A method for manufacturing a dry quenching coke oven inclined air duct support column assembly component

Abstract

The application discloses a kind of dry quenching coke oven inclined air duct support column assembly component manufacturing method, comprising the following steps: establishing inclined air duct support column BIM three-dimensional model;Adjust the size of internal castable block and mortar joint arrangement;Determine model parameters and boundary conditions, carry out simulation coupling calculation;Carry out calculation result analysis;Again analysis is carried out, and the structure of the stress concentration area of precast part is strengthened;According to the final analysis result production castable block, and castable block is built into precast part.The beneficial effects of the application are that: refractory castable can quickly produce various size castable blocks for inclined air duct support column, the size of block and arrangement can be optimized by combining digital BIM model technology and simulation calculation, the quality of inclined air duct support column precast part is controlled, and heat-resistant steel is added to the weak part of precast part block, which enhances the integrity, crack resistance and bending resistance of castable precast part, and improves the service life of dry quenching coke oven refractory lining.

Description

Technical Field

[0001] This invention belongs to the field of dry quenching coke oven technology, specifically relating to a method for manufacturing prefabricated components of inclined air duct support columns for dry quenching coke ovens based on castable and BIM technology. The prefabricated components are used for prefabricated maintenance of the inner lining of dry quenching coke ovens. Background Technology

[0002] The dry quenching coke oven is the core equipment of the dry quenching process, and the inclined air duct is a crucial component, ensuring its safe and stable operation and maximizing its advantages. The inclined air duct connects to the cooling section below and the annular air duct above. Its supports are inclined to support hundreds of tons of refractory material above, creating a temperature gradient of nearly 400°C between the upper and lower sections. It experiences over 1300 significant temperature fluctuations annually, resulting in frequent maintenance. The lining of the dry quenching coke oven is constructed using refractory bricks laid from bottom to top. For example, in a medium-to-large dry quenching coke oven (190t / h), the refractory brick types for the inclined air duct alone exceed 200, with a total weight exceeding 500t. When the refractory bricks supporting the inclined air duct are damaged and require repair, traditional maintenance techniques can only replace the surface-damaged refractory bricks. This process is complex, difficult, and results in poor repair quality, making it difficult to guarantee the service life of the repaired inclined air duct. Alternatively, the entire lining can be removed and rebuilt, which increases the operating costs of the dry quenching coke oven, making it uneconomical.

[0003] For the maintenance of refractory bricks in the inclined air duct support columns of dry quenching coke ovens after damage, a more advanced and reasonable technology is to use castable refractory to fabricate precast components of the inclined air duct support columns. By employing methods such as "upper pull and lower bracing" or creating specialized support frames, only the damaged inclined air duct support columns need to be replaced as a whole. This technical solution is highly targeted, has a short maintenance period, and low engineering costs. Furthermore, castable refractory, as an unshaped refractory material, possesses strong adaptability, rapid shaping, and no firing requirement, allowing for the rapid construction of precast inclined air duct support column components after being fabricated into blocks. However, existing technologies often rely on the experience of engineers when fabricating castable refractory precast components, lacking a scientifically sound design and configuration of the castable blocks. This results in poor mechanical properties and thermal shock stability of the precast dry quenching coke oven inclined air duct support columns. After being put into use, these components frequently fail due to weak points, significantly reducing their service life and affecting the normal operation of the dry quenching coke oven. Summary of the Invention

[0004] The purpose of this invention is to provide a method for manufacturing prefabricated components for inclined air duct support columns in dry quenching coke ovens. This method optimizes the arrangement of the castable refractory material for the inclined air duct support columns and incorporates a heat-resistant stainless steel frame in weak areas. This enhances the mechanical properties and thermal shock stability of the prefabricated components, improves their overall integrity, ensures the quality of dry quenching coke oven lining repair, extends the service life of the replaced inclined air ducts, and solves the problems of non-standard and unscientific manufacturing of existing prefabricated components.

[0005] The objective of this invention is achieved through the following technical solution:

[0006] A method for manufacturing an assembled component for a dry quenching coke oven inclined air duct support column includes the following steps:

[0007] S01, BIM Modeling: Based on the design drawings of the dry quenching coke oven lining, establish a BIM 3D model of the inclined air duct support column;

[0008] S02, Model Optimization: Based on the BIM 3D model, adjust the size of the internal castable blocks and the mortar joint layout;

[0009] S03, Simulation Calculation: Determine model parameters and boundary conditions, and perform coupled simulation calculations;

[0010] S04, Result Analysis: Analyze the calculation results. If the results meet the material strength requirements, proceed to step S05. If the results do not meet the requirements, repeat steps S02 and S03.

[0011] S05, Optimization and Strengthening: Analyze again and strengthen the structure of the compressive stress concentration area of ​​the precast component;

[0012] S06, Production of precast components: Based on the final analysis results, produce castable blocks and construct precast components from the castable blocks.

[0013] Furthermore, S01, BIM modeling: ensures that the overall shape and dimensions of the BIM 3D model of the inclined air duct support column are correct, for subsequent layout optimization.

[0014] Furthermore, in S02, model optimization: while keeping the overall shape and size of the BIM three-dimensional model of the inclined air duct support column unchanged, optimize the castable block. In the initial optimization adjustment, adjust the size of the castable block to 1 to 4 times the size of the refractory brick, and at the same time reduce the number of masonry layers of the inclined air duct support column to 40% to 80% of the original.

[0015] Furthermore, in S03, the simulation calculations include: determining the physical property parameters of the castable, including thermal conductivity, density, elastic modulus, and coefficient of thermal expansion; determining the high-temperature compressive strength and high-temperature flexural strength of the refractory mortar; determining the thermodynamic boundary conditions, treating the surface of the inclined duct support that directly contacts the red-hot coke as the first type of boundary condition, and the surface that does not contact the red-hot coke as the third type of boundary condition; determining the applied loads, equating the load of the upper refractory bricks to the upper part of the inclined duct support column, and restricting the vertical displacement of the model; and using three-dimensional simulation software to simulate the service conditions of the dry quenching coke oven for coupled calculations.

[0016] Furthermore, regarding S04, the results analysis: the stress conditions of the optimized castable block and the refractory mortar joint were analyzed. The stress of both the castable block and the refractory mortar joint should be less than 0.8 times their own material strength.

[0017] Furthermore, in S05, optimization and reinforcement: after simulation calculation, the compressive stress concentration area of ​​the precast component is identified. During the production of the castable block in this location, heat-resistant steel bars are added for reinforcement. The heat-resistant steel bars are placed during the production of the castable block.

[0018] Furthermore, the heat-resistant steel bars are erected to form a framework, and the horizontal, vertical, and lattice shapes of the framework are all grid-like.

[0019] Furthermore, in S06, the production of precast components: according to the size requirements of the precast components, the castable blocks are manufactured according to the dimensions within the allowable error range of ±2mm; the amount of water added is minimized while ensuring good fluidity of the castable; the curing temperature of the castable blocks is room temperature, and if the temperature is too low, heat preservation measures should be taken; the castable blocks can only be demolded after they have sufficient strength; after the castable blocks are naturally dried for 48 hours, a baking curve is formulated based on the influence factors of castable material, ambient temperature, and precast component size, and then they are baked in the furnace to 800℃ and naturally cooled, with a cooling rate not exceeding 25℃ per hour.

[0020] Furthermore, in S06, the production of precast components: after the castable blocks are made, the optimized BIM three-dimensional model is used to determine the masonry sequence, and the precast components of the inclined air duct support columns are masonred to form precast components.

[0021] The beneficial effects of this invention are:

[0022] (1) Refractory castables have the characteristics of strong adaptability, rapid shaping and no need for firing. They can quickly produce castable blocks of various sizes for inclined air duct support columns, and the size of the blocks can be adjusted and optimized as needed. Combined with digital BIM model technology for management and control, the quality of the prefabricated inclined air duct support columns can be controlled. With the help of numerical simulation calculation, the arrangement of castable blocks can be optimized and adjusted to enhance the integrity, crack resistance and bending resistance of the prefabricated castables and improve the service life of the refractory lining of dry quenching coke oven.

[0023] (2) Through numerical simulation coupled calculation, the stress state of castable blocks and refractory mortar joints under the service conditions of inclined wind support columns can be calculated relatively accurately, providing precise data support for optimizing the arrangement of castable blocks and the setting of refractory mortar joints. Furthermore, this method can be used to perform multiple optimization adjustments and comparisons to select the castable block matching scheme.

[0024] (3) The optimized arrangement of castables requires that the stress of the castable blocks and refractory mortar joints should be less than 0.8 times the material strength, so as to reserve the corresponding strength margin in actual working conditions; and for the stress concentration area of ​​the inclined wind duct support column that meets the requirements, heat-resistant stainless steel bars are added to the castable blocks to form a steel skeleton, which effectively improves the thermal shock stability of the castable blocks, extends the service life of the inclined wind duct support column, and ensures the quality after the inclined wind duct support column is replaced.

[0025] (4) The dry quenching coke oven inclined air duct support column produced by this method is highly efficient, compact, low-carbon and environmentally friendly. The arrangement of the castable blocks is scientific and reasonable, and the mechanical and thermal properties are improved. The prefabricated parts have strong integrity and the weak parts are reinforced in a targeted manner, which can effectively extend the service life of the dry quenching coke oven after replacement and maintenance.

[0026] The aforementioned main solution of the present invention and its various further alternative solutions can be freely combined to form multiple solutions, all of which are solutions that can be adopted and are claimed by the present invention; furthermore, the (non-conflicting alternatives) can also be freely combined with each other and with other alternatives. Those skilled in the art, after understanding the solution of the present invention, will realize from the prior art and common general knowledge that there are many combinations, all of which are technical solutions to be protected by the present invention, and will not be exhaustively listed here. Attached Figure Description

[0027] Figure 1 This is a flowchart illustrating the present invention.

[0028] Figure 2 This is a schematic diagram of the structure of the present invention.

[0029] Figure 3 This is a schematic diagram of the structure of the castable block of the present invention (with added heat-resistant steel bars). Detailed Implementation

[0030] The following non-limiting examples are used to illustrate the present invention.

[0031] Example 1:

[0032] refer to Figures 1-3 As shown, a method for manufacturing an assembled component for a dry quenching coke oven inclined air duct support column includes the following steps:

[0033] S01, BIM Modeling: Using BIM modeling software, based on the dry quenching coke oven lining design drawings, establish a BIM 3D model of the inclined air duct support column to ensure that the overall shape and dimensions of the inclined air duct support column BIM 3D model are correct for subsequent layout optimization.

[0034] S02, Model Optimization: Based on the BIM 3D model, while keeping the overall external dimensions of the BIM 3D model of the inclined air duct support column unchanged, adjust the size of the internal castable blocks and the mortar joint layout.

[0035] Because the original structure used fixed-pattern refractory bricks for construction, the size of the refractory bricks and the resulting brick joints remained unchanged. However, castable blocks could be fabricated on-site, and the size of the blocks could be controlled and adjusted according to the actual situation. After the blocks were fabricated, they were used to build precast inclined ventilation duct support columns using refractory mortar.

[0036] The inclined air duct support columns are constructed using refractory bricks, which typically result in numerous brick joints. This can easily lead to joint damage and brick detachment during service. Optimization by using castable refractory blocks aims to reduce brick joints, increase the size of the castable blocks, and rationally arrange the blocks and joints to improve the overall integrity of the inclined air duct support columns and optimize stress distribution. However, excessively large castable blocks also present construction difficulties. Therefore, the initial optimization of the castable blocks involves adjusting their size to 1-4 times the size of the refractory bricks, while simultaneously reducing the number of masonry layers in the inclined air duct support columns to 40%-80% of the original size.

[0037] S03, Simulation Calculation: Determine model parameters and boundary conditions, and perform coupled simulation calculations.

[0038] Determine the physical properties of the castable, including thermal conductivity, density, elastic modulus, and coefficient of thermal expansion (which can be measured experimentally). Determine the high-temperature compressive strength and high-temperature flexural strength of the refractory mortar (which can be measured experimentally). Determine the thermodynamic boundary conditions, treating the surface of the inclined duct support directly in contact with the red-hot slag as a first-type boundary condition and the surface not in contact with the red-hot slag as a third-type boundary condition. Determine the applied loads, applying the load of the upper refractory bricks to the upper part of the inclined duct support column, and restricting the vertical displacement of the model.

[0039] Three-dimensional simulation software was used to simulate the service conditions of a dry quenching coke oven and perform coupled calculations. During the calculation, the brick joints were equivalently set as contact surfaces.

[0040] S04, Result Analysis: Analyze the calculation results, including the stress on the optimized castable blocks and the refractory mortar joints (brick joints or mortar joints). The stress in both the castable blocks and the refractory mortar joints should be less than 0.8 times their own material strength. If the material strength requirement is met, proceed to step S05; otherwise, repeat steps S02 and S03 to further optimize the arrangement of the castable blocks.

[0041] S05, Optimization and Reinforcement: Further analysis is conducted, and through simulation calculations, the stress concentration areas of the precast component (generally the bottom and inner top of the support column) are identified. Structural reinforcement is then implemented in these stress concentration areas. During the production of the castable block at this location, φ10mm 0Cr25Ni20 (310S) heat-resistant stainless steel reinforcing bars are added for reinforcement. These heat-resistant reinforcing bars are inserted during the fabrication of the castable block.

[0042] Heat-resistant steel bars are erected in the horizontal, vertical and longitudinal directions to form a skeleton. The horizontal, vertical and longitudinal shapes of the skeleton are all grid-shaped, thereby improving the strength of the castable block in this part and enhancing the integrity, crack resistance and bending resistance of the castable precast component.

[0043] S06, Production of Precast Components: Check the dimensions of the inclined air duct support columns, brick joint positions, and masonry sequence of the optimized model. After confirming that there are no errors, produce castable blocks according to the final analysis results and masonry the castable blocks into precast components.

[0044] Based on the dimensional requirements of the precast components, the castable refractory blocks are manufactured to dimensions within an allowable error range of ±2mm, with negative tolerances made as much as possible to facilitate installation and masonry. Wooden formwork is used for casting. First, a mold template is made according to the shape of the precast component, then the mold template is fabricated, and the surrounding area is fixed with wooden blocks and bolts.

[0045] When casting refractory blocks, the amount of water added should be minimized while ensuring good flowability of the refractory. The curing temperature for the refractory blocks is room temperature; if the temperature is too low, insulation measures should be taken. Demolding should only be performed after the refractory blocks have sufficient strength.

[0046] After the castable blocks are naturally dried for 48 hours, a baking curve is developed based on the influence of the castable material, ambient temperature, and preform size. The blocks are then baked in an oven to 800℃ and allowed to cool naturally (sufficient holding time is required between 150 and 350℃), with a cooling rate not exceeding 25℃ per hour. An anti-explosion agent can be added to the castable during baking to prevent the blocks from cracking.

[0047] After the castable blocks are fabricated, the optimized BIM 3D model is used to determine the masonry sequence, and the prefabricated components of the inclined air duct support columns are constructed to form prefabricated components. Finally, the completed prefabricated components are installed into the coke oven.

[0048] The foregoing basic examples and their further alternative examples of the present invention can be freely combined to form multiple embodiments, all of which are embodiments that can be adopted and claimed by the present invention. In the present invention, each alternative example can be arbitrarily combined with any other basic example and alternative example.

[0049] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for manufacturing an assembled component for a dry quenching coke oven inclined air duct support column, characterized in that, Includes the following steps: S01, BIM Modeling: Based on the design drawings of the dry quenching coke oven lining, establish a BIM 3D model of the inclined air duct support column; S02, Model Optimization: Based on the BIM 3D model, adjust the size of the internal castable blocks and the mortar joint layout; S03, Simulation Calculation: Determine model parameters and boundary conditions, and perform coupled simulation calculations; S04, Result Analysis: Analyze the calculation results. If the results meet the material strength requirements, proceed to step S05. If the results do not meet the requirements, repeat steps S02 and S03. S05, Optimization and Strengthening: Analyze again and strengthen the structure of the compressive stress concentration area of ​​the precast component; S06, Production of precast components: Based on the final analysis results, produce castable blocks and construct precast components from the castable blocks; The aforementioned S03 simulation calculation: determines the physical property parameters of the castable, including thermal conductivity, density, elastic modulus and coefficient of thermal expansion; determines the high-temperature compressive strength and high-temperature flexural strength of the refractory mortar; Thermodynamic boundary conditions were determined by treating the surface of the inclined duct support that directly contacts the red-hot coke as the first type of boundary condition and the surface that does not contact the red-hot coke as the third type of boundary condition. The applied loads were determined by applying the load of the upper refractory bricks to the upper part of the inclined duct support column and restricting the vertical displacement of the model. Three-dimensional simulation software was used to simulate the service conditions of the dry quenching coke oven for coupled calculations.

2. The method for manufacturing prefabricated components for the inclined air duct support column of a dry quenching coke oven according to claim 1, characterized in that: S01, BIM modeling: Ensure the overall shape and dimensions of the BIM 3D model of the inclined air duct support column are correct for subsequent layout optimization.

3. The method for manufacturing prefabricated components for the inclined air duct support column of a dry quenching coke oven according to claim 1, characterized in that: S02, Model Optimization: While keeping the overall shape and size of the BIM 3D model of the inclined air duct support column unchanged, optimize the castable block. The initial optimization adjustment adjusts the size of the castable block to 1 to 4 times the size of the refractory brick, and at the same time reduces the number of masonry layers of the inclined air duct support column to 40% to 80% of the original.

4. The method for manufacturing prefabricated components for the inclined air duct support column of a dry quenching coke oven according to claim 1, characterized in that: S04, Result Analysis: The stress conditions of the castable block and the refractory mortar joint after optimization were analyzed. The stress of both the castable block and the refractory mortar joint should be less than 0.8 times their own material strength.

5. The method for manufacturing prefabricated components for the inclined air duct support column of a dry quenching coke oven according to claim 1, characterized in that: S05, optimization and reinforcement: After simulation calculation, the compressive stress concentration area of ​​the precast component is found. During the production of the castable block in this location, heat-resistant steel bars are added for reinforcement. The heat-resistant steel bars are placed during the production of the castable block.

6. The method for manufacturing prefabricated components for the inclined air duct support column of a dry quenching coke oven according to claim 5, characterized in that: The heat-resistant steel bars are erected to form a skeleton, and the horizontal, vertical and lattice shapes of the skeleton are all grid-like.

7. The method for manufacturing prefabricated components for the inclined air duct support column of a dry quenching coke oven according to claim 1, characterized in that: S06, Production of Precast Parts: According to the size requirements of the precast parts, the castable blocks are manufactured according to the dimensions within the allowable error range of ±2mm; the amount of water added is minimized while ensuring good fluidity of the castable; the curing temperature of the castable blocks is room temperature, and heat preservation measures should be taken if the temperature is too low; the castable blocks can be demolded only after they have sufficient strength; after the castable blocks are naturally dried for 48 hours, a baking curve is formulated based on the influence factors of castable material, ambient temperature, and precast part size, and then baked in the furnace to 800℃, and then naturally cooled, with the cooling rate not exceeding 25℃ per hour.

8. The method for manufacturing prefabricated components of the inclined air duct support column for a dry quenching coke oven according to claim 1 or 7, characterized in that: S06, Precast component production: After the castable block is made, the optimized BIM 3D model is used to determine the masonry sequence, and the precast components of the inclined air duct support column are masonred to form the precast components.

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