An electric furnace for smelting rock wool

Abstract

The present application relates to the technical field of rock wool production, and provides an electric furnace for smelting rock wool, which comprises a furnace body; the furnace body comprises a furnace bottom, a furnace wall and a water-cooled furnace top, the furnace wall is arranged along the circumference of the furnace bottom, and the water-cooled furnace top is arranged on the furnace wall to form a furnace chamber; the inner wall of the furnace bottom is provided with a first refractory lining structure, the inner wall of the furnace wall is provided with a second refractory lining structure and a third refractory lining structure; the bottom end of the second refractory lining structure is connected with the outer edge of the first refractory lining structure; the top end of the second refractory lining structure is connected with the bottom end of the third refractory lining structure; the furnace wall is provided with a feeding area and a discharging area, and the feeding area and the discharging area are both communicated with the furnace chamber of the furnace body, which is beneficial to increase the refractory performance of the electric furnace for smelting rock wool, so that continuous production can be realized in the long-term rock wool production process, the production operation rate of rock wool products is improved, and the production demand for rock wool products is met.

Description

Technical Field

[0001] This invention relates to the field of rock wool production technology, and in particular to an electric furnace for melting rock wool. Background Technology

[0002] Rock wool products are widely used in buildings and industrial facilities. They are a new type of lightweight thermal insulation material made primarily from basalt. The basalt is melted at high temperatures, spun into inorganic fibers using high-speed centrifugal equipment, then mixed with a special binder and dust-proofing oil. The arrangement of these inorganic fibers is altered using specialized equipment, and finally, the fibers are cured and shaped. Rock wool products possess excellent thermal properties, including high reflectivity, high emissivity, low thermal conductivity, and low heat storage coefficient, providing superior heat insulation and reflection capabilities.

[0003] Rock wool has a melting point of 1300-1450℃. The electric furnace used for melting rock wool is a key piece of equipment in rock wool production. The furnace lid, walls, and bottom are all constructed with refractory materials. During rock wool production, the temperature inside the furnace reaches as high as 1500-1600℃. As the rock wool raw material melts inside the furnace, the inner side of the furnace wall contains the high-temperature molten rock wool. When the high-temperature molten rock wool exits the furnace, the furnace wall is easily damaged due to the sudden drop in temperature on its inner side. Furthermore, during the melting process, the high-temperature molten rock wool is subjected to electromagnetic and mechanical stirring, which continuously erodes and washes over the furnace wall, also easily leading to its damage. Therefore, the protection requirements for the furnace wall are extremely stringent.

[0004] Currently, the main materials used for the inner lining of furnace walls are quartz, corundum ramming mix, high-alumina castable, and premium high-alumina bricks. In actual use, the inappropriate selection of materials for the furnace wall lining results in poor refractory performance of the electric furnaces used for smelting rock wool. This makes continuous production impossible during long-term operations, affecting the production rate of rock wool products and causing production lines to fail to reach full capacity, thus failing to meet the production demands of rock wool. Summary of the Invention

[0005] This application aims to provide an electric furnace for melting rock wool, which at least solves the problem that current electric furnaces used for melting rock wool have poor refractory properties, making it impossible to achieve continuous production in long-term production processes, thus affecting the production efficiency of rock wool products and making it difficult to meet the production needs of rock wool products.

[0006] This invention provides an electric furnace for melting rock wool, comprising: a furnace body;

[0007] The furnace body includes a furnace bottom, a furnace wall, and a water-cooled furnace top. The furnace wall extends circumferentially along the furnace bottom, and the water-cooled furnace top is located at the top of the furnace wall.

[0008] The inner wall of the furnace bottom is provided with a first refractory lining structure, and the inner wall of the furnace wall is provided with a second refractory lining structure and a third refractory lining structure.

[0009] The bottom end of the second refractory lining structure is connected to the outer edge of the first refractory lining structure; the top end of the second refractory lining structure is connected to the bottom end of the third refractory lining structure.

[0010] The furnace wall is provided with a feeding area and a discharging area, both of which are connected to the furnace chamber of the furnace body; the feeding area is located above the discharging area.

[0011] According to the present invention, an electric furnace for smelting rock wool is provided, wherein the water-cooled furnace top includes a cold water pipe and a first casting body; the cold water pipe is embedded inside the first casting body; and the first casting body is cast on the top of the second refractory lining structure.

[0012] According to the present invention, an electric furnace for smelting rock wool is provided, wherein the first refractory lining structure includes a first heat insulation layer, a first protective layer, a first refractory layer and a second protective layer;

[0013] One side of the first heat insulation layer is connected to the inner wall of the furnace bottom, and the other side is connected to the first protective layer;

[0014] The first protective layer, the first refractory layer, and the second protective layer are stacked sequentially towards the interior of the furnace chamber of the furnace body; the second protective layer is used to contact the molten slag at the bottom of the furnace chamber of the furnace body.

[0015] According to the present invention, an electric furnace for smelting rock wool is provided, wherein the material of the first heat insulation layer comprises clay bricks; the material of the first protective layer comprises aluminum silicon carbide carbon dry ramming mix; the material of the first refractory layer comprises magnesia bricks; and the material of the second protective layer comprises magnesia-calcium ramming mix.

[0016] According to the present invention, an electric furnace for smelting rock wool is provided, wherein the second refractory lining structure includes a buffer layer, a second heat insulation layer and a second refractory layer;

[0017] The buffer layer is disposed between the inner wall of the furnace wall and the second heat insulation layer, and the second heat insulation layer and the second refractory layer are stacked sequentially towards the interior of the furnace body; the second refractory layer is used to contact the molten slag inside the furnace body.

[0018] According to the present invention, an electric furnace for smelting rock wool is provided, wherein the material of the buffer layer comprises carbon ramming mix; the material of the second heat insulation layer comprises clay bricks; and the material of the second refractory layer comprises magnesia-chrome bricks.

[0019] According to the present invention, an electric furnace for smelting rock wool is provided, wherein the second refractory lining structure further includes a slag discharge area, the slag discharge area is located at the bottom of the second refractory lining structure, the slag discharge area is provided with a first channel, the first channel sequentially penetrating the second refractory layer, the second heat insulation layer and the buffer layer;

[0020] The slag discharge zone includes a seat brick and a core brick. The seat brick has a through hole, and the core brick is embedded in the through hole.

[0021] According to the present invention, an electric furnace for smelting rock wool is provided, wherein the third refractory lining structure includes a third heat insulation layer and a third refractory layer;

[0022] One side of the third insulation layer is connected to the inner wall of the furnace wall, and the other side is connected to the third refractory layer;

[0023] The third refractory layer is used to contact the rock wool solution inside the furnace chamber of the furnace body;

[0024] The material of the third heat insulation layer includes clay bricks; the material of the third refractory layer includes high-alumina bricks.

[0025] According to the present invention, an electric furnace for smelting rock wool is provided, wherein the third refractory lining structure is provided with a second channel, the second channel passing through the third refractory layer and the third heat insulation layer in sequence, and the discharge zone is connected to the furnace chamber of the furnace body through the second channel.

[0026] According to the present invention, an electric furnace for smelting rock wool is provided, wherein the feeding zone is provided with a fourth heat insulation layer and a second casting body; the fourth heat insulation layer is connected to the top of the furnace wall, and the second casting body is cast on the top of the second refractory lining structure;

[0027] The fourth heat insulation layer is stacked with the second casting body, and the fourth heat insulation layer is located on the outside of the second casting body;

[0028] The material of the fourth heat insulation layer includes clay bricks; the material of the second casting body includes aluminum silicon carbide carbon casting material.

[0029] This invention provides an electric furnace for smelting rock wool. The furnace wall extends circumferentially along the furnace bottom, and a water-cooled furnace top is located at the top of the furnace wall to form a cylindrical furnace body. The furnace wall has a feeding zone and a discharging zone, both of which are connected to the furnace chamber. Rock wool raw material is fed into the furnace chamber from the feeding zone and discharged from the discharging zone after smelting. The water-cooled furnace top, located at the top of the furnace wall, can effectively cool the high-temperature hot air generated by the molten rock wool, thereby achieving a cooling effect on the furnace body. Simultaneously, the inner wall of the furnace bottom is provided with a first refractory lining structure, and the inner wall of the furnace wall is provided with a second refractory lining structure. The bottom end of the second refractory lining structure is connected to the first refractory lining structure. The outer edge of the first refractory lining structure is connected to the second refractory lining structure. The first and second refractory lining structures can effectively isolate the molten slag at the bottom of the furnace from the high temperature and corrosion of the furnace bottom and furnace wall, and maintain the high temperature environment inside the furnace. The top of the second refractory lining structure is connected to the bottom of the third refractory lining structure. The second refractory lining structure can effectively isolate the erosion and high temperature of the rock wool molten liquid inside the furnace from the furnace wall. This is beneficial to increasing the refractory performance of the electric furnace used for smelting rock wool, so as to achieve continuous production in the long-term rock wool production process, improve the production efficiency of rock wool products, and meet the production demand of rock wool products. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0031] Figure 1 This is a cross-sectional view of the electric furnace for melting rock wool provided by the present invention;

[0032] Figure 2 This is a schematic diagram of the structure of the straight spherical bottom brick provided by the present invention;

[0033] Figure 3 This is a schematic diagram of the structure of the first refractory layer provided by the present invention;

[0034] Figure 4 This is a schematic diagram of the structure of the seat brick provided by the present invention;

[0035] Figure 5 This is a schematic diagram of the core brick structure provided by the present invention;

[0036] Figure 6 This is a schematic diagram of the connection structure between the seat brick and the core brick provided by the present invention.

[0037] Figure label:

[0038] 1. Furnace bottom; 11. First refractory lining structure; 111. First insulation layer; 112. First protective layer; 113. First refractory layer; 114. Second protective layer; 1131. Straight spherical bottom brick;

[0039] 2. Furnace wall; 21. Second refractory lining structure; 211. Buffer layer; 212. Second insulation layer; 213. Second refractory layer; 214. Slag discharge zone; 2141. Sealing brick; 2142. Core brick; 21401. First channel; 21411. Through hole;

[0040] 22. Third refractory lining structure; 221. Third insulation layer; 222. Third refractory layer;

[0041] 23. Feeding area; 231. Fourth insulation layer; 232. Second casting body; 2321. Second anchor;

[0042] 3. Water-cooled furnace top; 31. First casting body; 32. First anchor; 311. Operation window;

[0043] 4. Furnace cover; 41. Electrode holes. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0045] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0046] The following is combined Figures 1-6 The electric furnace for smelting rock wool provided in this invention will be described in detail through specific embodiments and application scenarios.

[0047] like Figure 1 As shown, the present invention provides an electric furnace for smelting rock wool, comprising: a furnace body. The furnace body includes a furnace bottom 1, a furnace wall 2, and a water-cooled furnace top 3. The furnace wall 2 extends circumferentially along the furnace bottom 1, and the water-cooled furnace top 3 is disposed on the furnace wall 2 to form a furnace chamber.

[0048] The inner wall of the furnace bottom 1 is provided with a first refractory lining structure 11, and the inner wall of the furnace wall 2 is provided with a second refractory lining structure 21 and a third refractory lining structure 22.

[0049] The bottom end of the second refractory lining structure 21 is connected to the outer edge of the first refractory lining structure 11. The top end of the second refractory lining structure 21 is connected to the bottom end of the third refractory lining structure 22.

[0050] The furnace wall 2 is provided with a feeding zone 23 and a discharging zone, both of which are connected to the furnace chamber. The feeding zone 23 is located above the discharging zone.

[0051] Understandably, electric furnaces used for melting rock wool are smelting furnaces that convert electrical energy into high-temperature heat to heat and melt the rock wool raw materials. For example... Figure 1 As shown, the furnace body is cylindrical. The furnace body includes a furnace bottom 1 and furnace walls 2. The furnace bottom 1 is nearly circular and is located at the bottom of the furnace body. The furnace walls 2 extend along the outer edge of the furnace bottom 1. Both the furnace bottom 1 and furnace walls 2 are relatively large in size to accommodate a large volume of rock wool raw material. Optionally, the furnace body's dimensions are: a radial dimension of 4.8 meters and a height of 3.4 meters.

[0052] Both the furnace bottom 1 and the furnace wall 2 are made of refractory materials. Alternatively, the furnace bottom 1 and the furnace wall 2 can be made of alloy steel.

[0053] like Figure 1 As shown, the furnace body also includes a water-cooled furnace roof 3. The water-cooled furnace roof 3 is located at the top of the furnace body. The top of the furnace wall 2 and the top of the third refractory lining structure 22 are both connected to the bottom of the water-cooled furnace roof 3. During the smelting of rock wool raw materials, the bottom of the furnace chamber contains molten rock wool slag, while the high-temperature gases generated inside the furnace chamber fill the top of the furnace body, i.e., the area where the water-cooled furnace roof 3 is located. The water-cooled furnace roof 3 can isolate the high-temperature gases generated inside the furnace chamber, providing excellent cooling and insulation performance.

[0054] like Figure 1 As shown, the water-cooled furnace top 3 is equipped with an operating window 311. Operators can observe the molten rock wool inside the furnace through the operating window 311 and facilitate maintenance of the equipment within the furnace. The furnace body also includes a furnace cover 4. During the smelting of rock wool raw materials, the furnace cover 4 is positioned over the operating window 311 to ensure a high-temperature, sealed environment within the furnace. When the furnace is not in use, the furnace cover 4 can be directly removed for maintenance of the equipment within the furnace.

[0055] In some embodiments, the furnace cover 4 is a preform. The preform can be a corundum precast component with embedded steel mesh and hooks in corundum material. The corundum precast component has better refractory and heat insulation properties and can adapt to the high temperature and high heat environment of the furnace.

[0056] The thickness of the corundum precast component can be 200-400mm. When the corundum precast component is placed over the operating window 311, it is slightly higher than the top surface of the water-cooled furnace top 3 to facilitate the user's disassembly and installation of the corundum precast component.

[0057] The furnace body also includes a high-speed centrifuge. Located inside the furnace chamber, the high-speed centrifuge agitates the molten rock wool, causing it to form inorganic fiber material. Specifically, the furnace cover 4 has electrode holes 41. The high-speed centrifuge is equipped with a drive motor and centrifugal components; the drive motor powers the centrifugal components. The output end of the drive motor passes through the electrode holes 41, extends into the furnace chamber, and connects to the centrifugal components.

[0058] It should be noted that the specific structures of the furnace bottom 1, furnace wall 2, and high-speed centrifugal equipment are all existing technologies and will not be elaborated here.

[0059] To ensure the furnace body is compatible with the high-temperature environment of smelting rock wool and improve its performance, the electric furnace for smelting rock wool according to this application is equipped with a refractory lining structure. The refractory lining structure has good thermal insulation properties, maintaining the high-temperature environment required for smelting rock wool within the furnace while also isolating the furnace bottom 1 and furnace wall 2 from the high temperatures inside the furnace. Furthermore, the refractory lining structure prevents the material inside the furnace from eroding and corroding the furnace bottom 1 and furnace wall 2, thus providing physical protection for them.

[0060] The refractory lining structure is installed on the furnace bottom 1 and the furnace wall 2, and covers all areas of the inner wall of the furnace bottom 1 and the inner wall of the furnace wall 2, so as to prevent the furnace body from being damaged by the high temperature of the rock wool melt in the furnace and improve the thermal insulation performance of the furnace body.

[0061] Specifically, the refractory lining structure includes a first refractory lining structure 11, a second refractory lining structure 21, and a third refractory lining structure 22. The first refractory lining structure 11 is fixed to the inner wall of the furnace bottom 1. The first refractory lining structure 11 is generally cylindrical in shape to cover the entire inner wall of the furnace bottom 1.

[0062] The furnace chamber includes a slag zone and a molten metal zone. During the smelting process, molten slag and iron slag in the furnace chamber sink to the furnace bottom 1 due to gravity. The bottom of the furnace bottom 1 and the bottom of the furnace wall 2 form the slag zone. The first refractory lining structure 11 is located at the bottom of the slag zone, and the second refractory lining structure 21 is located on the side of the slag zone. The molten metal zone is located above the slag zone. Molten rock wool is contained in the solution zone. The third refractory lining structure 22 is located on the furnace wall 2, corresponding to the position in the solution zone.

[0063] The first refractory lining structure 11, the second refractory lining structure 21, and the third refractory lining structure 22 are connected one-to-one according to their positions to ensure that all areas of the furnace bottom 1 and the furnace wall 2 are covered with refractory lining structures, thereby achieving heat insulation protection of the furnace body.

[0064] The first refractory lining structure 11, the second refractory lining structure 21, and the third refractory lining structure 22 are all multi-layered designs, with each substructure stacked on top of the others to ensure that the high temperature inside the furnace is reduced to a minimum before reaching the furnace bottom 1 or furnace wall 2. Furthermore, the number of layers and the types of materials used in the refractory lining structures vary in different parts of the furnace body. The selection of refractory insulation materials for each substructure is specifically designed based on the temperature and material erosion degree in the slag and molten metal zones, thus enabling the entire refractory lining structure to provide targeted refractory insulation protection for the furnace bottom 1 and furnace wall 2.

[0065] The top of the furnace wall 2 is provided with a feeding zone 23 and a discharging zone. The feeding zone 23 is located above the discharging zone.

[0066] The furnace is connected to the outside world through the feeding zone 23. The feeding zone 23 is used to feed rock wool raw materials into the furnace.

[0067] The area of ​​furnace wall 2 corresponding to the molten metal zone is equipped with a discharge zone. The discharge zone is connected to the furnace chamber. After the rock wool raw material is smelted, the molten rock wool is discharged from the discharge zone to the next process.

[0068] This invention provides an electric furnace for smelting rock wool. The furnace wall 2 extends circumferentially along the furnace bottom 1 to form a cylindrical furnace body. The furnace wall 2 has a feeding area 23 and a discharging area, both of which are connected to the furnace chamber. Rock wool raw material is fed into the furnace chamber from the feeding area 23 and discharged from the discharging area after smelting. A water-cooled furnace top 3 is located at the top of the furnace wall 2, effectively cooling the high-temperature hot air generated by the molten rock wool, thus achieving a cooling effect on the furnace body. Simultaneously, the inner wall of the furnace bottom 1 is provided with a first refractory lining structure 11, and the inner wall of the furnace wall 2 is provided with a second refractory lining structure 21. The bottom end of the second refractory lining structure 21 is connected to the first refractory lining structure 11. The outer edge of the lining structure 11 is connected, and the first refractory lining structure 11 and the second refractory lining structure 21 can effectively isolate the molten slag at the bottom of the furnace from the high temperature and corrosion of the furnace bottom 1 and the furnace wall 2, and maintain the high temperature environment inside the furnace; the top of the second refractory lining structure 21 and the bottom of the third refractory lining structure 22 are connected, and the second refractory lining structure 21 can effectively isolate the rock wool melt inside the furnace from the erosion and high temperature of the furnace wall 2, which is conducive to increasing the refractory performance of the electric furnace used for melting rock wool, so as to achieve continuous production in the long-term rock wool production process, improve the production operation rate of rock wool products, and meet the production needs of rock wool products.

[0069] In some embodiments, the water-cooled furnace top 3 includes a cold water pipe and a first casting body 31. The cold water pipe is embedded inside the first casting body 31. Figure 1 As shown, the first casting body 31 is cast onto the top of the second refractory lining structure 21.

[0070] Understandably, the cold water pipe is embedded in the first cast-in-place body. The first cast-in-place body 31 also includes steel fiber reinforced silicon carbide castable and multiple first anchors 32. The multiple first anchors 32 are arranged at designed intervals. During furnace construction, the top of the second refractory lining structure 21 is first supported by formwork, then the multiple first anchors 32 and the cold water pipe are welded together, and then the steel fiber reinforced silicon carbide castable is poured onto the formwork. Optionally, the first anchors 32 can be aluminum alloy Y-type anchors.

[0071] During the welding of the first anchor 32 and the cold water pipe, the first anchor 32 is pre-positioned within the first casting body 31 and near its outer side to avoid obstructing the cold water pipe. The cold water pipe is pre-positioned within the first casting body and near its inner side. Specifically, the cold water pipe has sufficient length to coil around within the first casting body and near its inner side.

[0072] After the steel fiber silicon carbide castable has cured, a solidified first casting body is formed. The thickness of the first casting body 31 can be set to 70-200mm. The first casting body is cast together with the second refractory lining structure 21 to ensure the integrity of the furnace body.

[0073] During the smelting process of rock wool raw materials, cold water is introduced into the cooling water pipes, thereby enabling the water-cooled furnace top 3 to cool the high-temperature gas inside the furnace, achieving physical cooling of the furnace body and ensuring its performance. Simultaneously, the steel fiber-reinforced silicon carbide castable used in the first casting also possesses excellent thermal insulation properties.

[0074] Specifically, such as Figure 1 As shown, in some embodiments, the first refractory lining structure 11 includes a first heat insulation layer 111, a first protective layer 112, a first refractory layer 113, and a second protective layer 114. The first heat insulation layer 111, the first protective layer 112, the first refractory layer 113, and the second protective layer 114 are stacked sequentially in the direction facing the furnace.

[0075] The first heat insulation layer 111 is connected to the inner wall of the furnace bottom 1, and the second protective layer 114 is used to contact the molten slag at the bottom of the furnace.

[0076] Understandably, such as Figure 1As shown, the first insulation layer 111, the first protective layer 112, the first refractory layer 113, and the second protective layer 114 are arranged in a stacked manner from the outside to the inside. The two adjacent substructure layers are tightly bonded together, and the high temperature in the furnace is absorbed layer by layer by the first refractory lining structure 11 from the inside to the outside, so as to ensure the heat insulation effect of the second refractory lining structure 21 on the furnace bottom 1 and the furnace wall 2.

[0077] Specifically, the first heat insulation layer 111 is located on the outermost layer of the first refractory lining structure 11. One side of the first heat insulation layer 111 is fitted to the inner wall of the furnace bottom 1, and the other side of the first heat insulation layer 111 is tightly fitted to the first protective layer 112.

[0078] The first insulation layer 111 comprises multiple sub-insulation layers. The side of the first insulation layer 111 away from the inner wall of the furnace bottom 1 is stepped. Optionally, such as... Figure 1 As shown, the number of sub-insulation layers in the middle region of the first insulation layer 111 is set to three, the number of sub-insulation layers in the side region of the first insulation layer 111 is set to four, and the number of sub-insulation layers in the outermost edge of the first insulation layer 111 is set to five.

[0079] Optionally, the total thickness of the first insulation layer 111 is 260–325 mm. Of course, the user can adapt the thickness of the first insulation layer 111 according to the actual specifications of the furnace body, and the present invention does not make a specific limitation in this regard.

[0080] In some embodiments, each sub-insulation layer is primarily composed of a clay brick layer. Clay bricks are made primarily from clay, shale, and coal gangue powders, through processes such as mud treatment, molding, drying, and firing. Clay bricks have a thermal conductivity of less than 0.6 W / (m·K), good fire resistance, and are inexpensive. During construction, the clay bricks are laid together layer by layer from the outside to the inside using a staggered dry masonry method.

[0081] Specifically, the first protective layer 112 is disposed on the side of the first insulation layer 111 away from the inner wall of the furnace bottom 1. The first refractory layer 113 is disposed on top of the first protective layer 112. The first refractory layer 113 is the most important load-bearing and refractory structural layer in the first refractory lining structure 11.

[0082] Optionally, the first refractory layer 113 is mainly composed of magnesia bricks. During construction, dry masonry is used, stacking multiple magnesia bricks together. Optionally, the thickness of the first refractory layer 113 is 250–600 mm.

[0083] In some embodiments, such as Figure 2As shown, the magnesia brick is a straight spherical bottom brick 1131 made of magnesia. The straight spherical bottom brick 1131 of magnesia is shaped like a trapezoidal truncated pyramid, narrow at the top and wide at the bottom. During construction, the narrower part of the straight spherical bottom brick 1131 of magnesia faces towards the inside of the furnace, and the wider part faces towards the outside of the furnace bottom 1. Thus, the first refractory layer 113 forms a structural layer that is light on top and heavy on the bottom, which can effectively resist the floating effect of molten metal in the furnace.

[0084] To adapt to the shape of the furnace bottom 1, when constructing the first refractory layer 113, as follows: Figure 3 As shown, a ring of circular, straight-bottomed spherical bricks 1131 is constructed along the outer edge of the first refractory layer 113. The narrower and wider ends of the straight-bottomed spherical bricks 1131 located along the outer edge of the first refractory layer 113 are on the same horizontal line. The narrower end of the straight-bottomed spherical brick 1131 is located on the inner side, and the wider end is located on the outer side. In the middle section of the first refractory layer 113, the straight-bottomed spherical bricks 1131 are arranged vertically, with the upper part of the masonry narrower than the lower part to effectively resist the floating effect of molten metal within the furnace.

[0085] The first protective layer 112 is disposed between the first insulation layer 111 and the first refractory layer 113. Optionally, the first protective layer 112 is an aluminum silicon carbide carbon dry ramming mix layer. Aluminum silicon carbide carbon dry ramming mix has good refractory properties. The aluminum silicon carbide carbon dry ramming mix has a certain thickness and is filled between magnesia bricks and clay bricks. On the one hand, it can buffer the first insulation layer 111 and the first refractory layer 113; on the other hand, it can improve the overall connection between the first insulation layer 111 and the first refractory layer 113. Optionally, the thickness of the first protective layer 112 is 100–150 mm.

[0086] During construction, the first protective layer 112 is compacted layer by layer using a progressive compaction method, with each layer of aluminum silicon carbide dry ramming mix compacted sequentially. The thickness of each layer of aluminum silicon carbide dry ramming mix does not exceed 50mm, thus ensuring the density of the first protective layer 112. During the progressive compaction process, the surfaces between adjacent layers of aluminum silicon carbide dry ramming mix need to be roughened to ensure good adhesion between them.

[0087] Furthermore, such as Figure 1 As shown, a second protective layer 114 is provided on top of the first refractory layer 113. The second protective layer 114 is used to withstand the impact and corrosion of the molten slag at the bottom of the furnace 1, and to level the first refractory layer 113, thereby improving the overall strength of the first refractory layer 113.

[0088] Optionally, the second protective layer 114 is primarily a magnesium-calcium ramming mix layer. The thickness of the second protective layer 114 is 80–200 mm.

[0089] During construction, the second protective layer 114 is compacted layer by layer using a progressive compaction method, with each layer of magnesium-calcium ramming material being compacted sequentially. The thickness of each layer of magnesium-calcium ramming material does not exceed 50mm to ensure the density of the second protective layer 114. During the progressive compaction process, the surfaces between adjacent layers of magnesium-calcium ramming material need to be roughened to ensure good adhesion between them.

[0090] Specifically, in some embodiments, the second refractory lining structure 21 includes a buffer layer 211, a second heat insulation layer 212, and a second refractory layer 213. The buffer layer 211, the second heat insulation layer 212, and the second refractory layer 213 are stacked sequentially in the direction of the furnace.

[0091] The buffer layer 211 is connected to the furnace wall 2. The second refractory layer 213 is used to contact the molten slag inside the furnace.

[0092] Understandably, the second refractory lining structure 21 is located in the slag zone of the furnace body. The second refractory layer 213 is the most important load-bearing and refractory structural layer in the second refractory lining structure 21. The second refractory layer 213 is located on the innermost side of the second refractory lining structure 21 and directly bears the impact and corrosion of the molten slag in the furnace.

[0093] Optionally, the thickness of the second refractory layer 213 is 250–600 mm. The second refractory layer 213 is primarily composed of magnesia-chrome bricks. The magnesia-chrome bricks are constructed using a circumferential staggered wet-laying method. This invention does not specify the number of magnesia-chrome brick layers.

[0094] The second refractory lining structure 21 also includes a second insulation layer 212. The second insulation layer 212 is disposed on the side of the second refractory layer 213 away from the furnace. The second refractory layer 213 bears most of the heat, and the remaining heat is transferred to the second insulation layer 212, thus forming effective insulation for the furnace wall 2 through the second insulation layer 212.

[0095] Optionally, the thickness of the second insulation layer 212 is 65–390 mm. The material of the second insulation layer 212 can be the same as that of the first insulation layer 111. The number of sub-insulation layers in the second insulation layer 212 can be adjusted adaptively according to actual conditions. The construction method of the second insulation layer 212 can refer to the first insulation layer 111 described above, and will not be repeated here.

[0096] Understandably, to accommodate the temperature and other characteristics of the slag and molten iron in the slag zone, the second refractory layer 213 is designed as a magnesia-chrome brick layer. Magnesia-chrome bricks have a large coefficient of thermal expansion. When the magnesia-chrome bricks expand due to heat, they will push the second insulation layer 212 to impact the furnace wall 2. To accommodate the expansion volume of the magnesia-chrome bricks, the second refractory lining structure 21 also includes a buffer layer 211. The buffer layer 211 is filled between the furnace wall 2 and the second insulation layer 212 to buffer the impact on the furnace wall 2 caused by the thermal expansion of the second refractory layer 213.

[0097] Optionally, the buffer layer 211 is primarily a carbon ramming mix layer. The compressibility of the carbon ramming mix can be as high as 5-8%, exhibiting excellent stretchable cushioning performance. Optionally, the thickness of the buffer layer 211 is 50-200 mm. The thickness of the buffer layer 211 can be adaptively adjusted according to the actual expansion of the second refractory layer 213; this invention does not impose a specific limitation on this.

[0098] It should be noted that the second refractory layer 213 and the second insulation layer 212 are constructed by staggered joints to ensure the overall connectivity and overall strength of the entire second refractory lining structure 21.

[0099] In some embodiments, such as Figure 1 As shown, the second refractory lining structure 21 has a slag discharge area 214. The slag discharge area 214 is located at the bottom of the second refractory lining structure 21 and passes through the second refractory layer 213, the second heat insulation layer 212 and the buffer layer 211 in sequence.

[0100] The slag discharge zone 214 is constructed of multiple composite bricks. The slag discharge zone 214 is equipped with a first channel 21401, which runs through the slag discharge zone 214.

[0101] The composite brick includes a base brick 2141 and a core brick 2142. The base brick 2141 has a through hole 21411, and the core brick 2142 is embedded in the through hole 21411.

[0102] Understandably, slag removal zone 214 is used to remove molten iron, slag, and other slag from the furnace. Specifically, such as... Figure 1 As shown, the slag discharge zone 214 is located at the bottom of the second refractory lining structure 21.

[0103] Specifically, the slag discharge zone 214 is provided with a first channel 21401. The first channel 21401 passes through the second refractory layer 213, the second insulation layer 212, and the buffer layer 211 in sequence. Correspondingly, the bottom of the furnace wall 2 is provided with a slag discharge port. The slag discharge port is connected to the furnace through the first channel 21401.

[0104] During the smelting process, the first channel 21401 is sealed with a sealing component. After smelting is completed, the sealing component is removed from the first channel 21401, and the molten slag passes through the first channel 21401 and is discharged to the outside through the slag outlet.

[0105] It is understandable that the borehole wall of the first channel 21401 will be subjected to a large impact force during the discharge of molten slag, making it prone to damage. Therefore, the slag discharge zone 214 is constructed by combining seat bricks 2141 and core bricks 2142 to improve the impact resistance of the borehole wall of the first channel 21401.

[0106] Specifically, such as Figure 4 As shown, the base brick 2141 is a square brick with a through hole 21411 in the center. (As...) Figure 5 As shown, the core brick 2142 is cylindrical and its size is matched with that of the through hole 21411.

[0107] During the construction process, perforations are reserved in the slag removal area 214 to form the first channel 21401. The seat brick 2141 can provide physical protection for the core brick 2142 and buffer the impact of the molten slag.

[0108] like Figure 6 As shown, the base brick 2141 and the core brick 2142 are detachably connected. When the core brick 2142 is damaged, the damaged core brick 2142 can be punched out from the through hole 21411, and a new core brick 2142 can be inserted into the through hole 21411.

[0109] The materials of the seat brick 2141 and the core brick 2142 can be the same as the material of the second refractory layer 213. Optionally, the materials of the seat brick 2141 and the core brick 2142 are both magnesia-chrome.

[0110] Specifically, in some embodiments, such as Figure 1 As shown, the third refractory lining structure 22 includes a third heat insulation layer 221 and a third refractory layer 222.

[0111] One side of the third insulation layer 221 is connected to the inner wall of the furnace wall 2, and the other side is connected to the third refractory layer 222.

[0112] The third refractory layer 222 is used to contact the rock wool solution inside the furnace chamber of the furnace body.

[0113] The material of the third insulation layer 221 includes clay bricks. The material of the third refractory layer 222 includes high-alumina bricks.

[0114] Understandably, the third refractory lining structure 22 is located in the molten zone. Specifically, the third refractory layer 222 is the most important load-bearing and refractory structural layer in the third refractory lining structure 22. The third refractory layer 222 is located on the innermost side of the third refractory lining structure 22, directly bearing the impact and corrosion of the molten rock wool in the furnace. Among them, the third insulation layer 221 is set on the side of the third refractory layer 222 away from the furnace, and is used to insulate the furnace wall 2.

[0115] Optionally, the third refractory layer 222 is a high-alumina brick layer. High-alumina bricks can withstand the temperature of the solution zone. The thickness of the third refractory layer 222 is 250–400 mm. The high-alumina bricks are constructed using a circumferential staggered wet-laying method. This invention does not specifically limit the number of high-alumina brick layers or their thickness.

[0116] The third refractory lining structure 22 also includes a third insulation layer 221. The third insulation layer 221 is disposed on the side of the third refractory layer 222 away from the furnace. The third refractory layer 222 bears most of the heat, and the remaining heat is transferred to the third insulation layer 221, thus forming effective insulation for the furnace wall 2 through the third insulation layer 221.

[0117] Optionally, the thickness of the third insulation layer 221 is 65–390 mm. The material of the third insulation layer 221 can be the same as that of the first insulation layer 111. The number of sub-insulation layers in the third insulation layer 221 can be adjusted adaptively according to actual conditions. The construction method of the third insulation layer 221 can refer to the first insulation layer 111 described above, and will not be repeated here.

[0118] It should be noted that the third refractory layer 222 and the third insulation layer 221 are constructed using a staggered joint method to ensure the overall connectivity and overall strength of the entire third refractory lining structure 22.

[0119] In some embodiments, the third refractory lining structure 22 is provided with a second channel, which passes through the third refractory layer 222 and the third heat insulation layer 221 in sequence, and the discharge area is connected to the furnace chamber of the furnace body through the second channel.

[0120] Understandably, the second channel is located within the third refractory lining structure 22. The second channel is used to drain the molten rock wool from the furnace.

[0121] Specifically, the second channel passes through the third refractory layer 222 and the third insulation layer 221 in sequence. Correspondingly, the discharge zone is located in the solution zone of the furnace wall 2. The discharge zone is connected to the furnace chamber through the second channel.

[0122] During the smelting process, the second channel is sealed. After smelting is complete, the second channel is opened, and the molten rock wool is discharged from the discharge area to the outside through the second channel.

[0123] In some embodiments, such as Figure 1 As shown, the feeding zone 23 is provided with a fourth heat insulation layer 231 and a second casting body 232. The fourth heat insulation layer 231 is connected to the top of the furnace wall 2, and the second casting body is cast on the top of the second refractory lining structure 21.

[0124] The fourth heat insulation layer 231 is stacked with the second casting body 232, and the fourth heat insulation layer 231 is located on the outside of the second casting body 232.

[0125] The fourth insulation layer 231 includes a clay brick layer. The material of the second casting body 232 includes an aluminum silicon carbide carbon castable layer.

[0126] Understandably, the feeding zone 23 includes a fourth insulation layer 231 and a second casting body 232. The second casting body 232 and the fourth insulation layer 231 are stacked. The fourth insulation layer 231 is located on the outer side of the feeding zone 23 and connected to the top of the furnace wall 2. The second casting body 232 is located on the inner side of the feeding zone 23 and connected to the top of the second refractory lining structure 21. The second casting body 232 is used to directly receive the rock wool raw material that is about to enter the furnace.

[0127] The second casting body 232 also includes aluminum silicon carbide carbon castable and multiple second anchors 2321. The multiple second anchors 2321 are disposed between the second casting body and the fourth insulation layer 231 to increase the connection stability between the second anchors 2321 and the second casting body. The multiple second anchors 2321 are arranged at designed intervals.

[0128] During furnace construction, the fourth insulation layer 231 is first laid, and a portion of each of the multiple second anchors 2321 is embedded within the fourth insulation layer 231. Then, formwork is erected on top of the second refractory lining structure 21, with the remaining portion of the multiple second anchors 2321 housed within the area enclosed by the formwork. Next, aluminum silicon carbide castable is poured onto the formwork. Optionally, the second anchors 2321 can be aluminum alloy Y-type anchors.

[0129] After the aluminum silicon carbide carbon castable has cured, a solidified second casting body is formed. The thickness of the second casting body 232 can be set to 200mm. The second casting body is cast together with the top of the second refractory lining structure 21 to ensure the integrity of the furnace body.

[0130] Optionally, the thickness of the fourth insulation layer 231 is 65mm. The fourth insulation layer 231 is used for thermal insulation against the external environment. The specific structure and materials of the fourth insulation layer 231 can be the same as those of the first insulation layer 111. The number of sub-insulation layers in the fourth insulation layer 231 can be adjusted adaptively according to actual conditions. The construction method of the fourth insulation layer 231 can refer to the first insulation layer 111 described above, and will not be repeated here.

[0131] During construction, the first insulation layer 111, the first protective layer 112, the first refractory layer 113, and the second protective layer 114 are constructed layer by layer from the outside to the inside. Then, the seat bricks 2141 in the slag discharge area 214 are constructed, and the core bricks 2142 are constructed into the through holes 21411 of the seat bricks 2141. After the slag discharge area 214 is constructed, the second insulation layer 212 and the second refractory layer 213 are constructed in sequence. Then, the inner wall of the furnace wall 2 and the second insulation layer 212 are filled with a compacted buffer layer 211. Next, the third insulation layer 221 and the third refractory layer 222 are constructed layer by layer from the outside to the inside. Then, the fourth insulation layer 231 of the feeding area 23 is constructed. Then, the second casting body of the feeding area 23 is constructed by formwork on the top of the furnace wall 2 and the third refractory lining structure 22. Finally, the water-cooled furnace top 3 is constructed by formwork.

[0132] The electric furnace for smelting rock wool provided by this invention rationally selects the materials for the first refractory lining structure 11, the second refractory lining structure 21, the third refractory lining structure 22, and the water-cooled furnace top 3 based on the different temperatures experienced by various areas on the furnace bottom 1 and the furnace wall 2. Furthermore, the structural layout of the first refractory lining structure 11, the second refractory lining structure 21, the third refractory lining structure 22, and the water-cooled furnace top 3 is improved to enhance the refractory performance of the electric furnace, thereby ensuring its long-term operation and increasing the production efficiency of rock wool.

[0133] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An electric furnace for melting rock wool, characterized in that, include: Furnace body; The furnace body includes a furnace bottom, a furnace wall, and a water-cooled furnace top; the furnace wall extends circumferentially along the furnace bottom, and the water-cooled furnace top is disposed on the furnace wall to form a furnace chamber between the furnace bottom, the furnace wall, and the water-cooled furnace top. The inner wall of the furnace bottom is provided with a first refractory lining structure, and the inner wall of the furnace wall is provided with a second refractory lining structure and a third refractory lining structure. The bottom end of the second refractory lining structure is connected to the outer edge of the first refractory lining structure; the top end of the second refractory lining structure is connected to the bottom end of the third refractory lining structure. The furnace wall is provided with a feeding area and a discharging area, both of which are connected to the furnace chamber; the feeding area is located above the discharging area. The first refractory lining structure includes a first heat insulation layer, a first protective layer, a first refractory layer, and a second protective layer; the first heat insulation layer, the first protective layer, the first refractory layer, and the second protective layer are sequentially stacked facing the furnace; the first heat insulation layer is connected to the inner wall of the furnace bottom, and the second protective layer is used to contact the molten slag at the bottom of the furnace; the first heat insulation layer includes a clay brick layer; the first protective layer includes an aluminum silicon carbide carbon dry ramming mix layer; the first refractory layer includes a magnesia brick layer; and the second protective layer includes a magnesia-calcium ramming mix layer. The second refractory lining structure includes a buffer layer, a second heat insulation layer, and a second refractory layer; the buffer layer, the second heat insulation layer, and the second refractory layer are stacked sequentially towards the furnace; the buffer layer is connected to the furnace wall; the second refractory layer is used to contact the molten slag in the furnace; the buffer layer includes a carbon ramming mix layer; the second heat insulation layer includes a clay brick layer; the second refractory layer includes a magnesia-chrome brick layer; the second refractory lining structure has a slag discharge area, which is located at the bottom of the second refractory lining structure and sequentially penetrates the second refractory layer, the second heat insulation layer, and the buffer layer; the slag discharge area is constructed of multiple composite bricks; the slag discharge area has a first channel that penetrates the slag discharge area; wherein, the composite brick includes a base brick and a core brick; the base brick has a through hole, and the core brick is embedded in the through hole.

2. The electric furnace for smelting rock wool according to claim 1, characterized in that, The water-cooled furnace top includes a cold water pipe and a first casting body; the cold water pipe is embedded inside the first casting body; the first casting body is cast on the top of the second refractory lining structure.

3. An electric furnace for smelting rock wool according to claim 1, characterized in that, The third refractory lining structure includes a third heat insulation layer and a third refractory layer; One side of the third insulation layer is connected to the inner wall of the furnace wall, and the other side is connected to the third refractory layer; The third refractory layer is used to contact the rock wool solution inside the furnace chamber of the furnace body; The third heat insulation layer includes a clay brick layer; the third refractory layer includes a high-alumina brick layer.

4. An electric furnace for smelting rock wool according to claim 3, characterized in that, The third refractory lining structure is provided with a second channel, which passes through the third refractory layer and the third heat insulation layer in sequence. The discharge area is connected to the furnace chamber of the furnace body through the second channel.

5. An electric furnace for smelting rock wool according to claim 1, characterized in that, The feeding area is provided with a fourth heat insulation layer and a second casting body; the fourth heat insulation layer is connected to the top of the furnace wall, and the second casting body is cast on the top of the second refractory lining structure; The fourth heat insulation layer is stacked with the second casting body, and the fourth heat insulation layer is located on the outside of the second casting body; The fourth heat insulation layer includes a clay brick layer; the second casting body includes an aluminum silicon carbide carbon casting material layer.

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