Emergency treatment method for Mini LED backplane glass furnace reversal failure

Abstract

The present invention discloses an emergency treatment method for the reversing failure of a Mini LED backplane glass furnace, which belongs to the technical field of glass furnaces. The technical solution is as follows: when a single pair of reversing gates fails to commutate: the natural gas and combustion-supporting air flow of the small furnace that failed to commutate are evenly distributed to other small furnaces; the feeding frequency of the feeding machine is reduced; when two or more pairs of reversing gates fail to commutate: the machine control switches to the human control, and manual reversing allows the original burning small furnace to continue burning. In actual production, the emergency treatment method of the present invention can be used as a reference in the emergency of glass furnace reversing failure, which can ensure the stability of the furnace and thus ensure the normal progress of production.

Description

Technical Field

[0001] The present invention relates to the technical field of glass furnaces, and in particular to an emergency treatment method for commutation failure of a Mini LED backplane glass furnace. Background Art

[0002] In current glass production, kiln process stability is crucial. Only by maintaining stable temperature, atmosphere, and pressure within the kiln can initial product quality standards be guaranteed at the hot end. Therefore, methods for kiln stability are crucial. Natural gas is the most common heating method in current float glass production. The kiln is heated by natural gas lances on either side, spraying flames. These lances periodically switch direction. This ensures constant temperature on both sides of the kiln, preventing significant temperature differences. Furthermore, this switching prevents the temperature on one side from rising too high, potentially damaging the lance. Finally, it prevents heating from one side alone, potentially burning the bricks in the corresponding position. Therefore, switching direction is crucial for hot-end processing.

[0003] The reversing system consists of electrically controlled mechanical components that, through a chain drive, pull the reversing gate at the small furnace, simultaneously controlling the opening and closing of the natural gas lance to achieve side-to-side switching. Due to the coordination between electrical and mechanical transmission, reversing failure is inevitable during operation. This failure directly destabilizes the internal temperature of the kiln. Furthermore, continuous use of the natural gas lance on one small furnace can damage the flame damper and lance, and even irreversibly affect the kiln breast wall opposite the lance. Prolonged high temperatures can destabilize the bricks. Therefore, developing an emergency response method for kiln reversing failure is essential. Summary of the Invention

[0004] The technical problem to be solved by the present invention is: to overcome the shortcomings of the existing technology and provide an emergency treatment method for the commutation failure of a Mini LED backplane glass kiln, which can be used as a reference in actual production when such an emergency occurs to ensure the stability of the kiln and thus ensure the normal progress of production.

[0005] The technical solution of the present invention is:

[0006] Emergency treatment method for reversing failure of Mini LED backplane glass furnace: when a single pair of reversing gates fails to commutate: distribute the natural gas and combustion-supporting air flow of the small furnace that failed to commutate to other small furnaces; reduce the feeding frequency of the feeding machine; when two or more pairs of reversing gates fail to commutate: switch from machine control to human control, and manually commutate to allow the original burning small furnace to continue burning.

[0007] Preferably, when a single pair of reversing gates fails to reverse, the combustion-supporting air flow in the small furnace is adjusted by the combustion-supporting air valve and the frequency of the combustion-supporting air fan.

[0008] Preferably, when a single pair of reversing gates fails to reverse, if the faulty small furnace still fails to reverse the next time it is reversed, the small furnace that failed to reverse is manually reversed. After reversing, natural gas is sprayed into the small furnace and combustion-supporting air is passed through according to the original setting values, and the natural gas and combustion-supporting air flow rates of other small furnaces are restored to the original setting values, and the frequencies of each feeder are restored to the original setting values.

[0009] Preferably, when two or more pairs of reversing gates fail to reverse, the frequency of manual reversing is 15 minutes per time.

[0010] Preferably, when more than two pairs of reversing gates fail to reverse, the specific operation is: machine control switches to human control, after pre-bell, turn off the natural gas of the small furnace to be burned and turn on the cooling gas of the natural gas spray gun of the small furnace to cool the natural gas spray gun, continue to use the original small furnace, turn off the cooling gas of the natural gas spray gun of the original small furnace, and turn on the natural gas of the original small furnace.

[0011] Preferably, when two or more pairs of reversing gates fail to reverse, the burning time of the original small combustion furnace is set to no more than 15 minutes.

[0012] Compared with the prior art, the present invention has the following beneficial effects:

[0013] The present invention provides an emergency treatment method for kiln reversing failure, which can be used as a reference when such emergency occurs in actual production to ensure the stability of the kiln and further ensure the normal progress of production. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, for ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0015] Figure 1 It is a top view of the kiln and the small furnace of the present invention.

[0016] In the picture, 1. Kiln; 2. Small furnace. DETAILED DESCRIPTION

[0017] In order to enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of the present invention.

[0018] The emergency treatment method for the Mini LED backplane glass furnace commutation failure of the present invention:

[0019] 1. When a single pair of reversing gates fails to reverse, such as Figure 1 As shown, the five north-facing small furnaces (2) should be switched to the five south-facing small furnaces (2). However, the switchover failed for furnace 1. However, the switchover process continued. The combustion system, including the natural gas burners, received control signals from the control system and switched, switching furnaces 2 through 5 to the south. During the switchover, the control system issued a switchover alarm. The staff observed a turbid flame in the kiln using the control system's high-temperature endoscope, confirming that the switchover was not complete. The control system's indicator lights confirmed that the fault was with the air exchanger (including the reversing gate, chain, etc.) in furnace 1.

[0020] At this time, the following adjustments need to be made for this type of sudden failure:

[0021] (1) Adjustment of air and fire volume

[0022] The ratio of the flow rate of combustion air to natural gas is usually called the air-fire volume. The natural gas and combustion air flow rates of the small furnace 2 that failed to switch are evenly distributed to the other small furnaces 2. The specific operations for adjusting the combustion air flow rate are: 1) Adjusting the valve position of the combustion air valves of the other small furnaces 2, evenly distributing the valve position value of the small furnace 2 that failed to switch to the valve position value of the other small furnaces 2, thereby increasing the combustion air flow rate of the other small furnaces 2. This can ensure the total amount of combustion air required for combustion within the kiln, ensure sufficient combustion of natural gas, avoid the generation of unburned excess gas and harmful oxides caused by incomplete combustion, and thus ensure a constant atmosphere within the kiln; 2) During the process of adjusting the combustion air valve position, the corresponding combustion air fan frequency must also be adjusted. The combustion air fan frequency of the other small furnaces 2 is adjusted, and the combustion air fan frequency of the small furnace 2 that failed to switch is evenly distributed to the other small furnaces 2. By adjusting the fan frequency and valve position accordingly, the fan frequency is increased while the valve position is increased, thereby ensuring constant pressure and atmosphere within the kiln without excessive pressure differentials, which is crucial for the kiln. In actual production, after such adjustment, the kiln pressure value displayed in the central control room remains basically unchanged, and the residual oxygen content in the flue remains basically unchanged (the residual oxygen content in the flue is an important indicator of the pressure and combustion degree in the reaction kiln).

[0023] Because a single pair of small furnaces 2 failed to commutate, the natural gas lances in that pair were unable to produce flames to provide heat. Therefore, the air and fire levels of the remaining small furnaces 2 that successfully commutated were adjusted. This means that the heat provided by the natural gas lances in the failed furnace 2 is evenly distributed among the other furnaces 2, thereby ensuring a constant overall heat level within the furnace. This adjustment ensures that the overall heat level within the furnace remains constant, preventing significant temperature differences and thus maintaining a stable temperature. In actual production, this adjustment maintains essentially constant total calorific value at each monitoring point within the furnace, effectively keeping temperature differences within a minimal range.

[0024] (2) Adjustment of feeding frequency of feeding machine

[0025] To ensure the rapid delivery of combustion-supporting air to small furnace 2 for normal combustion, it is necessary to monitor the material pile within the kiln and reduce the frequency of material additions from the feeder. This reduction in feed volume temporarily ensures kiln stability, preventing material accumulation and incomplete combustion caused by overly rapid feeds from the feeder. In actual production, a moderate reduction in feed volume can prevent incomplete melting of raw materials due to failed reversals in a group of small furnaces 2. This ensures that the glass melt is flattened and thinned while maintaining the same tin bath draw rate, preventing defects such as stones from forming within the glass melt.

[0026] In addition, when a single pair of reversing gates fails to reverse, if the faulty small furnace 2 still fails to reverse the next time it reverses, such as when the reorganized faulty small furnace 2 fails during the first north-to-south reversal, the reversal fails, and the above-mentioned method is used for emergency treatment; and when the reorganized faulty small furnace 2 still fails to reverse the next time it reverses from north to south, the small furnace 2 that failed to reverse is manually reversed, that is, personnel go to the air exchanger site to shut down the air exchanger of the small furnace 2 and cut off the power, and then the on-site personnel manually adjust the reversing gate into place. After the reversing gate is adjusted into place, natural gas and combustion-supporting air are sprayed into the small furnace 2 according to the original setting value, and according to the temperature and melting conditions in the kiln, the amount of wind and fire previously increased in other small furnaces 2 is reduced, and the natural gas and combustion-supporting air flow of other small furnaces 2 are gradually reduced to the original setting value at a certain frequency, and the frequency of each feeder is also restored to the original setting value.

[0027] 2. When more than two pairs of reversing gates fail to reverse, the reversing program is stuck at the air exchanger reversing step and cannot continue. At this time, the control system will issue a reversing alarm. The melter will determine that the reversing is not in place based on the fact that there is no flame in the faulty small furnace 2 in the kiln, and confirm that the faulty small furnace 2 is faulty.

[0028] At this time, in response to such sudden failures, the reversing system's machine control mode must be immediately switched to manual control mode, manual reversing must be performed, and small furnace 2 must be switched to the original burning small furnace 2. For example, after burning in the north-facing small furnace 2 for 15 minutes, it should automatically switch to the south-facing direction. However, at this time, reversing failures have occurred in two or more groups of small furnaces 2, resulting in the inability to reverse the direction of two or more groups of small furnaces 2. At this time, the program that has been switched to the south direction must be manually switched back to the north direction, and the north-facing small furnace 2 must continue to be used for combustion. During this process, it is necessary to check whether the reversing action indicator lights in the control system are abnormal.

[0029] The specific operation of manual reversing is: switch from machine control to human control, after 30 seconds of pre-ringing, turn off the natural gas of the small furnace 2 that should be burned (that is, the small furnace 2 that should be automatically switched to) and turn on the cooling gas of the natural gas spray gun that should burn the small furnace 2 to cool the natural gas spray gun, continue to use the original burning small furnace 2, turn off the cooling gas of the natural gas spray gun of the original burning small furnace 2, and turn on the natural gas of the original burning small furnace 2; at the same time, set the burning time of the original burning small furnace 2 to no more than 15 minutes, if the burning time of the original burning small furnace 2 can be shortened to 10 minutes, then reverse again to prevent the hot weather of the small furnace 2 on one side from being damaged by long-term use of the spray gun.

[0030] Example 1

[0031] A fault occurred when switching from northbound to southbound in small furnace No. 1. The southbound reversing gate did not open, causing the reversal to fail. The other four groups of small furnaces 2 switched to the southbound direction normally. The control system issued a reversal alarm. The staff observed a turbid flame inside the kiln using the control system's high-temperature endoscope, confirming that the reversal was not in place. The control system's indicator light confirmed that the fault was with the air exchanger in small furnace No. 1.

[0032] At this time, the following adjustments need to be made for this type of sudden failure:

[0033] (1) Adjustment of air and fire volume

[0034] The natural gas and combustion-supporting air flow of the No. 1 small furnace 2 are evenly distributed to the other small furnaces 2. The specific operation of adjusting the combustion-supporting air flow is as follows: 1) Adjust the valve position of the combustion-supporting air valve of the other small furnaces 2, and evenly distribute the valve position value of the small furnace 2 that failed to switch to the valve position value of the other small furnaces 2. The original valve positions of the combustion-supporting air valves of the No. 1 to No. 5 small furnaces 2 are 29.5%, 51.1%, 55.6%, 41.0%, and 41.2%, respectively. Since the switching of the No. 1 small furnace 2 failed, the valve position of the No. 2 valve is adjusted to 58.5%. The valve position of No. 3 is adjusted to 62.9%, the valve position of No. 4 is adjusted to 48.4%, and the valve position of No. 5 is adjusted to 48.6%; 2) Adjust the combustion-supporting air fan frequency of other small furnaces 2, and evenly distribute the combustion-supporting air fan frequency of the small furnace 2 that failed to commutate to other small furnaces 2. The original combustion-supporting air fan frequencies of small furnaces 2 from No. 1 to No. 5 are 24Hz, 35Hz, 36Hz, 32Hz, and 33Hz. Since the commutation of small furnace 2 No. 1 failed, the frequency of fan No. 2 is adjusted to 41Hz, the frequency of fan No. 3 is adjusted to 42 Hz, the frequency of fan No. 4 is adjusted to 38 Hz, and the frequency of fan No. 5 is adjusted to 39Hz.

[0035] Through the above adjustments, the original combustion air flow rates of small furnaces 1 to 5 were 1865Nm 3 / h、5371Nm 3 / h、7758Nm 3 / h, 4895 Nm 3 / h, 2667 Nm 3 / h, the natural gas flow rate is 186.5 Nm 3 / h, 537.1 Nm 3 / h, 775.8 Nm 3 / h, 489.5 Nm 3 / h, 266.7 Nm 3 / h. After adjustment, the combustion air flow rate of the No. 2 small furnace 2 is increased to 5837.25 Nm 3 / h, the combustion air flow rate of No. 3 small furnace 2 is increased to 8224.25Nm 3 / h, the combustion air flow rate of No. 4 small furnace 2 is increased to 5361.25 Nm 3 / h, the combustion air flow rate of No. 5 small furnace 2 is increased to 3133.25 Nm 3 / h; the natural gas flow rate of No. 2 small furnace 2 is increased to 583.725Nm 3 / h, the natural gas flow rate of No. 3 small furnace 2 increased to 822.425 Nm 3 / h, the natural gas flow rate of No. 4 small furnace 2 increased to 536.125 Nm 3 / h, the natural gas flow rate of No. 5 small furnace 2 increased to 313.325 Nm 3 / h. The total calorific value of each monitoring point inside the kiln remains basically unchanged, which can ensure that the temperature difference in the kiln is kept within a very small range.

[0036] (2) Adjustment of feeding frequency of feeding machine

[0037] The original feeding frequencies of feeders No. 1 to No. 4 (a total of four feeders) were 20.8 Hz, 23.0 Hz, 22.8 Hz, and 20.9 Hz. Due to the commutation failure of small furnace No. 1 2, the feeding frequencies of feeders No. 1 to No. 4 were reduced to 17.8 Hz, 20.0 Hz, 19.8 Hz, and 17.9 Hz.

[0038] Proper reduction in the feeding amount can avoid insufficient melting of raw materials caused by the reversing failure of small furnace No. 1 2, and ensure that the glass liquid is flattened and thinned while the pulling amount of the tin bath remains unchanged, and no defects such as stones are generated inside the glass liquid.

[0039] Example 2

[0040] A fault occurred when the northbound No. 1 and No. 2 small furnaces were switching to the southbound direction. The southbound reversing gate did not open, and the reversal failed. The control system issued a reversal alarm. The melter, observing the absence of flames in the kiln No. 1 and No. 2 small furnaces, determined that the reversal was not in place and confirmed that No. 1 and No. 2 small furnaces had failed.

[0041] At this time, in response to this type of sudden failure, the reversing system's machine control mode is immediately switched to manual control mode, manual reversing is performed, and small furnace 2 is switched to the original burning small furnace 2. That is, after the five small furnaces 2 in the north direction have been burning for 15 minutes, they should automatically switch to the five small furnaces 2 in the south direction. However, at this time, a reversing failure has occurred in small furnaces 2 No. 1 and 2, resulting in the inability to reverse the direction of small furnaces 2. At this time, the program that has been switched to the south direction is manually switched back to the north direction, and the five small furnaces 2 in the north direction continue to be used for combustion. During this process, it is necessary to check whether the display of the reversing action indicator lights in the control system is abnormal.

[0042] The specific operation of manual reversing is as follows: switch from machine control to manual control. After a 30-second pre-bell, turn off the natural gas supply to the south-facing small furnace 2 and turn on the cooling air to the natural gas spray gun of the south-facing small furnace 2 to cool the natural gas spray gun. Continue to use the five north-facing small furnaces 2, turn off the cooling air to the natural gas spray gun of the north-facing small furnace 2, and turn on the natural gas supply to the north-facing small furnace 2. At the same time, set the combustion time of the north-facing small furnace 2 to 10 minutes, and then reverse again to prevent the spray gun of the north-facing small furnace 2 from being damaged due to prolonged use in hot weather. While the north-facing small furnace 2 continues to be used, the air exchanger of the south-facing small furnace 2 is repaired to ensure that the kiln 1 can reversing normally.

[0043] Although the present invention has been described in detail with reference to the accompanying drawings and in combination with preferred embodiments, the present invention is not limited thereto. Without departing from the spirit and essence of the present invention, a person of ordinary skill in the art may make various equivalent modifications or substitutions to the embodiments of the present invention, and such modifications or substitutions shall be within the scope of the present invention. Any person skilled in the art who is familiar with the present invention may easily conceive of changes or substitutions within the technical scope disclosed in the present invention, and such changes or substitutions shall be within the scope of protection of the present invention. Therefore, the scope of protection of the present invention shall be subject to the scope of protection of the claims.

Claims

1. Emergency treatment method for Mini LED backplane glass furnace commutation failure, characterized by: When a single pair of reversing gates fails to reverse: the natural gas and combustion air flow of the small furnace that failed to reverse will be evenly distributed to other small furnaces; the feeding frequency of the feeding machine will be reduced; Adjust the combustion air flow in other small furnaces through the combustion air valve and the combustion air fan frequency; If the small furnace that has failed to reverse fails to reverse again during the next reversal, the small furnace that failed to reverse again will be manually reversed. After reversal, natural gas will be sprayed into the small furnace again and combustion-supporting air will be turned on. The natural gas and combustion-supporting air flow rates of other small furnaces will be restored to their original settings, and the frequencies of each feeder will be restored to their original settings. When more than two pairs of reversing gates fail to reverse: the machine control switches to the human control, and manual reversing allows the original small burning furnace to continue burning; the specific operation is: the machine control switches to the human control, after pre-ringing, the natural gas of the small furnace to be burned is turned off and the cooling gas of the natural gas spray gun of the small furnace to be burned is turned on to cool the natural gas spray gun, and the original small burning furnace continues to be used, and the cooling gas of the natural gas spray gun of the original small burning furnace is turned off, and the natural gas of the original small burning furnace is turned on.

2. The emergency treatment method for commutation failure of a Mini LED backplane glass furnace according to claim 1, characterized in that: When more than two pairs of reversing gates fail to reverse, the frequency of manual reversing is 15 minutes per time.

3. The emergency treatment method for commutation failure of a Mini LED backplane glass furnace according to claim 1, characterized in that: When two or more pairs of reversing gates fail to reverse, the burning time of the original small burning furnace shall be set to no more than 15 minutes.

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