A super large 1600t / d photovoltaic glass one-kiln five-line furnace

Abstract

This invention relates to the field of glass production technology, specifically to an ultra-large 1600t / d photovoltaic glass furnace with five production lines, comprising a furnace body, a regenerator, a bottleneck, and a conveying passage. The regenerator is located on both sides of the furnace body, and the furnace body, bottleneck, and conveying passage are connected sequentially. The conveying passage includes a horizontal passage and branch passages. The horizontal passage has a width of 3.5–4.5m, a length of 50–55m, and a depth of 1.2–1.4m. The horizontal passage intersects the furnace centerline perpendicularly, with one side connected to the furnace body and the other side perpendicularly connected to five branch passages. The beneficial effects of this invention are: because the outlet end of the melting furnace is equipped with a horizontal passage and five branch passages, it can achieve multi-line diversion of molten glass. This multi-branch passage configuration can increase glass production, match existing large-tonnage furnaces, and promptly transport the molten glass to the forming equipment for processing.

Description

Technical Field

[0001] This invention relates to the field of glass production technology, specifically to an ultra-large 1600t / d photovoltaic glass kiln with one furnace and five production lines. Background Technology

[0002] Photovoltaic glass and float glass are collectively referred to as flat glass. Made from low-iron glass raw materials and ultra-clear glass formulations, and produced using a rolling mill process, this type of ultra-clear patterned glass typically ranges in thickness from 2mm to 3.2mm. When this ultra-clear patterned glass is applied to the solar power generation field, it is commonly called photovoltaic glass, also known as ultra-clear rolled solar photovoltaic glass, or simply ultra-clear rolled glass, solar photovoltaic power generation glass, etc. For ease of explanation, it will be referred to as photovoltaic glass below.

[0003] Photovoltaic glass is a component of solar cell modules. To protect solar cells from direct exposure to natural conditions such as sunlight, rain, and snow, they are typically encapsulated to form a module. With the continuous development of bifacial solar cells, to ensure the power generation of bifacial solar cells, the backsheet used on the back of the module is replaced with photovoltaic glass, forming a double-glass module consisting of front glass, front EVA, bifacial solar cells, back EVA, and backsheet glass.

[0004] In China, with the rapid advancement of science and technology and the flourishing of technological innovation, flat glass furnaces have also made leaps and bounds in development and progress. Float glass production has evolved from the first generation of single-line furnaces with horseshoe flames and vertical flames of tens or hundreds of tons per day to single-line furnaces with two or even three lines per day, capable of melting over 1,000 tons per day. Simultaneously, precise control and stable production and operation of single-line furnaces with a capacity of over 1,200 tons per day have been achieved, realizing numerous advantages of scale, including stable production, high quality, high yield, low energy consumption, and high labor efficiency.

[0005] In the existing technology, ultra-large ultra-white rolled photovoltaic glass furnaces with a daily melting capacity of thousands of tons have generally been developed to more than 1200t / d, and there are many patented technical solutions, such as: CN112299684 B; CN201301274 Y; CN208747914 U; CN110526553 A; CN201901633 U; CN207347383 U; CN102234172 A; CN111233305 A; US 4389725 A, etc.

[0006] According to publicly available data and a review of the photovoltaic glass industry, as of November 2023, 36 domestic photovoltaic glass companies owned a total of 27 photovoltaic glass kilns, with 453 photovoltaic glass production lines in operation and a total production capacity of 90,730 tons per day.

[0007] Publicly available data shows that among the 127 kilns in operation, there is 1 with a capacity of 1250 t / d, 27 with a capacity of 1200 t / d, 22 with a capacity of 1000 t / d, 5 with a capacity of 900 t / d, 2 with a capacity of 850 t / d, and 5 with a capacity of 800 t / d. Currently, there is no information or data reported domestically or internationally regarding kilns with a capacity greater than 1250 t / d.

[0008] Of the 127 photovoltaic glass kilns, there is one kiln with eight production lines, nine kilns with six production lines, 30 kilns with five production lines, 36 kilns with four production lines, two kilns with three production lines, 22 kilns with two production lines, and nine kilns with one production line.

[0009] Of the 127 photovoltaic glass furnaces, the maximum daily melting capacity of one furnace with eight production lines is 1200 t / d; the daily melting capacity of one furnace with six production lines is between 1200 and 1250 t / d; the daily melting capacity of one furnace with five production lines is between 650 and 1200 t / d; the daily melting capacity of one furnace with four production lines is between 500 and 1200 t / d; the daily melting capacity of one furnace with three production lines is between 550 and 650 t / d; and the daily melting capacity of one furnace with two production lines is between 150 and 350 t / d.

[0010] Based on publicly available information, statistical calculations and analyses of photovoltaic glass furnaces yielded the following seven results:

[0011] 1. The kiln tonnage range of one kiln and one line is 120-200t / d. Based on the maximum tonnage of 200t / d, the maximum load of a unit branch line is 200t / d.

[0012] 2. The kiln tonnage range of the two lines of the kiln is 150 to 350 t / d. Based on the maximum tonnage of 350 t / d, the maximum load per branch line of the two lines of the kiln is 175 t / d.

[0013] 3. There are two kilns with capacities of 550t / d and 650t / d in the three-line kiln system. Based on the maximum capacity of 650t / d, the maximum load per branch line of the three-line kiln system is 216t / d.

[0014] 4. The kiln tonnage range of one kiln with four production lines is 500-1200t / d. Based on the maximum tonnage of 1200t / d, the maximum load per branch line of one kiln with four production lines is 300t / d.

[0015] 5. The kiln tonnage range of one kiln with five production lines is 650-1200t / d. Based on the maximum tonnage of 1200t / d, the maximum load per branch line of one kiln with five production lines is 240t / d.

[0016] 6. There are two kilns with a capacity of 1200t / d and one kiln with a capacity of 1250t / d in China. Based on the maximum tonnage of 1250t / d, the maximum load per branch line of the kiln with a capacity of 1200t / d is 200t / d.

[0017] 7. There is one 1200t / d kiln in China with a kiln line of eight. The unit branch line load of the kiln line of eight is even lower: 150t / d.

[0018] The above statistics show that the overall situation of domestic photovoltaic glass enterprises is characterized by "numerous but not large, large but not strong, and strong but not refined." Specifically: First, of the 127 kilns and 453 photovoltaic glass raw material production lines, only 35 kilns have a capacity greater than 800t / d, accounting for 27.56%, while 92 kilns have a capacity less than 800t / d, accounting for 72.44%. The overall small tonnage results in low kiln thermal efficiency, high energy consumption per unit product, and low labor efficiency and economies of scale. In general, this presents an industry situation of "numerous but small." Second, among the 127 kilns, the largest capacity is in the range of 1000t / d to 1250t / d. Although kiln technology innovation and progress have been rapid, and kiln tonnage has seen accelerated development and leaps, the tonnage is still relatively small, and the capacity load per branch line remains low. In general, this presents an industry situation of "large but not strong." Third, among the 127 photovoltaic glass furnaces, although there are 64 furnaces with a capacity greater than 800 t / d, 22 with a capacity of 1000 t / d, 27 with a capacity of 1200 t / d, and even one furnace with a capacity of 1250 t / d, the extra-large furnaces with a capacity greater than 1200 t / d only account for 37.09%. The unit branch load still hovers in the range of 150-200 t / d, which is significantly low, indicating a problem of "powerful but not precise".

[0019] In the current technology, due to factors such as investment barriers and technical barriers, the tonnage of photovoltaic glass furnaces is basically below 1250t / d, the number of small furnaces in the furnace design does not exceed 9 pairs, and the yield rate hovers in the range of 84% to 87%.

[0020] In existing technologies, the width of photovoltaic glass raw sheets is generally around 2803–3675 mm, as shown in Tables 1 and 2. Relatively speaking, these are all considered narrow sheets. A current problem with existing technologies is the low yield rate. In reality, the yield rate of photovoltaic glass production lines in China is generally in the range of 84–87%, which is significantly lower than the overall yield rate of approximately 94.00%–97.50% for a single-line or two-line float glass furnace of the same size. This difference lies in the fact that the raw sheet width of the aforementioned float glass production lines of the same size is larger than that of photovoltaic glass furnaces of the same size, resulting in less edge loss, higher yield and cutting rate, and thus a higher yield. Therefore, existing photovoltaic glass furnaces still have significant untapped potential and considerable room for improvement in yield rate.

[0021] In response to the narrow plate problem in existing photovoltaic glass technology, technological iteration, in addition to developing towards larger kilns, also needs to improve the scale efficiency and lower unit consumption of the new generation of ultra-large kilns by increasing the unit branch load, width of the plate, and overall yield, so as to achieve the development goal of "high quality, high output and low consumption".

[0022] Therefore, for an ultra-large 1600t / d photovoltaic glass furnace, to further improve thermal efficiency and reduce production costs, an important technological approach is to increase the yield rate, given the limited potential for increasing melting capacity. This becomes crucial for increasing production capacity, reducing costs, improving labor efficiency, lowering overall energy consumption per unit product, and achieving energy conservation and carbon reduction. Leveraging decades of experience in glass production, the technical team of Xinfuxing Glass Industry Group has creatively optimized the design of two ultra-large photovoltaic glass furnaces with a daily melting capacity of 1600t / d, operating on a single furnace and five production lines. The aim is to utilize wide-plate production technology to further achieve significant technological advancements, including increasing drawing capacity, improving yield rate, enhancing thermal efficiency, reducing unit energy consumption, lowering manufacturing costs, improving energy efficiency, and reducing emissions and carbon emissions.

[0023] Table 1: List of Original Plate Width Dimensions for Kiln A Production Line (Unit: mm)

[0024]

[0025] Table 2: List of Original Plate Width Dimensions for Kiln B Production Line (Unit: mm)

[0026] Summary of the Invention

[0027] The technical problem to be solved by the present invention is to provide an ultra-large 1600t / d photovoltaic glass kiln with one furnace and five production lines.

[0028] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: to provide an ultra-large 1600t / d photovoltaic glass kiln with one furnace and five production lines, including the kiln body, heat storage chamber, bottleneck and conveying passage;

[0029] The heat storage chamber is located on both sides of the kiln body, and the kiln body, the neck, and the conveying passage are connected in sequence.

[0030] The conveying path includes a horizontal path and branch paths. The horizontal path is 3.5-4.5m wide, 50-55m long, and 1.2-1.4m deep. The horizontal path intersects the center line of the kiln perpendicularly. One side of the horizontal path is connected to the kiln body, and the other side is perpendicularly connected to 5 branch paths.

[0031] The kiln body is 65-75m long, 13-15.5m wide, and 1.2-1.8m deep;

[0032] The width of the transverse passage is 3.5–4.5 m, the length is 50–55 m, and the depth is 1.2–1.4 m;

[0033] The five branch paths are labeled CY1, CY2, CY3, CY4 and CY5 respectively.

[0034] The branch passageway slab is 4.05–5.4m wide and 1.2–1.4m deep;

[0035] The positions of CY1 and CY5 are symmetrically arranged, with the same length, width and depth, the length being 4 to 4.5m, the width being 4.05 to 5.4m and the depth being 1.2 to 1.4m;

[0036] The positions of CY2 and CY4 are symmetrically arranged, with the same length, width and depth, ranging from 10.2 to 13.5m in length, 4.05 to 5.4m in width and 1.2 to 1.4m in depth;

[0037] The CY3 is centrally located, with a length of 20–22 m, a width of 4.05–5.4 m, and a depth of 1.2–1.4 m.

[0038] The beneficial effects of this invention are as follows: In the ultra-large 1600t / d photovoltaic glass furnace with one kiln and five lines provided by this invention, the low-iron glass batch is melted into molten glass in the melting section of the furnace body. After clarification, it enters the conveying passage. Since the outlet end of the melting furnace is equipped with a horizontal passage and five branch passages, it can realize multi-line diversion of molten glass. This multi-branch passage setting method can increase glass production, match existing large-tonnage furnaces, and transport the molten glass from the furnace to the forming equipment for processing in a timely manner. Attached Figure Description

[0039] Figure 1This is a schematic diagram of the overall structure of a super-large 1600t / d photovoltaic glass kiln with five production lines, according to a specific embodiment of the present invention.

[0040] Figure 2 This is a schematic diagram of the glass rolling section of a five-line, one-furnace photovoltaic glass furnace with an ultra-large 1600t / d capacity, according to a specific embodiment of the present invention.

[0041] Label Explanation:

[0042] 1. Kiln body;

[0043] 2. Regenerator; 21. 10 pairs of small furnaces; 22. No. 0 small furnace;

[0044] 3. Neck jamming; 31. Neck jamming large water bag; 32. Horizontal mixer

[0045] 4. Conveying pathway; 41. Cross pathway; 42. Branch pathway;

[0046] 5. Wide-lip brick with large overflow outlet; 6. Lower roll of calender; 7. Upper roll of calender; 8. Receiving roll; 9. Molten glass. Detailed Implementation

[0047] To explain in detail the technical content, objectives, and effects of the present invention, the following description is provided in conjunction with the embodiments and accompanying drawings.

[0048] Please see Figure 1 The present invention provides an ultra-large 1600t / d photovoltaic glass kiln with one furnace and five production lines, including a kiln body 1, a heat storage chamber 2, a bottleneck 3 and a conveying passage 4; the heat storage chamber 2 is arranged on both sides of the kiln body 1, and the kiln body 1, the bottleneck and the conveying passage 4 are connected in sequence.

[0049] The conveying passage 4 includes a horizontal passage 41 and branch passages 42. The horizontal passage 41 has a width of 3.5 to 4.5 m, a length of 50 to 55 m, and a depth of 1.2 to 1.4 m. The horizontal passage 41 intersects the center line of the kiln perpendicularly. One side of the horizontal passage 41 is connected to the kiln body 1, and the other side is perpendicularly connected to 5 branch passages 42.

[0050] The kiln body 1 is 65-75m long, 13-15.5m wide, and 1.2-1.8m deep;

[0051] The transverse passage 41 has a width of 3.5–4.5 m, a length of 50–55 m, and a depth of 1.2–1.4 m;

[0052] The five branch paths 42 are labeled CY1, CY2, CY3, CY4 and CY5 respectively.

[0053] The branch passage 42 has a width of 4.05–5.4 m and a depth of 1.2–1.4 m;

[0054] The positions of CY1 and CY5 are symmetrically arranged, with the same length, width and depth, the length being 4 to 4.5m, the width being 4.05 to 5.4m and the depth being 1.2 to 1.4m;

[0055] The positions of CY2 and CY4 are symmetrically arranged, with the same length, width and depth, ranging from 10.2 to 13.5m in length, 4.05 to 5.4m in width and 1.2 to 1.4m in depth;

[0056] The CY3 is centrally located, with a length of 20–22 m, a width of 4.05–5.4 m, and a depth of 1.2–1.4 m.

[0057] The beneficial effects of this invention are as follows: The ultra-large 1600t / d photovoltaic glass furnace with one kiln and five lines provided by this invention melts the low-iron glass batch into molten glass in the melting section. After clarification, it enters the conveying passage 4. Since the outlet end of the melting furnace is equipped with five branch passages 42, it can realize multi-line diversion of molten glass. This multi-branch passage 42 setting method can increase glass production, match existing large-tonnage furnaces, and transport the molten glass from the furnace to the forming equipment for processing in a timely manner.

[0058] The kiln of this invention has the following advantages: In the prior art, due to limitations such as capital barriers, technical barriers, molding equipment and processes, and end product specifications, only narrow plate production can be adopted. This invention specifically increases the kiln length, appropriately increases the kiln width, adds the 0# double oxygen lance side firing process technology, increases the heat storage chamber 2 to 10 pairs of small furnaces 21, and changes to wide flow channels, wide lip bricks, wide annealing kilns and other process technology equipment, enabling this invention to achieve wide plate production.

[0059] This invention can increase the melting capacity of a traditional five-line photovoltaic melting furnace by more than 400 t / d without significant additional investment. This invention creatively achieves the technological advantages of fewer branch lines and higher load capacity in ultra-large photovoltaic glass furnaces. Generally, ultra-large photovoltaic glass furnaces, especially those with a melting capacity exceeding 1250 t / d, employ a six-line or eight-line configuration. However, having more branch lines leads to drawbacks such as higher investment, greater land occupation, larger space requirements, and higher edge losses.

[0060] This invention creatively increases the width of all branch line original plates to over 4.05 meters, an increase of 10.2% to 44.49%, representing a significant contribution to photovoltaic glass production. This invention also creatively reduces edge loss from 7.68% to 4.96%. Furthermore, this invention creatively increases the yield to over 90%, an improvement of 2.72 basis points.

[0061] Preferably, in the above-mentioned ultra-large 1600t / d photovoltaic glass kiln with one kiln and five production lines, the heat storage chamber 2 includes 10 pairs of small furnaces 21 and one pair of No. 0 small furnaces 22. The No. 0 small furnace 22 adopts two No. 0 oxygen lances for side firing, and the distance between the two No. 0 oxygen lances is set at 0.5 to 2.5m.

[0062] As described above, the furnace regenerator 2 includes 10 pairs of small furnaces 21 and 1 pair of #0 small furnaces 22. The #0 small furnace 22 is located between the front end of the #1 small furnace and the feeding port. The #0 small furnace 22 uses double #0 oxygen lances for side firing. The distance between the two pairs of #0 oxygen lances is 0.5 to 2.5 meters. The distance between the first pair of #0 oxygen lances and the front wall of the 45°L hanging wall is 2 to 5 meters. The specific location is shown in the appendix. Figure 1 As shown, the dual 0# oxygen lance design can further promote the increase of the drawing volume. It also plays a role in pre-melting the batch material, avoiding freezing of the material, reducing the melting load, improving the thermal efficiency of the melting furnace, increasing the furnace output, and reducing heat consumption and the overall energy consumption cost per unit product.

[0063] Preferably, in the aforementioned ultra-large 1600t / d photovoltaic glass furnace with one kiln and five production lines, a double-row bottom bubbling device is installed in the hot spot of the melting section of the furnace, near the area of ​​small furnaces #5 to #7. The specific location is shown in the appendix. Figure 1 The position shown adopts a water-cooled bubbling method.

[0064] Preferably, in the above-mentioned ultra-large 1600t / d photovoltaic glass kiln with one kiln and five production lines, a pair of horizontal glass melt agitators 32 are installed at the bottleneck.

[0065] As described above, a pair of horizontal glass melt agitators 32, as well as transmission devices and tracks, are installed at the bottleneck to stabilize and regulate the temperature and uniformity of the glass melt in the horizontal passage 41 and the branch passage, so as to adapt to the production of thin and wide photovoltaic glass products.

[0066] The molten glass flows from the bottleneck channel to the stirring area, where the agitator further homogenizes it. Agitator inlets and outlets are pre-installed on the side walls of the bottleneck during kiln construction to facilitate the agitator's advancement or demotion. The agitator is mounted on an agitator trolley, which has four symmetrically arranged, heat-resistant steel wheels that slide forward or backward on heat-resistant triangular iron tracks perpendicular to the kiln's centerline.

[0067] The stirrer plays a role in further homogenizing the molten glass, laying the technological foundation for the production of wide-format and thin photovoltaic glass products. It also prevents defects such as uneven stress, edge warping, panel bending, and edge chipping caused by poor homogenization and uneven composition of the molten glass.

[0068] Preferably, in the aforementioned ultra-large 1600t / d photovoltaic glass kiln with one furnace and five production lines, the outlet of the glass melt 9 at the rear end of the branch passage 42 is sequentially provided with a wide lip brick, a large overflow port, and a receiving roller 8. The wide lip brick and the large overflow port 5 are made of sintered zircon mullite material. The sintered zircon mullite lip brick comprises the following components by mass percentage: SiO2 15-20%; Al2O3 60-85%; ZrO2 6-12%; Fe2O3 <0.30%; CaO <0.40%.

[0069] As described above, to adapt to wide plates, large output, and high branch line load, the large overflow port 5 of the wide-lip brick of this invention uses sintered zircon mullite material and adopts the above formula, so that the ZrO2 content is 6-12% by mass, Al2O3 ≥ 60%, refractoriness ≥ 1800℃, softening start temperature under 0.2MPa load ≥ 1670℃, and the average linear expansion coefficient from room temperature to 1300℃ is 6.68 × 10⁻⁶. -6 l / ℃, porosity <21%, density ≥2.15g / cm³, water-cooled thermal shock resistance ≥10 cycles at 1100℃. Overflow port width is 2.8~3.8m.

[0070] Preferably, in the aforementioned ultra-large 1600t / d photovoltaic glass kiln with one kiln and five production lines, the receiving roller 8 comprises the following components in the following weight ratios: C: 0.10–0.30 parts; Si: 0.10–0.50 parts; Mn: 0.20–0.50 parts; Ni: 0.10–0.70 parts; Cr: 10–16 parts; Mo: 0.03–0.65 parts; N: 0.01–0.075 parts; Al: 0.01–0.05 parts; P < 0.02 parts; S < 0.07 parts; Cu < 0.02 parts.

[0071] As described above, to accommodate wide plates, thin plates, large output volumes, and heavy loads on branch lines, the upper roller of the calendering roller table is made of a specific 2Cr13 material with a diameter of Φ430±mm. The lower roller is also made of a specific 2Cr13 material with a diameter of Φ400±0mm. The roller table width is approximately 3.6~4.6m.

[0072] Example 1

[0073] Please refer to Figure 1 and Figure 2 A super-large 1600t / d photovoltaic glass kiln with one furnace and five production lines includes a kiln body 1, a heat storage chamber 2, a bottleneck 3, and a conveying passage 4; the heat storage chamber 2 is located on both sides of the kiln body 1, and the kiln body 1, the bottleneck, and the conveying passage 4 are connected in sequence.

[0074] The conveying passage 4 includes a horizontal passage 41 and branch passages 42. The horizontal passage 41 has a width of 3.5 to 4.5 m, a length of 50 to 55 m, and a depth of 1.2 to 1.4 m. The horizontal passage 41 intersects the center line of the kiln perpendicularly. One side of the horizontal passage 41 is connected to the kiln body 1, and the other side is perpendicularly connected to 5 branch passages 42.

[0075] The kiln body 1 is 65-75m long, 13-15.5m wide, and 1.2-1.8m deep;

[0076] The transverse passage 41 has a width of 3.5–4.5 m, a length of 50–55 m, and a depth of 1.2–1.4 m;

[0077] The five branch paths 42 are labeled CY1, CY2, CY3, CY4 and CY5 respectively.

[0078] The branch passage 42 has a width of 4.05–5.4 m and a depth of 1.2–1.4 m;

[0079] The positions of CY1 and CY5 are symmetrically arranged, with the same length, width and depth, the length being 4 to 4.5m, the width being 4.05 to 5.4m and the depth being 1.2 to 1.4m;

[0080] The positions of CY2 and CY4 are symmetrically arranged, with the same length, width and depth, ranging from 10.2 to 13.5m in length, 4.05 to 5.4m in width and 1.2 to 1.4m in depth;

[0081] The CY3 is centrally located, with a length of 20–22 m, a width of 4.05–5.4 m, and a depth of 1.2–1.4 m.

[0082] To improve the thermal efficiency of this ultra-large kiln, the feeding port of the kiln body, like current float glass and photovoltaic kilns, also adopts modern energy-saving technologies, such as a 45° L-shaped suspended wall structure and a neck-type suspended flat arch structure. It employs a wide melting pool, a uniformly wide feeding pool, a narrow neck and suspended flat arch, and a stepped pool bottom structure.

[0083] The kiln body 1 implements a fully sealed and strong heat preservation technology to improve thermal efficiency, save fuel, reduce consumption, and reduce greenhouse gas emissions. In key parts of the kiln body 1, the best-performing refractory materials are also used.

[0084] Furthermore, the kiln body 1 employs two #0 oxygen lances for side firing in the #0 small furnace 22, with the distance between the two #0 oxygen lances ranging from 0.5 to 2.5 meters. This facilitates better pre-melting of the glass batch material, thereby increasing the melting capacity of the kiln body 1 and improving its output. The small furnace structure of the kiln body 1 is a side-firing plus bottom-firing method.

[0085] Furthermore, a double-row bubbling device is installed at the hot spot of the melting section of the furnace body 1, using a water-cooled bubbling method. The purpose is to enhance the movement of the molten glass to generate a mixing and stirring effect, strengthen the convection of the molten glass in the furnace, increase the temperature of the molten glass in the furnace, especially the temperature of the molten glass at the bottom of the tank, improve the chemical and physical homogeneity of the molten glass, increase the melting rate, and increase the output.

[0086] Furthermore, the furnace pool depth is designed to be 1.2–1.8 m, further determined based on the basic chemical composition of the glass products being produced. Generally, when the iron content is between 80 and 120 ppm, the furnace pool depth is around 1.2–1.8 m. This innovative approach is a summary of forty years of production experience, research findings, and computer numerical simulation technology research by the Xinfuxing technical team. The depth of the pool is creatively increased to slow down temperature conduction in the depth direction of the molten glass, creating a larger temperature gradient. This facilitates the clarification of the molten glass, thereby meeting the process requirements for bubble absorption and elimination.

[0087] Furthermore, there are corresponding heat storage chambers 2 on both sides of the kiln body 1. The heat storage chamber 2 is 5-6m wide, 40-43m long, and the checker bricks are 9-10m high. The heat storage chamber 2 is equipped with 10 pairs of small furnaces 21. The inner width of the opening of small furnaces 1# to 9# is 2.5-3.5m, and the center line spacing of small furnaces 1# to 9# is 4-5.5m.

[0088] Because of its proximity to the clarification section and the smaller load distribution in the operating process, the No. 10 furnace is slightly smaller in size than the previous No. 1 to No. 9 furnaces. The inner width of the No. 10 furnace opening is 1.5 to 2.1 m, and the center-to-center spacing of the furnaces is 3 to 4 m. The checker bricks in the regenerator 2 are constructed from bottom to top with high-quality refractory materials such as magnesia-chrome bricks, magnesia bricks, and chrome corundum bricks.

[0089] Furthermore, the regenerator chambers 2 on both sides of the kiln are separated in pairs using cylindrical checker bricks to ensure the optimal ratio of heat storage area to melting area, and to steadily improve the preheating temperature of the combustion air and the heat recovery rate of the checker bricks in regenerator chamber 2. Appropriate small furnace structure and reasonable flame space design improve flame radiation efficiency and prevent the breast wall from tilting inwards towards the kiln. A reasonable small furnace opening design, variable frequency control of combustion air, and branch flue air intake are used. The air intake ratio between small furnaces is adjusted on the air intake branch pipes of each branch flue, which is beneficial for adjusting the air-to-gas ratio of each small furnace. Exhaust gas is diverted using branch flues.

[0090] The neck section adopts a low-hanging flat arch structure to improve the stability of the kiln neck structure. Its dimensions are: length 4.5–6.5m, width 3.8–4.8m, and depth 1.2–1.8m. A pair of adjustable-height cooling water tanks 31 and their corresponding water tank carriages are installed at the neck position to increase the reflux flow of molten glass before the neck, which helps to enhance the clarification and homogenization of the molten glass, improve its quality, and simultaneously reduce the reflux flow of molten glass in the cooling section. To strictly control the quality of the molten glass entering the forming process and to ensure more uniform temperature and chemical composition, a pair of horizontal molten glass agitators, along with transmission devices and tracks, are installed at the neck position to stabilize the kiln pressure and temperature in the horizontal passage 41 and branch passages, and to homogenize the molten glass.

[0091] The conveying passage 4 includes a horizontal passage 41 and branch passages 42. The horizontal passage 41 is 3.5–4.5 m wide, 50–55 m long, and 1.2–1.4 m deep. It intersects the center line of the kiln perpendicularly. Behind the horizontal passage 41, there are five vertical passages, each connecting to one of the five branch passages, namely branch passages CY1, CY2, CY3, CY4, and CY5. The five branch passages 42 are perpendicularly connected to the horizontal passage 41.

[0092] Five branch paths, all using wide plates. Branch paths CY1 and CY5 are symmetrically distributed, with identical length, width, and depth dimensions: 4–4.5m in length, 4.05–5.4m in width, and 1.2–1.4m in depth. Branch paths CY2 and CY4 are also symmetrically distributed, with identical length, width, and depth dimensions: 10.2–13.5m in length, 4.05–5.4m in width, and 1.2–1.4m in depth. Branch path CY3 is centrally located, with a length of 20–22m, a width of 4.05–5.4m, and a depth of 1.2–1.4m. The plate width for all five branch paths is 4.05–5.4m. Using wide plates for each branch path reduces edge loss and increases the yield rate, which is beneficial for achieving high output, low consumption, reduced costs, and energy conservation and carbon reduction.

[0093] Five branch passages, CY1, CY2, CY3, CY4, and CY5, connect to five overflow outlets. The five overflow outlets have the same length and depth, ranging from 0.3 to 1.8 meters in length and 0.1 to 0.3 meters in depth, to meet the needs of wide plate production.

[0094] On the photovoltaic glass production line, after the last horizontal passage 41 and the branch passage at the end of the kiln, that is, after the branch passage 42, is the rolling process. The rolling system consists of several parts, including the branch passage 42, the lip brick system, the lower roll of the rolling mill, the upper roll of the rolling mill, the receiving roll 8, the glass melt, and the control system.

[0095] Each branch passage 42 is connected to the wide lip brick large overflow port 5. The wide lip brick large overflow port 5 is connected to the calender. Below the wide lip brick large overflow port 5 is the lower roller 6 of the calender. Above the wide lip brick large overflow port 5 is the upper roller 7 of the calender. Behind the upper and lower rollers of the calender is the receiving roller platform 8. There is molten glass 9 between the wide lip brick large overflow port 5 and the upper and lower rollers, as well as on the receiving roller 8.

[0096] To adapt to high production capacity, high yield, and wide plate drawing, this invention creatively adopts high overflow temperature, large output and optimal cooling water temperature control technology, wide lip brick, calender lower roll 6, calender upper roll 7, wide receiving roll 8 platform and other technologies.

[0097] To accommodate wide plates, large output volumes, and heavy loads on branch lines, this invention utilizes sintered zircon-mullite material for the wide-lip brick's large overflow outlet 5. The ZrO2 content is 6-12% by mass, Al2O3 ≥ 60%, refractoriness ≥ 1690℃, porosity ≥ 21%, density ≥ 2.15 g / cm³, and water-cooled thermal shock resistance ≥ 10 cycles at 1100℃. The overflow outlet width is 2.8-3.8 m.

[0098] To accommodate wide plates, large output volumes, and heavy loads on branch lines, this invention uses a specific 2Cr13 material for the upper roller of the calendering roller table, with a diameter of Φ430+5 / -0mm. The lower roller is also made of 2Cr13 material, with a diameter of Φ400+5 / -0mm. The roller table length is 3.6~4.6m.

[0099] Specifically, the wide-lip brick large overflow port 5 is made of sintered zircon mullite material, which includes the following components by mass percentage: SiO2 15-20%; Al2O3 60-85%; ZrO2 6-12%; Fe2O3 <0.30%; CaO <0.40%.

[0100] The receiving roller 8 comprises the following components in the following weight ratios: C: 0.10–0.30 parts; Si: 0.10–0.50 parts; Mn: 0.20–0.50 parts; Ni: 0.10–0.70 parts; Cr: 10–16 parts; Mo: 0.03–0.65 parts; N: 0.01–0.075 parts; Al: 0.01–0.05 parts; P < 0.02 parts; S < 0.07 parts; Cu < 0.02 parts.

[0101] The above-mentioned ultra-large 1600t / d photovoltaic glass kiln with one furnace and five production lines is used as follows:

[0102] According to the company's photovoltaic glass formula and feeding sequence, low-iron quartz sand, low-iron dolomite, low-iron limestone, aluminum hydroxide, heavy soda ash, sodium sulfate, and some minor materials are accurately weighed. The ultra-white rolled photovoltaic glass batch material is prepared according to the set batching parameters to ensure that the standard deviation of the batch material is controlled below 0.20% and the iron content is guaranteed to be around 100 ppm. The prepared high-quality batch material is sent to the kiln head silo after multi-stage iron removal on the original melting belt, and then sent to the kiln body 1 for melting via the kiln head silo and the feeding machine.

[0103] The molten glass, melted, clarified, and homogenized in the furnace body 1, enters the conveying passage 4 through the neck. At the neck, the molten glass is affected by the water inlet; some glass flows back to the furnace, while some passes under the water inlet. The depth of the water inlet is determined according to the production process requirements, generally around 180-560mm. The melted, clarified, and homogenized molten glass flows from the neck passage to the stirring area. Under the action of the stirrer, the molten glass is better homogenized, reducing and avoiding the impact of glass fibers on quality. The uniformly stirred molten glass flows to the conveying passage 4, where it is slowly cooled and absorbs any remaining tiny air bubbles, resulting in a higher quality molten glass.

[0104] The molten glass is diverted and drawn to five branch channels through branch channel 42. The molten glass flows through CY1, CY2, CY3, CY4, and CY5 to the lip brick. The molten glass then flows from the lip brick to the lower roller 6 and upper roller of the rolling mill. Under the action of the upper and lower rollers of the rolling mill, the molten glass flows to the receiving roller 8. The molten glass 9 enters the annealing furnace through the receiving roller 8. After fine annealing in the annealing furnace, the glass undergoes cold end inspection, longitudinal cutting, transverse cutting, breaking, edge cleaning, sheeting, edge grinding, cleaning, drilling, cleaning, printing, drying, coating, drying, tempering, inspection, packaging, and finished product warehousing.

[0105] The advantages of the ultra-large 1600t / d photovoltaic glass kiln with five production lines of this invention are as follows:

[0106] First, it is "large". This invention increases the melting capacity by 400t / d without requiring a large increase in investment.

[0107] Secondly, it features "fewer" branch lines. This invention creatively achieves the technological characteristic of "fewer" branch lines in ultra-large photovoltaic kilns, reducing investment, increasing yield, and lowering costs and unit consumption. Generally, ultra-large photovoltaic glass kilns, especially those with a melting capacity greater than 1200t / d, adopt a configuration of one kiln with six or eight lines. For example, on April 29, 2023, a domestic new energy materials company successfully piloted the world's first photovoltaic glass production line with a daily melting capacity of 1200 tons and eight lines. While the aforementioned 1200t / d eight-line production line has a smaller tonnage than this invention, it does have drawbacks such as more branch lines, higher investment, greater land occupation and space requirements, narrower sheet size, and higher edge loss.

[0108] Thirdly, it is "wide". This invention creatively increases the width of the original plate for all five branch lines to over 4.05m, which is 10.2% to 44.49% wider than the existing technology.

[0109] Fourthly, it is "low". This invention creatively reduces edge loss from 7.68% to 4.96%, a reduction of 35.94%, creating a world miracle and setting an example and benchmark for the photovoltaic industry to reduce waste and save resources.

[0110] Fifth, it is "high". This invention also creatively increases the yield rate to over 90%, an increase of over 2.72% basis points. This invention also creatively increases output by over 13.6% (2.72% × 5 lines / kiln). This invention creatively improves the kiln's heat storage capacity and thermal efficiency, achieving energy conservation and carbon reduction, and meeting national ultra-low emission standards.

[0111] Sixth, it is "good". The benefits of this invention are "good". It can creatively reduce the comprehensive energy consumption per unit product by 5 basis points, increase the average yield by more than 2 points, increase production capacity by 30%, and increase annual profits by more than 230 million yuan. Based on the increased output and reduced unit consumption and other costs of this invention, and calculated using the current economic and technical indicators of a 1200t / d photovoltaic one-kiln-five-line system, it is estimated that this invention can increase the economic benefits of the national photovoltaic glass industry by more than 17 billion yuan in one kiln period (calculated over 10 years), and can save more than 200 billion yuan in investment for new photovoltaic glass projects nationwide.

[0112] Looking at the current configuration of photovoltaic glass furnaces and their branch lines in China, the breakthrough and advancement of this invention in terms of tonnage far surpasses the current global photovoltaic glass industry's largest furnace capacity of only 1250t / d. Maximum load per branch line (300t / d) (The branch) is the largest.

[0113] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent modifications made based on the content of the present invention specification and drawings, or direct or indirect applications in related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A super extra large 1600 t / d photovoltaic glass one-kiln five-line furnace, characterized in that, It includes a kiln body, a heat storage chamber, a bottleneck, and a conveying passage; the heat storage chamber is located on both sides of the kiln body, and the kiln body, the bottleneck, and the conveying passage are connected in sequence. The conveying path includes a horizontal path and branch paths. The horizontal path is 3.5-4.5m wide, 50-55m long, and 1.2-1.4m deep. The horizontal path intersects the center line of the kiln perpendicularly. One side of the horizontal path is connected to the kiln body, and the other side is perpendicularly connected to 5 branch paths. The kiln body is 65-75m long, 13-15.5m wide, and 1.2-1.8m deep; The five branch paths are labeled CY1, CY2, CY3, CY4 and CY5 respectively. The branch passageway slab is 4.05–5.4m wide and 1.2–1.4m deep; The positions of CY1 and CY5 are symmetrically arranged, with the same length, width and depth, the length being 4 to 4.5m, the width being 4.05 to 5.4m and the depth being 1.2 to 1.4m; The positions of CY2 and CY4 are symmetrically arranged, with the same length, width and depth, ranging from 10.2 to 13.5m in length, 4.05 to 5.4m in width and 1.2 to 1.4m in depth; The CY3 is centrally located, with a length of 20–22 m, a width of 4.05–5.4 m, and a depth of 1.2–1.4 m; The regenerator includes 10 pairs of small furnaces and 1 pair of No. 0 small furnaces. The No. 0 small furnace is side-fired with two No. 0 oxygen lances, and the distance between the two No. 0 oxygen lances is 0.5 to 2.5m. The hot spot of the melting section of the kiln body is equipped with a bottom-cooled double-row bubbling device. A pair of horizontal stirrers for stirring molten glass are installed at the bottleneck.

2. The ultra-large 1600 t / d photovoltaic glass one-kiln five-line furnace according to claim 1, characterized in that, The glass melt outlet at the rear end of the branch passage is sequentially equipped with a wide-lip brick large overflow port and a receiving roller. The wide-lip brick large overflow port is made of sintered zircon mullite material, which includes the following components by mass percentage: SiO2 15-20%; Al2O3 60-85%; ZrO2 6-12%; Fe2O3 <0.30%; CaO <0.40%, and the sum of all components is 100%.

3. The ultra-large 1600 t / d photovoltaic glass one-kiln five-line furnace according to claim 2, characterized in that, The receiving roller comprises the following components in the following weight ratios: C: 0.10–0.30 parts; Si: 0.10–0.50 parts; Mn: 0.20–0.50 parts; Ni: 0.10–0.70 parts; Cr: 10–16 parts; Mo: 0.03–0.65 parts; N: 0.01–0.075 parts; Al: 0.01–0.05 parts; P < 0.02 parts; S < 0.07 parts; Cu < 0.02 parts.

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