. Within the firing zone, a flame-shielding plate assembly and a second burner are provided on both the upper and lower sides of each transport roller, both located within the kiln cavity of the firing zone. The surface of the flame-shielding plate assembly facing away from the transport roller, together with the wall of the kiln cavity, defines a fire channel. The front end of the fire channel is an open structure, and the fire channel sequentially connects the kiln cavity of the firing zone and the kiln cavity of the flue gas exhaust zone. The second burner is located on the side of the flame-shielding plate away from the transport roller.

[0007] The present invention has at least the following beneficial effects: A first burner is installed in the preheating zone, allowing the flue gas generated by the combustion of gas to directly contact the daily-use ceramics. The preheating zone primarily utilizes convective heat transfer, supplemented by radiative and conductive heat transfer, to preheat the daily-use ceramics, thereby enhancing the heat exchange effect, improving heating efficiency, and saving energy. A flame baffle assembly and a second burner are installed in the firing zone. When the second burner is operating, the flame baffle assembly blocks the flue gas generated by the combustion of gas, preventing the colorant in the daily-use ceramics from being absorbed into the flame. At high temperatures, the gas reacts chemically with components in the flue gas and becomes darker. The heat from the flue gas is radiated to the daily-use ceramics through the flame baffle assembly to complete the high-temperature firing process of the daily-use ceramics. Since the fire channel in the firing zone is connected to the kiln cavity in the firing zone and the kiln cavity in the exhaust zone in sequence, under the forced exhaust effect of the exhaust zone, the high-temperature flue gas in the fire channel can flow to the preheating zone and the exhaust zone, and mix and stir with the flue gas in the preheating zone and the exhaust zone respectively. This can reduce the temperature difference in the kiln cavity, maximize the utilization of heat, and achieve the purpose of energy saving.

[0008] As a further improvement to the above technical solution, within the firing zone, support members are also provided on the upper and lower sides of the transport roller. Multiple flame deflector assemblies are provided and arranged along the front and back. Two adjacent flame deflector assemblies are overlapped vertically. The support members are located below the flame deflector assemblies and are connected to the flame deflector assemblies. The flame deflector assembly includes a flame deflector plate, the flame deflector plate has a stepped portion, and multiple flame deflector plates are provided and arranged along the left and right sides. Two adjacent flame deflector plates are spliced ​​together through the stepped portion.

[0009] Due to the long length of the firing zone, the temperature distribution varies with its length. Therefore, multiple baffle plate assemblies are arranged along the front-to-back direction of the firing zone and connected by overlapping joints. Supported by structural members, these assemblies prevent flue gas from leaking through the gaps between adjacent baffle plate assemblies and coming into contact with the ceramics. Furthermore, during the switching between operation and shutdown of the roller kiln, the baffle plate assemblies undergo high-temperature expansion and cooling contraction. Because each baffle plate assembly deforms minimally and does not affect or accumulate deformation, they are less prone to significant deformation or damage, thus extending their service life. Adjacent baffle plates are joined by stepped sections to form a flat baffle plate assembly. The temperature difference across the cross-section of the baffle plate in the firing zone causes minimal deformation. This stepped joint method ensures that the deformation of each baffle plate is independent, preventing severe unevenness or deformation of the assembly.

[0010] As a further improvement to the above technical solution, a first sealing element is provided between two adjacent flame baffle assemblies, and a second sealing element is provided between the stepped portions of two adjacent flame baffles. This arrangement enhances the sealing effect between the two flame baffle assemblies and between the two flame baffles, preventing the flue gas generated during combustion from leaking through the gap between the two flame baffle assemblies or between the two flame baffles and coming into contact with the daily-use ceramics on the conveyor roller.

[0011] As a further improvement to the above technical solution, both the first and second sealing elements are ceramic paper. Ceramic paper has good heat resistance and sealing properties. Therefore, ceramic paper can enhance the sealing effect between two adjacent flame baffle assemblies, withstand the high-temperature environment of the firing zone, and when the flame baffle assembly is displaced due to deformation, the ceramic paper can withstand the force from the flame baffle assembly due to its good wear resistance and flexibility.

[0012] As a further improvement to the above technical solution, an upper fire channel is defined between the flame baffle assembly located on the upper side of the conveyor roller and the upper wall of the kiln cavity, and a lower fire channel is defined between the flame baffle assembly located on the lower side of the conveyor roller and the lower wall of the kiln cavity. Both the upper and lower fire channels have a front opening and a rear opening. The front opening is connected to the kiln cavity of the preheating zone, and the rear opening is provided with a sealing brick structure.

[0013] With this configuration, when the second burner is working, the sealing brick structure can play a good sealing role, preventing the flue gas in the firing zone from flowing into the quenching zone and affecting the cooling effect of the quenching zone. Moreover, the flue gas in the upper and lower combustion ducts flows to the preheating zone through the front opening, mixes and stirs with the flue gas in the preheating zone, and flows to the exhaust zone, so that the heat of the flue gas in the firing zone can be recovered and utilized.

[0014] As a further improvement to the above technical solution, both the inlet and outlet of the firing zone are equipped with liftable baffles, which are located above the conveyor rollers. A fire-resistant wall is provided at the front opening, and both the upper and lower fire channels are connected to the kiln cavity of the preheating zone. The fire-resistant wall and liftable baffles reduce the size of the front openings of the upper and lower fire channels, thereby reducing the amount of gas entering the upper and lower fire channels and the product channel.

[0015] As a further improvement to the above technical solution, a product channel is defined between the flame baffle assemblies located on the upper and lower sides of the conveyor roller. The height of the product channel is smaller than the height of the kiln cavity in the preheating zone. This arrangement reduces the space of the product channel, shortens the distance between the flame baffles and the daily-use ceramics, enhances the heat transfer effect, and reduces the heat dissipation area of ​​the product channel, thereby improving heat utilization and achieving energy saving.

[0016] As a further improvement to the above technical solution, the outlet of the preheating zone is equipped with an oxidation air curtain, and the roller kiln body also includes a quenching zone located behind the firing zone, with a quenching air curtain at its inlet. The oxidation air curtain prevents flue gas from flowing from the preheating zone into the firing zone and affecting its operation; the quenching air curtain prevents air from flowing from the quenching zone into the firing zone, thus preventing drastic temperature fluctuations in the firing zone.

[0017] As a further improvement to the above technical solution, the structure of the oxidation air curtain is consistent with that of the quench air curtain, both including a top pipe and side pipes. The top pipe extends horizontally and is located above the side pipes. The top pipe has multiple downward-facing air holes arranged horizontally. The side pipes are located on the left and right sides of the roller kiln body, extending horizontally and into the kiln cavity. Multiple side pipes are arranged vertically, with the ends of the side pipes near the kiln cavity having an open structure that communicates with the kiln cavity. This arrangement ensures that both the oxidation air curtain and the quench air curtain have excellent sealing properties, preventing gases from the preheating and quenching zones from flowing into the firing zone.

[0018] As a further improvement to the above technical solution, the quench zone is equipped with cooling pipes and air blowing pipes. The cooling pipes extend laterally and are located within the kiln cavity, above the air blowing pipes. Air blowing pipes are located on both the left and right sides of the quench zone, extending laterally and into the kiln cavity. An air outlet is located at the end of the air blowing pipe near the kiln cavity, and the air outlet communicates with the kiln cavity. This arrangement enables the quench zone to employ a combination of indirect and direct cooling, achieving rapid cooling while reducing the air volume required for direct cooling, thus achieving energy savings. Attached Figure Description

[0019] The present invention will be further described below with reference to the accompanying drawings and embodiments;

[0020] Figure 1 This is a schematic diagram of the semi-flameproof, high-efficiency, energy-saving roller kiln provided in the embodiment of the present invention on the XZ plane;

[0021] Figure 2 This is a schematic diagram of the flame baffle assembly of the firing zone provided in an embodiment of the present invention on the XZ plane;

[0022] Figure 3 This is a schematic diagram of the flame baffle assembly of the firing zone provided in an embodiment of the present invention on the YZ plane;

[0023] Figure 4 This is a schematic diagram of the structure of the fire baffle in the firing zone provided in an embodiment of the present invention on the YZ plane;

[0024] Figure 5 This is a schematic diagram of the structure of the oxidation air curtain provided in the embodiment of the present invention on the YZ plane;

[0025] Figure 6 This is a schematic diagram of the structure of the rapid cooling air curtain provided in the embodiment of the present invention on the YZ plane;

[0026] Figure 7 This is a schematic diagram of the cooling pipe structure of the rapid cooling zone provided in this embodiment of the invention on the YZ plane;

[0027] Figure 8 This is a schematic diagram of the structure of the air duct of the rapid cooling zone provided in the embodiment of the present invention on the YZ plane.

[0028] The following markings are used in the attached diagram: 110, Exhaust Zone; 120, Preheating Zone; 130, Firing Zone; 140, Quenching Zone; 150, Conveying Roller; 160, Kiln Cavity; 200, Fire Baffle Plate; 300, Flame Isolation Plate Assembly; 301, Upper Fire Channel; 302, Lower Fire Channel; 310, Square Beam; 320, Support Column; 410, Firewall; 420, Sealing Brick Structure; 500, Second Burner; 510, Burner Assembly Gas Pipe; 5 20. Burner assembly air supply duct; 610. Oxidation air curtain; 611. First top duct; 612. First side duct; 613. First air supply duct; 620. Quenching air curtain; 621. Second top duct; 622. Second side duct; 623. Second air supply duct; 700. Daily-use ceramics; 811. Cold air box; 812. Hot air box; 813. Cooling pipe; 821. Blowing duct; 822. Air supply duct. Detailed Implementation

[0029] This section will describe in detail specific embodiments of the present invention. Preferred embodiments of the present invention are shown in the accompanying drawings. The purpose of the drawings is to supplement the textual description with graphics, so that people can intuitively and vividly understand each technical feature and overall technical solution of the present invention, but they should not be construed as limiting the scope of protection of the present invention.

[0030] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0031] In the description of this invention, the use of terms such as "a number" means one or more, with "more than" meaning two or more. Terms like "greater than," "less than," and "exceeding" are understood to exclude the stated number, while terms like "above," "below," and "within" are understood to include the stated number. The use of terms like "first," "second," and "third" is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, the number of indicated technical features, or the sequential relationship between indicated technical features.

[0032] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0033] Reference Figures 1 to 8 The following are several embodiments of the semi-flameproof, high-efficiency, energy-saving roller kiln of the present invention.

[0034] like Figures 1 to 8 As shown, Embodiment 1 of the present invention provides a semi-flame-proof, high-efficiency, energy-saving roller kiln, which is used for the firing of daily-use ceramics 700, especially for the high-temperature baking of daily-use ceramics 700. This high-efficiency, energy-saving roller kiln employs a preheating zone 120 for open-flame firing and a firing zone 130 for flame-proof firing, avoiding the influence of combustion exhaust gases from the firing zone 130 on the colorants of the daily-use ceramics 700. Furthermore, it effectively overcomes the problem of easy deformation and damage to the flame-proof plates, extending their service life.

[0035] This high-efficiency and energy-saving roller kiln includes a roller kiln body, which has a kiln cavity 160 and conveying rollers 150. The kiln cavity 160 extends from front to back, with both its front and rear ends being open structures. The front end of the roller kiln body is the kiln head, and the rear end is the kiln tail. The conveying rollers 150 are used for transporting daily-use ceramics 700. Multiple conveying rollers 150 are located within the kiln cavity 160 and are arranged at intervals along the front-to-back direction of the roller kiln body. Driven by a transmission motor, all the conveying rollers 150 operate, transporting the daily-use ceramics 700 from the kiln head to the kiln tail.

[0036] From a process perspective, the structure of the roller kiln body includes, in sequence from front to back, an exhaust zone 110, a preheating zone 120, a firing zone 130, a quench zone 140, a slow cooling zone, and a tail cooling zone. In this embodiment, since no improvements are proposed to the exhaust zone 110, the slow cooling zone, and the tail cooling zone, the following description mainly focuses on the preheating zone 120, the firing zone 130, and the quench zone 140.

[0037] Within the preheating zone 120, first burners are installed on both the upper and lower sides of the conveyor roller 150. These first burners are mounted on the kiln wall of the preheating zone 120 and are located within the kiln cavity 160 of the preheating zone 120. It is understood that multiple first burners and burner control groups are arranged along the front-to-back direction of the preheating zone 120. Each burner control group includes an independent air supply pipe, a gas supply pipe, and an electric valve, capable of automatically adjusting the air and gas volume, which are supplied to the first burners via branch pipes with valves. When the first burners are activated, the combustion gas is fully combusted under the action of the combustion-supporting air. The high-temperature flue gas generated by the combustion flows towards the kiln head (i.e., the forward direction) under the suction force of the exhaust fan at the exhaust zone 110, directly contacting the daily-use ceramics 700 and achieving heat exchange.

[0038] The preheating zone 120 uses convection as the main heat transfer method and radiation and conduction as auxiliary heat transfer methods to preheat the daily-use ceramics 700. Compared with the flame isolation method, it can enhance the heat exchange effect of the preheating zone 120 on the daily-use ceramics 700, improve heating efficiency, and save energy.

[0039] A liftable baffle plate 200 can be installed between the preheating zone 120 and the smoke exhaust zone 110 to control the flow rate of flue gas from the preheating zone 120 to the smoke exhaust zone 110.

[0040] Within the firing zone 130, a flame baffle assembly 300, a support member, and a second burner 500 are provided on both the upper and lower sides of the conveyor roller 150. The flame baffle assembly 300, the second burner 500, and the support member are all located within the kiln cavity 160 of the firing zone 130. The surface of the flame baffle assembly 300 facing away from the conveyor roller 150 and the wall of the kiln cavity 160 together define a fire channel. The front end of the fire channel is an open structure, and the rear end of the fire channel is a closed structure. The fire channel connects sequentially to the kiln cavity 160 of the firing zone 130 and the kiln cavity 160 of the exhaust zone 110.

[0041] Specifically, an upper fire channel 301 is formed between the flame baffle assembly 300 located on the upper side of the conveyor roller 150 and the upper wall surface of the kiln cavity 160 (i.e., the kiln top insulation layer). A lower fire channel 302 is formed between the flame baffle assembly 300 located on the lower side of the conveyor roller 150 and the lower wall surface of the kiln cavity 160 (i.e., the kiln bottom insulation layer).

[0042] Furthermore, the flame deflector assemblies 300 located on the upper and lower sides of the conveyor roller 150 define a product channel in the firing zone 130. That is, the product channel is located between the upper firing channel 301 and the lower firing channel 302. Specifically, the upper flame deflector assembly 300 and the lower flame deflector assembly 300 together define the product channel, at which time the conveyor roller 150 and the daily-use ceramic 700 are located within the product channel.

[0043] It is understandable that a flame baffle assembly 300 and a second burner 500 are installed in the firing zone 130. The upper and lower walls of the kiln cavity 160 and the corresponding flame baffle assembly 300 form the upper fire channel 301 and the lower fire channel 302, respectively. When the second burner 500 is working, the flame baffle assembly 300 blocks the flue gas generated by the combustion of the gas, preventing the colorant of the daily-use ceramics 700 from reacting chemically with the components in the flue gas at high temperatures and becoming dull. The flame baffle assembly 300 radiates the heat of the flue gas to the daily-use ceramics 700 to complete the high-temperature firing process of the daily-use ceramics 700. The flue gas in the upper fire channel 301 and the lower fire channel 302 flows to the preheating zone 120 and the exhaust zone 110 under the suction of the exhaust fan in the exhaust zone 110, and mixes and stirs with the flue gas in these zones. This reduces the temperature difference and maximizes the utilization of heat, achieving the goal of energy saving.

[0044] In some embodiments, the flame baffle assembly 300 is composed of multiple plates continuously combined together, and its length is consistent with the length of the firing zone 130.

[0045] In other embodiments, there are multiple flame deflector assemblies 300, which are arranged along the front-back direction of the firing zone 130, and adjacent flame deflector assemblies 300 overlap vertically. Figure 1 and Figure 2As shown, in two adjacent flame deflector assemblies 300, the front flame deflector assembly 300 is positioned above the rear flame deflector assembly 300. It is understood that the height of the odd-numbered flame deflector assemblies 300 can be higher or lower than the height of the even-numbered flame deflector assemblies 300. All odd-numbered flame deflector assemblies 300 are on the same horizontal plane, and all even-numbered flame deflector assemblies 300 are on the same horizontal plane. Multiple flame deflector assemblies 300 are connected front to back to form a long flame deflector plate, the length of which is adapted to the length of the firing zone 130.

[0046] The main function of the support members is to support the flame deflector assembly 300. There are multiple support members, which are located below the flame deflector assembly 300 and can be connected and fixed to the flame deflector assembly 300. Each flame deflector assembly 300 is equipped with two or more support members, so that the flame deflector assembly 300 can be in a stable suspended state.

[0047] Specifically, for the flame deflector assembly 300 on the upper side of the conveyor roller 150, the support member is a square beam 310. Both ends of the square beam 310 extend along the left-right direction of the firing zone 130, and the square beam 310 can be a hollow structure. Both ends of the square beam 310 are mounted on the kiln wall of the firing zone 130. The upper surface of the square beam 310 contacts the lower surface of the flame deflector assembly 300 to provide strong support.

[0048] For the flame baffle assembly 300 under the conveyor roller 150, the support is a column 320. The lower surface of the column 320 is in contact with the inner bottom wall of the kiln cavity 160, and the upper surface of the column 320 is in contact with the lower surface of the flame baffle assembly 300, so that the flame baffle assembly 300 is in a stable state.

[0049] Each flame deflector assembly 300 includes a flame deflector plate, which has a stepped portion that is integrally formed with the flame deflector plate. There are multiple flame deflector plates arranged along the left-right direction of the firing zone 130, with adjacent flame deflector plates joined together by the stepped portion.

[0050] The following description uses one of the flame baffle assembly 300 as an example. This flame baffle assembly 300 includes three flame baffles, each with a stepped portion at its left and right ends, located at the bottom of the flame baffle. One end of the leftmost flame baffle is connected and fixed to the left wall of the firing zone 130, and one end of the rightmost flame baffle is connected and fixed to the right wall of the firing zone 130. The stepped portions are located at their bottoms. The middle flame baffle is rotated 180° and then fitted between the left and right flame baffles.

[0051] It is understandable that, due to the large length of the firing zone 130, the temperature distribution of the firing zone 130 varies with the length of the firing zone 130. Therefore, multiple flame baffle assemblies 300 are arranged along the front and back direction of the firing zone 130 and connected by overlapping at the top and bottom, and supported by the support components. Refractory ceramic paper is provided at the overlapping points to prevent flue gas from leaking through the gap between two adjacent flame baffle assemblies 300 and coming into contact with the daily ceramics 700. Moreover, during the switching between operation, heating, cooling and shutdown of the roller kiln, the flame baffle assemblies 300 will undergo high-temperature expansion and cooling contraction (that is, each flame baffle is movable in the front and back and left and right, with enough distance to withstand thermal expansion and contraction. If it is rigidly connected or bricked, it will crack or deform).

[0052] Because each flame deflector assembly 300 exhibits minimal deformation and does not affect or accumulate with each other, it is less prone to significant deformation or damage, thus extending its service life. Adjacent flame deflector assemblies are joined using a stepped joint to form a flat flame deflector assembly 300. The flame deflector assemblies experience minimal deformation due to the temperature difference across the cross-section in the firing zone 130. This stepped joint method ensures that the deformation of each flame deflector assemblies is independent, preventing severe uneven deformation of the assembly 300. Furthermore, it facilitates installation and avoids large gaps between adjacent flame deflector assemblies.

[0053] The second burner 500 is located on the side of the flame deflector plate away from the conveyor roller 150.

[0054] Specifically, for the flame deflector plate on the upper side of the conveyor roller 150, the second burner 500 is located above the flame deflector plate. For the flame deflector plate on the lower side of the conveyor roller 150, the second burner 500 is located below the flame deflector plate.

[0055] The structure of the second burner 500 is basically the same as that of the first burner, both being equipped with a burner control group. Specifically, the second burner 500 has a gas inlet and a combustion air inlet, wherein the gas inlet is connected to the burner group gas pipe 510, and the combustion air inlet is connected to the burner group air supply pipe 520.

[0056] After the second burner 500 is activated, the flue gas generated by the combustion of the gas is blocked by the flame baffle and cannot directly contact the daily-use ceramic 700 on the conveyor roller 150. Therefore, the color of the daily-use ceramic 700 is prevented from becoming dull due to contact with the flue gas and not meeting the user's needs.

[0057] In some embodiments, a first seal is provided between two adjacent flame deflector assemblies 300. It is understood that the upper surface of the first seal contacts the upper flame deflector assembly 300, and the lower surface of the first seal contacts the lower flame deflector assembly 300. This enhances the sealing effect between the two flame deflector assemblies 300 and prevents the smoke generated during combustion from leaking through the gap between the two flame deflector assemblies 300.

[0058] Furthermore, a second seal is provided between the stepped portions of two adjacent flame-damping plates. It is understood that the upper surface of the second seal contacts the upper stepped portion, and the lower surface of the second seal contacts the lower stepped portion. This arrangement promotes a better seal between the two flame-damping plates, preventing the leakage of combustion fumes and their contact with the daily-use ceramics 700 on the transport roller 150.

[0059] In this embodiment, both the first and second seals are ceramic paper. The overlaps between each flame deflector assembly 300 are sealed with soft, elastic high-temperature ceramic paper. The overlaps between each flame deflector plate are also sealed with soft high-temperature ceramic paper.

[0060] Because ceramic paper has good heat resistance and sealing properties, it can enhance the sealing effect between two adjacent flame baffle assemblies 300, withstand the high temperature environment of the firing zone 130, and when the flame baffle assembly 300 is displaced due to deformation, the ceramic paper can withstand the force from the flame baffle assembly 300 due to its good flexibility and is not easily damaged.

[0061] Because the flame baffle assembly 300 on the upper side of the conveyor roller 150 defines an upper fire channel 301 extending front to back between the upper wall of the kiln cavity 160, the front end of the upper fire channel 301 is an open structure, and the front opening of the upper fire channel 301 connects to the preheating zone 120. Moreover, the second burner 500 is located in the upper fire channel 301. When the second burner 500 is working, it will generate high-temperature flue gas. In order to prevent the flue gas from flowing to the quench zone 140 through the rear end of the upper fire channel 301, a sealing brick structure 420 is provided at the rear end of the upper fire channel 301. The sealing brick structure 420 includes multiple refractory bricks, which are stacked in the vertical direction to form a good sealing wall. Under the blocking effect of the sealing wall, the flue gas cannot flow into the quench zone 140, thereby ensuring that the quench zone 140 can complete the rapid cooling of the daily-use ceramics 700.

[0062] Similarly, since the flame baffle assembly 300 on the lower side of the conveyor roller 150 defines the lower fire channel 302 between the lower wall of the kiln cavity 160, the front end of the lower fire channel 302 is an open structure, and the front opening of the lower fire channel 302 is connected to the preheating zone 120. A second burner 500 is also provided in the lower fire channel 302. In order to block the connection between the rear end of the lower fire channel 302 and the quench zone 140, a sealing brick structure 420 is also provided at the rear end of the lower fire channel 302.

[0063] In some embodiments, not only is a baffle plate 200 provided between the preheating zone 120 and the smoke exhaust zone 110, but also a liftable baffle plate 200 is provided at both the inlet and outlet of the firing zone 130.

[0064] like Figure 1 , Figure 2 and Figure 4 As shown, the fire baffle 200 is located above the conveyor roller 150, and the height of the fire baffle 200 can be adjusted manually.

[0065] The front opening of the upper heating channel 301 is equipped with a fire baffle 410. Moreover, the front opening of the upper heating channel 301 is connected to the kiln cavity 160 of the preheating zone 120.

[0066] The front opening of the downcomer 302 is also equipped with a fire baffle 410. Moreover, the front opening of the downcomer 302 is connected to the kiln cavity 160 of the preheating zone 120.

[0067] Understandably, by installing the liftable baffle plate 200 and fire wall 410, the front openings of the upper combustion chamber 301 and lower combustion chamber 302 can be reduced, thereby decreasing the amount of gas entering the upper combustion chamber 301, lower combustion chamber 302, and product passage. Therefore, the amount of flue gas flowing out of the upper combustion chamber 301 and lower combustion chamber 302 can be adjusted by changing the height of the baffle plate 200 and fire wall 410.

[0068] In some embodiments, the height of the product passage in the firing zone 130 is smaller than the height of the kiln cavity 160 in the preheating zone 120. It is understood that no flame baffle assembly 300 is provided in the kiln cavity 160 of the preheating zone 120; therefore, the kiln cavity 160 of the preheating zone 120 is also a product passage.

[0069] Specifically, the height of the upper flame baffle assembly 300 is lowered, while the height of the lower flame baffle assembly 300 is raised, thereby reducing the space inside the kiln, bringing the flame baffle closer to the daily ceramic 700, enhancing the heat transfer effect, and reducing the heat dissipation area, improving the heat utilization rate, and achieving the goal of energy saving.

[0070] In some embodiments, an oxidation air curtain 610 is provided at the outlet of the preheating zone 120, and the oxidation air curtain 610 is located between the preheating zone 120 and the firing zone 130. A quench air curtain 620 is provided at the inlet of the quench zone 140, and the quench air curtain 620 is located between the firing zone 130 and the quench zone 140. It is understood that the oxidation air curtain 610 can prevent the flue gas in the preheating zone 120 from flowing into the firing zone 130 and affecting the operation of the firing zone 130; the quench air curtain 620 can prevent the air in the quench zone 140 from flowing into the firing zone 130 and causing drastic temperature fluctuations in the firing zone 130, while also rapidly cooling the product.

[0071] In this embodiment, the structure of the oxidation air curtain 610 is the same as that of the quench air curtain 620.

[0072] like Figure 5 As shown, the structure of the oxidation air curtain 610 includes a first side pipe 612 and a first top pipe 611.

[0073] A first top pipe 611 is provided. Both ends of the first top pipe 611 extend in the left and right direction and are located in the kiln cavity 160. The first top pipe 611 is located above the first side pipe 612. The first top pipe 611 is provided with multiple air holes with the openings facing downwards. The multiple air holes are arranged in the left and right direction of the first top pipe 611.

[0074] Furthermore, a first side pipe 612 is provided on the left side of the roller kiln body, and the first side pipe 612 is installed on the kiln wall of the roller kiln body. A first side pipe 612 is also provided on the right side of the roller kiln body, and the first side pipe 612 is fixed to the kiln wall of the roller kiln body.

[0075] The first side pipe 612 extends along the left and right direction of the roller kiln body. One end of the first side pipe 612 extends into the kiln cavity 160, and the end of the first side pipe 612 near the kiln cavity 160 is an open structure, which is connected to the kiln cavity 160.

[0076] There are multiple first side pipes 612, and these multiple first side pipes 612 are arranged along the vertical direction of the kiln cavity 160.

[0077] Both the first top pipe 611 and the first side pipe 612 are connected to a first air supply pipe 613. The first air supply pipe 613 may be equipped with a fan. Under the action of the fan, air flows through the first air supply pipe 613 to the first top pipe 611 and the first side pipe 612 respectively. Some air is ejected downward from the air hole of the first top pipe 611, and some air is ejected horizontally from the opening structure of the first side pipe 612, forming an air wall.

[0078] like Figure 6As shown, the quench air curtain 620 includes a second side duct 622 and a second top duct 621.

[0079] There is one second top pipe 621, and both ends of the second top pipe 621 extend along the left and right directions of the quench zone 140. The second top pipe 621 is located in the kiln cavity 160, and both ends of the second top pipe 621 penetrate the kiln wall.

[0080] The second top pipe 621 is located above the second side pipe 622. The second top pipe 621 is provided with air holes with the openings facing downwards. There are multiple air holes, which are arranged along the left and right directions of the second top pipe 621.

[0081] A second side pipe 622 is provided on the left side of the roller kiln body and a second side pipe 622 is also provided on the right side of the roller kiln body. The second side pipe 622 extends in the left and right direction and extends into the kiln cavity 160. The end of the second side pipe 622 near the kiln cavity 160 is an open structure, and the open structure is connected to the kiln cavity 160.

[0082] The second side pipe 622 consists of multiple pipes, which are arranged at intervals in the vertical direction.

[0083] The second top pipe 621 and the second side pipe 622 are both connected to the second air supply pipe 623. The second air supply pipe 623 can be equipped with a fan. Under the action of the fan, air flows through the second air supply pipe 623 to the second top pipe 621 and the second side pipe 622 respectively. Some air is sprayed downward from the air hole of the second top pipe 621, and some air is sprayed horizontally from the opening structure of the second side pipe 622, forming a wall of air.

[0084] In some embodiments, such as Figure 7 and Figure 8 As shown, the rapid cooling zone 140 is equipped with an air blowing pipe 821, a cold air box 811, a hot air box 812, and a cooling pipe 813.

[0085] The cooling pipe 813 extends laterally at both ends and is located within the kiln cavity 160, above the air blowing pipe 821. One end of the cooling pipe 813 is connected to the outlet of the cold air box 811 via a pipe, and the other end is connected to the inlet of the hot air box 812 via a pipe. When air flows from the cold air box 811 to the cooling pipe 813, because the cooling pipe 813 is located within the kiln cavity 160, it can carry away some heat and then flows to the hot air box 812. The air in the hot air box 812 can be used to dry the daily-use ceramics 700 or as combustion air. It is understood that there are multiple cooling pipes 813, arranged at intervals along the front-back direction of the quench zone 140. In the cross-section of the quench zone 140, there is only one cooling pipe 813.

[0086] A blower pipe 821 is provided on the left side of the quench zone 140, and another blower pipe 821 is provided on the right side of the quench zone 140. Both ends of the blower pipe 821 extend in the left-right direction and extend into the kiln cavity 160. An air outlet is provided at the end of the blower pipe 821 near the kiln cavity 160, and the air outlet is connected to the kiln cavity 160.

[0087] Specifically, the right end of the air blowing pipe 821 located on the left side of the quench zone 140 is the air outlet, and the left end of the air blowing pipe 821 located on the right side of the quench zone 140 is the air outlet. The air blowing pipe 821 is connected to an air supply pipe 822 via a pipeline, and a fan can be installed on the air supply pipe 822. It can be understood that air blowing pipes 821 can be installed above and below the conveyor roller 150, and there are multiple air blowing pipes 821, which are arranged at intervals along the front-back direction of the quench zone 140.

[0088] This configuration enables the rapid cooling zone 140 to use a combination of indirect and direct cooling to achieve rapid cooling while reducing the air volume required for direct cooling, thus achieving energy savings.

[0089] The preferred embodiments of the present invention have been described in detail above, but the present invention is not limited to the embodiments described. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention, and these equivalent modifications or substitutions are all included within the scope defined by the claims of this application.

Claims

1. A semi-flame-proof, high-efficiency, energy-saving roller kiln, comprising a roller kiln body, the roller kiln body having a kiln cavity and multiple conveying rollers, the multiple conveying rollers being disposed within the kiln cavity and arranged front to back, the roller kiln body comprising a flue gas exhaust zone, a preheating zone, and a firing zone arranged sequentially from front to back; characterized in that, In the preheating zone, first burners are provided on both the upper and lower sides of the conveyor roller. The first burners are located in the kiln cavity of the preheating zone, so that the preheating zone completes the preheating of daily-use ceramics mainly by convection heat transfer, supplemented by radiation heat transfer and heat conduction. In the firing zone, flame baffle assemblies and second burners are provided on both the upper and lower sides of the conveyor roller. Both the flame baffle assembly and the second burner are located in the kiln cavity of the firing zone. The length of the flame baffle assembly is the same as the length of the firing zone. The surface of the flame baffle assembly facing away from the conveyor roller and the wall of the kiln cavity define a fire channel. The front end of the fire channel is an open structure. The fire channel is connected sequentially to the kiln cavity of the preheating zone and the kiln cavity of the flue gas exhaust zone. The second burner is located on the side of the flame baffle away from the conveyor roller, so that the heat of the flue gas is radiated to the daily-use ceramics through the flame baffle assembly. An upper fire channel is defined between the flame baffle assembly located on the upper side of the conveyor roller and the upper wall of the kiln cavity, and a lower fire channel is defined between the flame baffle assembly located on the lower side of the conveyor roller and the lower wall of the kiln cavity. Both the upper and lower fire channels have a front opening and a rear opening. The front opening is connected to the kiln cavity of the preheating zone, and the rear opening is provided with a sealing brick structure. The preheating zone and the exhaust zone, as well as the inlet and outlet of the firing zone, are equipped with liftable baffles to control the flow of flue gas to the exhaust zone. The baffles are located above the conveying rollers, and the front opening is equipped with a fire wall. The upper and lower fire channels are connected to the kiln cavity of the preheating zone so that the high-temperature flue gas from the upper and lower fire channels can flow to the preheating zone and the exhaust zone and mix with the flue gas from the preheating zone and the exhaust zone. A product channel is defined between the flame baffle assemblies located on the upper and lower sides of the transport roller, and the height of the product channel is smaller than the height of the kiln cavity in the preheating zone.

2. The semi-flame-proof, high-efficiency energy-saving roller kiln according to claim 1, characterized in that, Within the firing zone, support members are provided on the upper and lower sides of the transport roller. Multiple flame deflector assemblies are provided and arranged along the front and back. Two adjacent flame deflector assemblies are overlapped vertically. The support members are located below the flame deflector assemblies and are connected to them. Each flame deflector assembly includes a flame deflector plate, which has a stepped portion. Multiple flame deflector plates are provided and arranged along the left and right sides. Two adjacent flame deflector plates are joined together through the stepped portion.

3. The semi-flame-proof, high-efficiency energy-saving roller kiln according to claim 2, characterized in that, A first sealing element is provided between two adjacent flame deflector assemblies, and a second sealing element is provided between the stepped portions of two adjacent flame deflector assemblies.

4. The semi-flame-proof, high-efficiency energy-saving roller kiln according to claim 3, characterized in that, Both the first and second sealing elements are ceramic paper.

5. The semi-flame-proof, high-efficiency energy-saving roller kiln according to claim 1, characterized in that, The outlet of the preheating zone is equipped with an oxidation air curtain, and the roller kiln body also includes a quench zone, which is located behind the firing zone, and the inlet of the quench zone is equipped with a quench air curtain.

6. The semi-flame-proof, high-efficiency energy-saving roller kiln according to claim 5, characterized in that, The structure of the oxidation air curtain is the same as that of the quench air curtain, both including a top pipe and side pipes. The top pipe extends left and right and is located in the kiln cavity. The top pipe is located above the side pipes and has multiple downward-facing air holes. The multiple air holes are arranged left and right. The side pipes are located on the left and right sides of the roller kiln body. The side pipes extend left and right and extend into the kiln cavity. There are multiple side pipes arranged up and down. The end of the side pipe near the kiln cavity is an open structure, and the open structure is connected to the kiln cavity.

7. The semi-flame-proof, high-efficiency energy-saving roller kiln according to claim 5, characterized in that, The quench zone is equipped with a cooling pipe and a blower pipe; the cooling pipe extends left and right and is located inside the kiln cavity, the cooling pipe is located above the blower pipe, the blower pipe is provided on the left and right sides of the quench zone, the blower pipe extends left and right and extends into the kiln cavity, the end of the blower pipe near the kiln cavity is provided with an air outlet, the air outlet is connected to the kiln cavity.

Images