Method and system for controlling current loading in heating process of glass kiln

Abstract

The invention provides a control method and system for current loading in the heating process of a glass kiln, and the method comprises the steps: starting an electrode when the glass liquid level of the kiln reaches the height of the electrode capable of loading current, and setting an initial current value for loading; adjusting the loading current according to the rise of the glass liquid level and the increase of the glass raw material amount, and adjusting the gear of the current by combining the parameters of voltage, resistance and electric power; in the rinsing stage of the kiln, feeding of the glass raw materials is stopped, the temperature of the kiln is kept stable, and the loading current is adjusted; after the kiln rinsing stage is finished, glass raw materials are put into the kiln again, and distribution of current of the control electrode is adjusted; and when the kiln control process reaches the production control range, the loading current is adjusted to a stable numerical value required by the final process. The service life of the kiln and the electrode equipment is prolonged through a reasonable current loading mode, and the temperature rise process of the kiln can be accurately and automatically controlled through preset process parameters and real-time monitoring and adjustment based on the parameters of the kiln.

Description

Technical Field

[0001] The present invention belongs to the technical field of current loading control process methods during the heating process of a kiln, and in particular relates to a current loading control method and system during the heating process of a glass kiln. Background Art

[0002] In the production of glass furnaces, molten glass is conductive. The electric boosting system uses the heat energy generated by the resistance of the molten glass under the condition of applying voltage to heat the raw material to make it melt at high temperature, fully completing the chemical reaction to melt the glass. The working principle is the same as that of the all-electric melting furnace, but there are differences in design. The electric boosting system plays an auxiliary role in glass melting, and flame melting plays a major role. When the electric boosting system is working, 80% to 85% of the electric energy is consumed to generate heat energy in the molten glass, and only about 15% of the electric energy is generated by the electrode current. These two energies play the role of melting glass at the same time. Generally, when the temperature of the molten glass is 1450℃, the surface temperature of the electrode is as high as 1650℃, and the difference is about 200℃. Therefore, users should use suitable electrode products to meet the glass quality requirements. When the electrode works at a high temperature of 1500 to 2000℃, local strong convection and local high temperature will be generated inside the kiln. Therefore, how to arrange the basic structural design of the kiln for the electrode position and the structure around the electrode and the rational use of the electrode current during the kiln heating is a very important issue. Real-time control and adjustment of the kiln current is crucial to the kiln production.

[0003] At present, after the construction and manufacturing of the kiln is completed, there is no preset complete kiln current loading plan, especially for the process plan of the kiln for producing ultra-thin glass. As a result, after the technicians complete the construction and manufacturing of the overall material and equipment structure of the kiln, they only know that the kiln needs to perform current auxiliary loading work during the glass raw material delivery process to make the kiln perform high-temperature melting of glass, without fully considering the current value changes and stage effects in the process. Therefore, for the time being, the current loading and control methods during the heating process of the glass kiln are not accurate and real-time enough, resulting in inappropriate temperatures and currents at different stages that may have adverse effects on the working life of the kiln and the quality of the glass. Summary of the invention

[0004] The present invention provides a control method and system for current loading in the heating process of a glass kiln, aiming to solve the problem that the current loading and control methods in the heating process of the glass kiln are insufficient in accuracy and real-time performance, resulting in inappropriate temperatures and currents at different stages that may have adverse effects on the service life of the kiln and the quality of the glass.

[0005] In order to achieve the above object, the present invention adopts the following technical scheme: The present invention provides a method for controlling current loading during a heating process of a glass furnace, comprising the following steps: S1. When the glass raw material is put into the furnace and the temperature starts to rise, when the glass liquid level in the furnace reaches the height at which the electrode can load the current, the electrode is started and the initial current value is set for loading; S2: Based on the height of the glass liquid level in the furnace and the amount of glass raw materials added at a preset time interval, the loading current is adjusted, and the current gear is adjusted in combination with the parameters of voltage, resistance and electric power; S3: During the kiln rinsing stage, stop feeding glass raw materials, keep the kiln temperature stable, and adjust the loading current to a value suitable for kiln rinsing; S4: After the rinsing stage, the furnace starts to feed glass raw materials again, and the loading value of the electrode current in each area of ​​the furnace is adjusted; S5: When the kiln glass raw material process and temperature control process have reached the production control range, the loading current will be adjusted to a stable value required by the process.

[0006] In some implementations, in S1, the initial current value is set based on the structural characteristic parameters of the furnace, the initial amount of glass raw materials fed, and the preset furnace temperature target value.

[0007] Furthermore, in S1, the structural characteristic parameters of the kiln include the length, width and height of the kiln, the number of groups of electrode equipment, the size of the kiln feeding port, and the structural characteristics of the kiln design and installation.

[0008] Furthermore, in S1, the parameters of the glass raw materials added during the heating process of the kiln are the components of the raw materials, and the raw materials include one or more combinations of quartz sand, limestone, boric acid, barium carbonate and soda ash.

[0009] In some embodiments, in S1, the temperature parameters of the kiln include: actual temperature values ​​monitored for each area of ​​the kiln during the heating process of the kiln.

[0010] In some implementations, in S2, the current level is adjusted in combination with the actual temperature distribution of each area in the kiln.

[0011] In some embodiments, in S3, during the heating process of the kiln, the parameters of the kiln temperature, current, and voltage are monitored in real time by a preset monitoring unit, and the loading current is automatically adjusted according to the monitoring results.

[0012] In some embodiments, in S3, when the glass liquid level in the furnace reaches a preset height, the furnace starts a rinsing phase.

[0013] In some embodiments, in S4, after the rinsing stage is completed, the current to be loaded is controlled to increase based on the increase of glass raw materials and the increase of the bottom temperature of the furnace.

[0014] The present invention also provides a control system for current loading during the heating process of a glass furnace, the system comprising a current loading module, a monitoring module, a control module, a data processing module and a human-computer interaction module, wherein: The current loading module is used to load current in stages during the kiln heating process according to a preset current loading process; The monitoring module is used to monitor the temperature, current and voltage parameters of the kiln in real time; The data processing module is used to process the data monitored by the monitoring module to evaluate the heating status of the kiln and generate adjustment instructions to send to the control module; The control module is used to adjust the loading current of the current loading module according to the adjustment instruction, and control the gear, frequency and time of the loading current; The human-computer interaction module is used to display the operating status and parameters of the kiln, and to allow the user to input preset process parameters and instructions.

[0015] Compared with the prior art, the control method and system of current loading in the heating process of a glass kiln of the present invention has the following beneficial effects: S1, in the process of heating the kiln by adding glass raw materials, when the kiln glass liquid level reaches the preset height of the electrode that can be loaded with current, the electrode is started, and the initial current value is set for loading; S2: based on the height of the kiln glass liquid level and the amount of glass raw materials added in the preset time interval, the loading current is adjusted, and the current gear is adjusted in combination with the parameters of voltage, resistance and electric power; S3: during the kiln rinsing stage, the glass raw materials are stopped, the kiln temperature is kept stable, and the loading current is adjusted to a value suitable for kiln rinsing; S4: after the rinsing stage, the kiln starts to add glass raw materials again, and the loading value of the electrode current in each area of ​​the kiln is adjusted and controlled; S5: when the kiln glass raw material feeding process and the temperature control process reach the production control range, the loading current is adjusted to the stable value required by the process. Based on the above, the present invention realizes stable control and optimization of the kiln temperature by controlling the current loading in the heating process of the glass kiln in stages. The present invention dynamically adjusts the loading current according to multiple factors such as the height of the glass liquid level in the kiln, the amount of raw materials input, the preset time interval, the extreme values ​​of voltage, resistance and electric power, etc., to ensure that the temperature of each area of ​​the kiln is uniform and stable during the heating process. The present invention improves the heating efficiency of the kiln by accurately controlling the current loading, ensures the stability of the kiln temperature by dynamically adjusting the current, and avoids the influence of temperature fluctuations on the quality of the glass. The reasonable current loading method prolongs the service life of the kiln and electrode equipment, and realizes the automatic control of the kiln heating process based on the kiln parameters through preset process parameters and real-time monitoring and adjustment. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The drawings in the specification are used to provide further understanding of the present invention and constitute a part of the present invention. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute improper limitations on the present invention.

[0017] Figure 1 The present invention is a flow chart of a method for controlling current loading during the heating process of a glass furnace and a method in the system. DETAILED DESCRIPTION

[0018] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0019] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0021] In the description of the embodiments of the present invention, it should be noted that if the terms "upper", "lower", "horizontal", "inner", etc. indicate an orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the product of the invention is usually placed when in use, it is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention. In addition, the terms "first", "second", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0022] In addition, if the term "horizontal" appears, it does not mean that the component must be absolutely horizontal, but can be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical", which does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0023] In the description of the embodiments of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "set", "install", "connect", and "connect" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal connection of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0024] How to improve the accuracy and automation of current loading and control methods during the current glass furnace heating process, thereby increasing the furnace's service life and glass quality.

[0025] like Figure 1 As shown, the present invention provides a method for controlling current loading during the heating process of a glass furnace, comprising the following steps: S1. When the glass raw material is put into the furnace and the temperature starts to rise, when the glass liquid level in the furnace reaches the height at which the electrode can load the current, the electrode is started and the initial current value is set for loading; S2: Based on the height of the glass liquid level in the furnace and the amount of glass raw materials added at a preset time interval, the loading current is adjusted, and the current gear is adjusted in combination with the parameters of voltage, resistance and electric power; S3: During the kiln rinsing stage, stop feeding glass raw materials, keep the kiln temperature stable, and adjust the loading current to a value suitable for kiln rinsing; S4: After the rinsing stage, the furnace starts to feed glass raw materials again, and the loading value of the electrode current in each area of ​​the furnace is adjusted; S5: When the kiln glass raw material process and temperature control process have reached the production control range, the loading current will be adjusted to a stable value required by the process.

[0026] In some embodiments, the control method of current loading during the heating process of a glass kiln of the present invention divides the preset current loading process of the kiln into multiple stages according to the structural characteristic parameters of the kiln, the parameters of the glass raw materials added to the kiln during the heating process, and the temperature parameters of the kiln, and formulates a corresponding kiln current loading control process. Based on the above characteristic parameters, the control stage is divided into the initial stage of current loading, the current upshift adjustment stage, the furnace run-in current adjustment stage, the material quantity change current adjustment stage, and the final process stabilization stage. Through the adjustment changes at different stages, different current loading control processes are adopted for the corresponding kilns, so that the kiln current loading process tends to be stable when the kiln is continuously fed with glass raw materials.

[0027] The control method of current loading during the heating process of the glass kiln of the present invention is aimed at the different structural features of different kilns, such as the length, width, height, and several groups of electrode equipment of the kiln design and installation structural characteristics. When there is a large increase or decrease in the numerical process of the glass raw materials fed into the kiln, or when the temperature at the bottom of the kiln does not reach the required temperature control range, the overall value of the kiln loading current, the value of the current loaded by each group of electrodes, and the frequency and duration of the loading current and other process settings can be adjusted. It is beneficial for the glass raw materials fed into the kiln to melt and react quickly in a short time after entering the kiln. It provides a strong basic guarantee for its subsequent continuous and long-term ultra-high temperature normal kiln production. The invention is used to solve the problem that the process preparation of the glass raw materials fed into the kiln in the early stage is not in place, which affects the subsequent normal production.

[0028] The present invention can select suitable electrode equipment in advance and set equipment operating parameters according to equipment needs through actual design dimensions such as the hourly numerical value of glass raw materials that can be added during the initial kiln heating stage and the normal production stage, the numerical value of the temperature control range required during the kiln heating stage and the normal production stage, and the numerical value of the limiting current loading of the electrode system equipment.

[0029] The present invention specifically adds current value control at each stage for the electrode refractory material and the supporting materials needed for the electric-assisted melting furnace, that is, the electrode refractory material can be used with better effect at each stage.

[0030] In the current upshift adjustment stage, the present invention not only regulates and limits the current loading adjustment amount and adjustment frequency. The relevant voltage values, resistance values ​​and electric power are all set. In this way, the entire kiln heating process can be controlled from multiple technical parameters. By regulating multiple process parameters, the safety and stability of the process limit values ​​are guaranteed, the safe and stable use of the electrode equipment and other ancillary equipment of the kiln is guaranteed, and the control accuracy during the kiln heating process can be improved.

[0031] The present invention can perform process inspection and equipment inspection on the kiln during the kiln rinsing stage, and can effectively check and troubleshoot the process execution status during the rapid heating process of the entire kiln. Because during the kiln rinsing stage, the kiln does not need to be fed with glass raw materials, the kiln is in a relatively static and stable state, the kiln is not fed with materials, and the temperature of the kiln does not fluctuate, and it is always in a stable state. Therefore, the current loading will not be adjusted, the value remains unchanged, and the process is relatively stable. Therefore, inspections and sorting can be carried out at this stage. When the process executor or equipment manager finds a problem, the problem can be solved and improved during the kiln insulation stage.

[0032] In the initial stage of current loading of the present invention, after the glass liquid level in the furnace reaches a height value at which the electrode can load current, the electrode starts to load current according to a certain preset initial value.

[0033] In the current upshift adjustment stage of the present invention, when the glass liquid level in the kiln is rising, the current loading value is adjusted according to whether the temperature at the bottom of the kiln pool reaches the range required by the process and the amount of glass raw materials entering the kiln per hour.

[0034] In the furnace lubrication current adjustment stage of the present invention, during the refractory material lubrication process in the furnace, the temperature is kept constant and the glass liquid does not flow, and the value of the current is loaded.

[0035] The material quantity change current adjustment stage of the present invention refers to the material quantity adjustment according to the hourly weight of glass liquid flowing out of the kiln required by the normal production process after the kiln completes the rinse process, and the value of the kiln loading current is adjusted accordingly.

[0036] The final process stabilization stage of the present invention is to make a final adjustment of the current value according to the required temperature of each part of the kiln after the material production amount of the kiln reaches the normal production process value range.

[0037] As an embodiment, in actual operation, the process setting values ​​such as the current loading value, the current change rate, the voltage control limit value, etc. at each stage of the present invention can be adjusted according to actual needs. The process parameters can be formulated in a targeted manner according to the structural characteristics of the kiln, the characteristics of the refractory materials used, and the control parameters required for subsequent normal production, which is relatively flexible.

[0038] The present invention also provides a control system for current loading during the heating process of a glass furnace, the system comprising a current loading module, a monitoring module, a control module, a data processing module and a human-computer interaction module, wherein: The current loading module is used to load current in stages during the kiln heating process according to the preset current loading process; the monitoring module is used to monitor the temperature, current and voltage parameters of the kiln in real time; the data processing module is used to process the data monitored by the monitoring module to evaluate the heating state of the kiln, and generate adjustment instructions to send to the control module; the control module is used to adjust the loading current of the current loading module according to the adjustment instructions, and control the gear, frequency and time of the loading current; the human-computer interaction module is used to display the operating state and parameters of the kiln, and to allow the user to input preset process parameters and instructions. The present invention realizes comprehensive monitoring and control of the kiln heating process through system control, human-computer interaction and display, and improves the control accuracy of the glass kiln.

[0039] The following is a detailed description of a method and system for controlling current loading during the heating process of a glass furnace according to the present invention through specific embodiments.

[0040] In this embodiment, the glass kiln of the present invention is used for producing ultra-thin sheet glass for electronic display devices. The upper structure is hydrogen-oxygen combustion, and the lower structure is an electrode refractory brick material loaded with current. The raw materials react to produce glass mainly by hydrogen-oxygen combustion, and current loading is used as a supplement to provide heat.

[0041] The electrode in the kiln of the present invention is a heating device that converts its own electrical energy into heat energy by applying current from the outside, and then applies it to the glass liquid in contact to increase its temperature. The electrode of the kiln is made of refractory bricks composed of one or more conductive materials such as molybdenum, carbon and tin oxide. As an option, the electrode is assembled from multiple rectangular small blocks of electrode bricks, one end of the electrode is connected to the power supply device, and the other end contacts the glass liquid.

[0042] The kiln heating process of the present invention is a process of continuously heating the kiln from a normal temperature state by providing heat through reaction, especially heating the refractory material of the entire kiln, so that the kiln enters a certain high temperature state.

[0043] The glass raw material is put into the kiln of the present invention by using a special conveying device to deliver the raw material into the kiln through a hole preset in the kiln. The raw material is melted by chemical reaction under the condition of continuous high temperature heating in the kiln. The glass raw material is a material composed of one or more inorganic mineral materials such as quartz sand, limestone, boric acid, barium carbonate and soda ash. The glass raw material can be in the form of fine powder particles or flakes.

[0044] In the present invention, the structural characteristic parameters of the kiln refer to the structural characteristics of the kiln design and installation, such as the length, width and height of the kiln, the number of groups of electrode equipment and the size of the feeding port. The characteristic parameters will be used as a process reference during the current loading process. The kiln temperature parameters refer to the actual temperature values ​​of each area of ​​the kiln during the heating process of the kiln, rather than the theoretical temperature values. The characteristic parameters will be used as a process reference during the current loading process. The preset current loading process parameter value means that during the process of feeding glass raw materials, the kiln needs to continuously provide heat through the electrodes to melt the glass raw materials into glass liquid. The process reference parameters of the current value required to be set for the electrodes.

[0045] The control method for current loading during the heating process of the glass kiln of the present invention is to start feeding glass raw materials when the kiln is heated. The glass raw materials gradually melt and establish the glass liquid level of the kiln. When the glass liquid level contacts the electrode material and exceeds its minimum height, the electrode is started, the initial current value is set, and the current is loaded. The glass liquid level of the kiln continues to rise, and the amount of glass raw materials per hour increases. The loading current should be adjusted according to the process, but the gear should be adjusted according to the voltage, resistance and electric power extreme values. And the gear refers to the loading range of the current within a process range of the voltage. The glass liquid level of the kiln rises to the right place, the kiln is rinsed, the kiln does not feed glass raw materials, and the kiln temperature is also stable and unchanged. Then the loading current should be adjusted by process reduction. The kiln starts to feed glass raw materials again, and the amount of materials per hour is continuously increased. The temperature at the bottom of the kiln will also rise. The loading current will be increased and adjusted, and the currents of each electrode in the kiln begin to be set from high to low. The kiln glass raw material feeding process and temperature control process have reached the normal production control range, and the loading current should be gradually adjusted to the process requirement range.

[0046] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Any ordinary technician in the industry can smoothly implement the present invention as shown in the specification and described above. However, any equivalent changes, modifications and evolutions made by technicians familiar with the profession without departing from the scope of the technical solution of the present invention using the technical content disclosed above are all equivalent embodiments of the present invention. At the same time, any equivalent changes, modifications and evolutions made to the above embodiments based on the essential technology of the present invention are still within the protection scope of the technical solution of the present invention.

Claims

1. A method for controlling current loading during the heating process of a glass furnace, characterized in that: The steps include: S1. When the glass raw material is put into the furnace and the temperature starts to rise, when the glass liquid level in the furnace reaches the height at which the electrode can load the current, the electrode is started and the initial current value is set for loading; S2: Based on the height of the glass liquid level in the furnace and the amount of glass raw materials added at a preset time interval, the loading current is adjusted, and the current gear is adjusted in combination with the parameters of voltage, resistance and electric power; S3: During the kiln rinsing stage, stop feeding glass raw materials, keep the kiln temperature stable, and adjust the loading current to a value suitable for kiln rinsing; S4: After the rinsing stage, the furnace starts to feed glass raw materials again, and the loading value of the electrode current in each area of ​​the furnace is adjusted; S5: When the kiln glass raw material process and temperature control process have reached the production control range, the loading current will be adjusted to a stable value required by the process.

2. The method for controlling current loading during the heating process of a glass furnace according to claim 1, characterized in that: In the step S1, the initial current value is set based on the structural characteristic parameters of the furnace, the initial amount of glass raw materials fed, and the preset furnace temperature target value.

3. The method for controlling current loading during the heating process of a glass furnace according to claim 2, characterized in that: In S1, the structural characteristic parameters of the kiln include the length, width and height of the kiln, the number of groups of electrode equipment, the size of the kiln charging port, and the structural characteristics of the kiln design and installation.

4. The method for controlling current loading during the heating process of a glass furnace according to claim 2, characterized in that: In S1, the parameters of the glass raw materials added during the heating process of the kiln are the components of the raw materials, and the raw materials include one or more combinations of quartz sand, limestone, boric acid, barium carbonate and soda ash.

5. The method for controlling current loading during the heating process of a glass furnace according to claim 1, characterized in that: In S1, the temperature parameters of the kiln include: actual temperature values ​​monitored at various areas of the kiln during the heating process of the kiln.

6. The method for controlling current loading during the heating process of a glass furnace according to claim 1, characterized in that: In S2, the adjustment of the current level is also combined with the distribution of actual temperatures in various areas of the kiln.

7. The method for controlling current loading during the heating process of a glass furnace according to claim 1, characterized in that: In S3, during the heating process of the kiln, the parameters of the kiln temperature, current and voltage are monitored in real time by a preset monitoring unit, and the loading current is automatically adjusted according to the monitoring results.

8. The method for controlling current loading during the heating process of a glass furnace according to claim 1, characterized in that: In S3, when the glass liquid level in the furnace reaches a preset height, the furnace starts a rinsing phase.

9. The method for controlling current loading during the heating process of a glass furnace according to claim 1, characterized in that: In S4, after the rinsing stage is completed, the loading current is controlled to increase based on the increase of glass raw materials and the rise of the bottom temperature of the furnace.

10. A system based on the control method of current loading during the heating process of a glass furnace as claimed in any one of claims 1 to 9, characterized in that: The system includes a current loading module, a monitoring module, a control module, a data processing module and a human-computer interaction module, wherein: The current loading module is used to load current in stages during the kiln heating process according to a preset current loading process; The monitoring module is used to monitor the temperature, current and voltage parameters of the kiln in real time; The data processing module is used to process the data monitored by the monitoring module to evaluate the heating status of the kiln and generate adjustment instructions to send to the control module; The control module is used to adjust the loading current of the current loading module according to the adjustment instruction, and control the gear, frequency and time of the loading current; The human-computer interaction module is used to display the operating status and parameters of the kiln, and to allow the user to input preset process parameters and instructions.

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