A method for quickly repairing refractory materials of the bottom roller of a roller-hearth heating furnace

Abstract

The present invention relates to a method for quickly repairing refractory materials of the hearth roller of a roller-hearth heating furnace. The method comprises the following steps: Step 1: cleaning the furnace rollers, removing the original refractory materials on the roller bodies, exposing the metal surfaces of the roller bodies and both sides of the roller rings, and ensuring that they are dust-free; Step 2: making a push plate; Step 3: making ceramic fiber asbestos felt strips according to the outer diameter of the roller body; Step 4: spraying adhesive on the surface of the roller body, both sides of the roller rings, and the ceramic fiber asbestos felt strips; wrapping the ceramic fiber asbestos felt strips around and bonding them to the roller body, compacting them with a push plate while bonding; Step 5: after bonding the ceramic fiber asbestos felt strips on both sides of the furnace roller, welding a stainless steel ring sheet to the roller body at the outer end of the ceramic fiber asbestos felt, spraying adhesive on the surface of the stainless steel ring sheet, and wrapping the ceramic fiber asbestos felt ring around the outside of the stainless steel ring sheet. The method improves work efficiency, reduces repair costs, and extends the service life of the furnace rollers.

Description

Technical Field

[0001] The present invention relates to the field of heating furnaces, and in particular to a method for quickly repairing refractory materials of a bottom roller of a roller-hearth heating furnace. Background Art

[0002] The refractory material used in the hearth rollers of roller-hearth heating furnaces is refractory castables. During actual operation, thermal shock from furnace shutdowns and the vibrations of the billets during operation act like hammers, repeatedly striking the castables and generating mechanical vibrations. Furthermore, when the roller steel base deforms, the rigid castable is subjected to internal stress, making it difficult for it to adhere tightly to the roller steel base, leading to detachment. Consequently, castable-based refractory materials often fail to meet their designed service life. Furthermore, if damaged refractory material is not promptly replaced, the lifespan of the surrounding refractory material and the roller rings will be rapidly reduced. Lowering the furnace temperature during operation absorbs significant amounts of heat, resulting in significant direct and indirect losses. Furthermore, due to the characteristics of the castable, the refractory material repair process requires molding, solidification, and drying. This is time-consuming, and often requires shipping the material back to the manufacturer for repair, as users lack specialized drying equipment, resulting in high repair costs. In view of the above situation, through technical benchmarking and patent inquiries with other steel mills, there is no method to quickly repair and use furnace roller refractory materials at the production site.

[0003] CN100516249C discloses a method for increasing the lifespan of roller insulation materials for roller-hearth heating furnaces. The method utilizes a composite lightweight refractory material structure consisting of a ceramic fiber blanket, ceramic fiber rope, high-temperature refractory mortar, and heat-resistant anchoring nails. This method combines the high strength and vibration resistance of heavy refractory materials with the thermal insulation properties of lightweight refractory materials. Applicable to water-cooled rollers used for conveying steel plates in high-speed rotating environments, the method is not only heat-resistant and blocks heat transfer to the water cooling system, reducing energy waste, but also resists the intense vibration caused by slabs impacting the rollers. Consequently, the method offers advantages such as excellent vibration resistance and thermal insulation, a long service life, ease of manufacture, and cost-effectiveness. However, the patented method requires baking in a baking furnace, which takes a long time and is environmentally unfriendly. The patented process is complex, and the asbestos ropes are secured solely through bonding with the mortar, in addition to winding. No additional fixing methods are available. Due to the thermal stress generated by the different materials and repeated heating and cooling of the furnace after use, the mortar, which is only three millimeters thick, inevitably breaks and falls off, thus reducing its ability to secure the asbestos ropes. The refractory material is easily disintegrated when passing through the furnace rollers. Therefore, the asbestos rope is completely fixed by the cement, which is its weakness. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method for quickly repairing the refractory material of the bottom roller of a roller-hearth heating furnace, thereby improving work efficiency and reducing repair costs.

[0005] To achieve the above objectives, the present invention adopts the following technical solutions:

[0006] A method for quickly repairing refractory materials of a roller hearth heating furnace bottom roller, comprising the following steps:

[0007] Step 1: Clean the furnace rollers and remove the original refractory materials on the roller body to expose the metal surfaces on both sides of the roller body and roller ring, ensuring that there is no dust;

[0008] Step 2: Make the push plate;

[0009] Step 3: Make ceramic fiber asbestos felt strips according to the outer diameter of the roller body;

[0010] Step 4: Spray adhesive on the roller surface, both sides of the roller ring and the ceramic fiber asbestos felt strips; wrap the ceramic fiber asbestos felt strips and bond them to the roller body, pressing them with a push plate while bonding;

[0011] Step 5: After the ceramic fiber asbestos felt strips on both sides of the furnace roller are bonded, a stainless steel ring is welded to the roller body at the outer end of the ceramic fiber asbestos felt, and then adhesive is sprayed on the surface of the stainless steel ring, and the ceramic fiber asbestos felt ring is covered on the outside of the stainless steel ring.

[0012] As a further solution of the present invention, the adhesive is a ceramic fiber high-temperature adhesive.

[0013] As a further solution of the present invention, the length of the ceramic fiber asbestos felt strip is consistent with or greater than the circumference of the roller body. When the length of the ceramic fiber asbestos felt strip is consistent with the circumference of the roller body, the two ends of the ceramic fiber asbestos felt strip are tightly connected on the roller body, and the seams of the ceramic fiber asbestos felt strips on the roller body are staggered. When the length of the ceramic fiber asbestos felt strip is greater than the circumference of the roller body, the ceramic fiber asbestos felt strip is spirally wound on the roller body and overlapped at the seams.

[0014] As a further solution of the present invention, the specific operation of step 4 is:

[0015] When bonding the ceramic fiber asbestos felt strips between the roller rings, after bonding several ceramic fiber asbestos felt strips, use a pushing plate to push the ceramic fiber asbestos felt strips from one side to the other to compact them;

[0016] When bonding the ceramic fiber asbestos felt strips without roller ring obstruction at both ends of the roller body, both sides of the furnace roller are bonded from the inside to the outside at the same time. After bonding several ceramic fiber asbestos felt strips on both sides of the furnace roller, push plates are placed on both sides, and the push plates on both sides are connected with ropes. The length of the rope is artificially shortened to press the ceramic fiber asbestos felt strips on both sides inwards at the same time.

[0017] As a further solution of the present invention, the push plate includes a pressing plate body, the pressing plate body is provided with an opening for placing the furnace roller body, and rope holes are provided at the four corners of the pressing plate body.

[0018] Compared with the existing technology, the beneficial effects of the present invention are:

[0019] The present invention allows for rapid repair of roller-hearth furnace rollers, using ceramic fiber asbestos felt instead of the original refractory castable. This eliminates the need for baking or sintering, improving work efficiency, reducing roller-hearth furnace roller repair costs, and extending roller service life. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 Schematic diagram of furnace roller Figure 1 .

[0021] Figure 2 Schematic diagram of furnace roller Figure 2 .

[0022] Figure 3 Schematic diagram of the push plate working.

[0023] Figure 4 This is a view of the furnace roller shaft.

[0024] Figure 5 Schematic diagram of the push plate.

[0025] In the figure: roller body 1, roller ring 2, ceramic fiber asbestos felt strip 3, push plate 4, pressure plate body 5, opening 6, rope hole 7, rope 8, stainless steel ring piece 9, ceramic fiber asbestos felt ring 10. DETAILED DESCRIPTION

[0026] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other.

[0027] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0028] A method for quickly repairing refractory materials of a roller hearth heating furnace bottom roller, comprising the following steps:

[0029] Step 1: Clean the furnace rollers and remove the original refractory material on the roller body 1 to expose the metal surfaces on both sides of the roller body 1 and the roller ring 2 (see Figure 1 ), ensure there is no dust;

[0030] Step 2: Make a push plate 4; the push plate 4 includes a plate body 5, the plate body 5 is provided with an opening 6 for placing the roller body 1 of the furnace roller, and the four corners of the plate body 5 are provided with rope holes 7; (see Figure 5 )

[0031] Step 3: Make ceramic fiber asbestos felt strips 3 according to the outer diameter of the roller body 1; the length of the ceramic fiber asbestos felt strips 3 is the same as or greater than the circumference of the roller body 1;

[0032] Step 4: Spray ceramic fiber high temperature adhesive on the surface of the roller body 1, both sides of the roller ring 2 and the ceramic fiber asbestos felt strips 3; Cover and bond the ceramic fiber asbestos felt strips 3 to the roller body 1 (see Figure 2 ), while bonding and compacting with the push plate 4; the specific operation is:

[0033] When the length of the ceramic fiber asbestos felt strips 3 is consistent with the circumference of the roller body 1, the two ends of the ceramic fiber asbestos felt strips 3 are tightly connected on the roller body 1, and the joints of the ceramic fiber asbestos felt strips 3 on the roller body 1 are staggered;

[0034] When the length of the ceramic fiber asbestos felt strips 3 is greater than the circumference of the roller body 1 , the ceramic fiber asbestos felt strips 3 are spirally wound on the roller body 1 and overlapped at the joints.

[0035] When bonding the ceramic fiber asbestos felt strips 3 between the roller rings 2, after bonding several ceramic fiber asbestos felt strips 3, use the opening 6 of the pushing plate 4 to fit on the roller body 1, and push the ceramic fiber asbestos felt strips 3 from one side to the other side to tighten them;

[0036] When bonding the ceramic fiber asbestos felt strips 3 without roller rings blocking the two ends of the roller body 1, both sides of the furnace roller are bonded from the inside to the outside at the same time. After bonding several ceramic fiber asbestos felt strips 3 on both sides, push plates 4 are placed on both sides, and the openings 6 are sleeved on the roller body 1. The rope holes 7 of the push plates 4 on both sides are connected with ropes 8. The length of the ropes 8 is artificially shortened, and the ceramic fiber asbestos felt strips 3 on both sides are pressed inwards and tightened at the same time (see Figure 3 ).

[0037] Step 5: After the ceramic fiber asbestos felt strips 3 on both sides of the furnace roller are bonded, a stainless steel ring piece 9 is welded to the roller body at the outer end of the ceramic fiber asbestos felt. Then, a ceramic fiber high-temperature adhesive is sprayed on the surface of the stainless steel ring piece 9, and a ceramic fiber asbestos felt ring 10 is wrapped around the outside of the stainless steel ring piece 9 to ensure that the stainless steel ring piece 9 is covered in the ceramic fiber asbestos felt. Figure 4 )

[0038] The preferred embodiments of the present invention are described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the specific details in the above embodiments. Within the scope of the technical concept of the present invention, the technical solution of the present invention can be subjected to a variety of simple modifications, and these simple modifications all fall within the scope of protection of the present invention. It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner unless there is any contradiction. In order to avoid unnecessary repetition, the present invention will no longer describe various possible combinations separately. In addition, the various different embodiments of the present invention can also be arbitrarily combined, and as long as they do not violate the concept of the present invention, they should also be regarded as the contents disclosed by the present invention.

[0039] To make the objectives, technical solutions, and technical effects of the present invention more clear, the technical solutions in the embodiments of the present invention are now clearly and completely described. However, the embodiments described below are only some of the embodiments of the present invention, not all of them. In combination with the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.

[0040] Example 1

[0041] A method for quickly repairing refractory materials of a roller hearth heating furnace bottom roller, comprising the following steps:

[0042] Step 1: Clean the furnace rollers and remove the original refractory material on the roller body 1 of the furnace roller to expose the metal surfaces on both sides of the roller body 1 and the roller ring 2, ensuring that there is no dust;

[0043] Step 2: Make a push plate 4; the push plate 4 includes a press plate body 5, the press plate body 5 is provided with an opening 6 for placing the furnace roller body 1, and the four corners of the press plate body 5 are provided with rope holes 7;

[0044] Step 3: Make ceramic fiber asbestos felt strips 3 according to the outer diameter of the roller body 1; the length of the ceramic fiber asbestos felt strips 3 is consistent with the circumference of the roller body 1;

[0045] Step 4: Spray ceramic fiber high-temperature adhesive on the surface of the roller body 1, both sides of the roller ring 2, and the ceramic fiber asbestos felt strips 3; Wrap the ceramic fiber asbestos felt strips 3 and bond them to the roller body 1, compacting them with the push plate 4 while bonding; after bonding, the outer diameter of the ceramic fiber asbestos felt strips 3 is consistent with the outer diameter of the roller ring 2. The specific operations are as follows:

[0046] During bonding, both ends of the ceramic fiber asbestos felt strips 3 are tightly butted against each other on the roller body 1 , and the joints of the ceramic fiber asbestos felt strips 3 on the roller body 1 are arranged in a staggered manner.

[0047] When bonding the ceramic fiber asbestos felt strips 3 between the roller rings 2, after bonding several ceramic fiber asbestos felt strips 3, use the opening 6 of the pushing plate 4 to fit on the roller body 1, and push the ceramic fiber asbestos felt strips 3 from one side to the other side to tighten them;

[0048] When bonding the ceramic fiber asbestos felt strips 3 without roller ring obstruction at both ends of the roller body 1, both sides of the furnace roller are bonded from the inside to the outside at the same time. After bonding several ceramic fiber asbestos felt strips 3 on both sides, push plates 4 are placed on both sides, and the openings 6 are sleeved on the roller body 1. The rope holes 7 of the push plates 4 on both sides are connected with ropes 8, and the length of the ropes 8 is artificially shortened to press the ceramic fiber asbestos felt strips 3 on both sides inwards at the same time.

[0049] Step 5: After the ceramic fiber asbestos felt strips 3 on both sides of the furnace roller are bonded, a stainless steel ring piece 9 is welded to the roller body at the outer end of the ceramic fiber asbestos felt, and then a ceramic fiber high-temperature adhesive is sprayed on the surface of the stainless steel ring piece 9, and a ceramic fiber asbestos felt ring 10 is wrapped around the outside of the stainless steel ring piece 9 to ensure that the stainless steel ring piece 9 is covered in the ceramic fiber asbestos felt.

[0050] Example 2

[0051] A method for quickly repairing refractory materials of a roller hearth heating furnace bottom roller, comprising the following steps:

[0052] Step 1: Clean the furnace rollers and remove the original refractory material on the roller body 1 of the furnace roller to expose the metal surfaces on both sides of the roller body 1 and the roller ring 2, ensuring that there is no dust;

[0053] Step 2: Make a push plate 4; the push plate 4 includes a press plate body 5, the press plate body 5 is provided with an opening 6 for placing the furnace roller body 1, and the four corners of the press plate body 5 are provided with rope holes 7;

[0054] Step 3: Make ceramic fiber asbestos felt strips 3 according to the outer diameter of the roller body 1; the length of the ceramic fiber asbestos felt strips 3 is greater than the circumference of the roller body 1;

[0055] Step 4: Spray ceramic fiber high-temperature adhesive on the surface of the roller body 1, both sides of the roller ring 2, and the ceramic fiber asbestos felt strips 3; Wrap the ceramic fiber asbestos felt strips 3 and bond them to the roller body 1, compacting them with the push plate 4 while bonding; after bonding, the outer diameter of the ceramic fiber asbestos felt strips 3 is consistent with the outer diameter of the roller ring 2. The specific operations are as follows:

[0056] During bonding, the ceramic fiber asbestos felt strips 3 are spirally wound on the roller body 1 and overlapped at the joints.

[0057] When bonding the ceramic fiber asbestos felt strips 3 between the roller rings 2, after bonding several ceramic fiber asbestos felt strips 3, use the opening 6 of the pushing plate 4 to fit on the roller body 1, and push the ceramic fiber asbestos felt strips 3 from one side to the other side to tighten them;

[0058] When bonding the ceramic fiber asbestos felt strips 3 without roller ring obstruction at both ends of the roller body 1, both sides of the furnace roller are bonded from the inside to the outside at the same time. After bonding several ceramic fiber asbestos felt strips 3 on both sides, push plates 4 are placed on both sides, and the openings 6 are sleeved on the roller body 1. The rope holes 7 of the push plates 4 on both sides are connected with ropes 8, and the length of the ropes 8 is artificially shortened to press the ceramic fiber asbestos felt strips 3 on both sides inwards at the same time.

[0059] Step 5: After the ceramic fiber asbestos felt strips 3 on both sides of the furnace roller are bonded, a stainless steel ring piece 9 is welded to the roller body at the outer end of the ceramic fiber asbestos felt, and then a ceramic fiber high-temperature adhesive is sprayed on the surface of the stainless steel ring piece 9, and a ceramic fiber asbestos felt ring 10 is wrapped around the outside of the stainless steel ring piece 9 to ensure that the stainless steel ring piece 9 is covered in the ceramic fiber asbestos felt.

[0060] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principles and basic spirit of the invention, and the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A method for quickly repairing the refractory material of the bottom roller of a roller-hearth heating furnace, comprising the following steps: Step 1: Clean the furnace rollers and remove the original refractory materials on the roller body to expose the metal surfaces on both sides of the roller body and roller ring, ensuring that there is no dust; Step 2: Make a push plate; the push plate includes a press plate body, the press plate body is provided with an opening for placing the furnace roller body, and the four corners of the press plate body are provided with rope holes; Step 3: Make ceramic fiber asbestos felt strips according to the outer diameter of the roller body; Step 4: Spray adhesive on the roller surface, both sides of the roller ring and the ceramic fiber asbestos felt strips; wrap the ceramic fiber asbestos felt strips and bond them to the roller body, compacting them with a push plate while bonding; the specific operations are as follows: When bonding the ceramic fiber asbestos felt strips between the roller rings, after bonding several ceramic fiber asbestos felt strips, use a pushing plate to push the ceramic fiber asbestos felt strips from one side to the other to compact them; When bonding the ceramic fiber asbestos felt strips without roller rings blocking both ends of the roller body, both sides of the furnace roller are bonded from the inside to the outside at the same time. After bonding several ceramic fiber asbestos felt strips on both sides of the furnace roller, push plates are placed on both sides, and the push plates on both sides are connected with ropes. The length of the ropes is artificially shortened to press the ceramic fiber asbestos felt strips on both sides inwards at the same time; Step 5: After the ceramic fiber asbestos felt strips on both sides of the furnace roller are bonded, a stainless steel ring is welded to the roller body at the outer end of the ceramic fiber asbestos felt, and then adhesive is sprayed on the surface of the stainless steel ring, and the ceramic fiber asbestos felt ring is covered on the outside of the stainless steel ring.

2. A method for quickly repairing refractory materials of a roller-hearth heating furnace according to claim 1, characterized in that: The adhesive is a ceramic fiber high-temperature adhesive.

3. The method for quickly repairing the refractory material of the bottom roller of a roller-hearth heating furnace according to claim 1 is characterized in that: The length of the ceramic fiber asbestos felt strips is consistent with or greater than the circumference of the roller body. When the length of the ceramic fiber asbestos felt strips is consistent with the circumference of the roller body, the two ends of the ceramic fiber asbestos felt strips are tightly butted on the roller body, and the seams of the ceramic fiber asbestos felt strips on the roller body are staggered. When the length of the ceramic fiber asbestos felt strips is greater than the circumference of the roller body, the ceramic fiber asbestos felt strips are spirally wound on the roller body, and the seams are overlapped.

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