Float glass kiln flue online trepanning building method smoke guide environment-friendly system

Abstract

The invention discloses a float glass kiln flue online trepanning building method which comprises the following steps: step 1, looking up an original flue design drawing; step 2, positioning an opening part on the flue; thirdly, surface heat preservation cotton and heat preservation bricks in the trepanning area are dismantled, and an inner layer is reserved; fourthly, a ring beam manufactured in advance is installed at the hole opening position; fifthly, the steel flue and the ring beam are in butt joint and fully welded; sixthly, a temporary steel gate plate is installed; seventhly, the inner layer of the trepanning area is dismantled from top to bottom, and the temporary flashboard is put down to cover the dismantling position every time a layer of bricks is dismantled; and eighthly, the gate plate door is installed. The device is used for ensuring that a flue wall is stable for a long time after tapping, and is smoothly butted with an environment-friendly standby system interface, so that the environment-friendly standby system can normally introduce flue gas for environment-friendly treatment and stable operation, and the aim of up-to-standard emission of float glass enterprises is fulfilled.

Description

Technical Field

[0001] The invention relates to an online hole-opening construction method for a flue of a float glass furnace and a smoke-inducing environmental protection system. Background Art

[0002] Since the original float glass production line in the building has an environmental protection system installed, once it fails, the smoke can only be discharged directly from the chimney, causing environmental pollution until the environmental protection system resumes normal operation. From July 1, 2024, in accordance with the new environmental protection standards issued by the state, direct discharge of smoke is not allowed, and 100% environmental standards must be met.

[0003] In order to solve the problem of direct exhaust of flue gas, the company needs to build another set of environmental protection backup system. However, when building an environmental protection backup system, the first problem encountered is the online opening of the original kiln flue. Since the beams in the flue opening area were not built into "arches" or "flats" in advance during the masonry, it is easy to cause the wall or flue crown above the flue opening to collapse during the flue opening process; in addition, the exhaust gas in the online opening flue not only has a high temperature of about 500℃, but also contains harmful gases such as SO2, NOX and dust, which increases the technical difficulty of online opening for operators, and at the same time has a great impact on the "kiln pressure stability" of the "four stability" of the kiln, which directly affects the yield of glass production.

[0004] How to drill holes for the flue online, how to avoid kiln pressure fluctuations, the collapse of the flue wall and the safety of construction workers, etc., are a series of technical problems that urgently need to be solved in this technical solution. Summary of the invention

[0005] The purpose of the present invention is to provide a float glass furnace flue online opening construction method to solve at least one of the above technical problems. The method of the present invention comprises the following steps:

[0006] Step 1: Check the original flue design drawings to understand the masonry thickness of the flue wall, masonry brick materials and the distribution of the flue structure;

[0007] Step 2: Refer to the flue structure design drawing, combine the basic positioning axis and reference points required by the environmental protection backup system, and use instruments to locate the openings on the flue;

[0008] Step 3: Remove the surface insulation cotton and insulation bricks in the opening area and keep the inner layer;

[0009] Step 4: After the surface insulation cotton and insulation bricks of the flue are removed, the pre-made ring beam is installed in the opening position according to the designed opening size; the gap between the ring beam and the lightweight insulation red brick is sealed with high-temperature resistant concrete, and after the high-temperature concrete hardens, the ring beam is fixed on the flue to form a whole;

[0010] Step 5: After the ring beam is installed, weld the pre-made steel flue to the ring beam;

[0011] Step 6: Install a temporary steel gate plate near the ring beam of the steel flue;

[0012] Step 7: Remove the inner layer of the opening area from top to bottom. After each layer of bricks is removed, lower the temporary gate to cover the removal position. Remove and hook out the clay bricks layer by layer, and gradually lower the temporary gate. Repeat the operation until all the clay bricks inside are removed and hooked out, and all the temporary gates fall down.

[0013] Step eight, weld the prefabricated steel flue firmly and install the gate door; after the gate door is installed, cut off the lowest horizontal plate of the temporary gate, weld the temporary manhole door, and after the flue is connected, fully drop the gate door, take out the temporary gate, fill the upper gap with steel plate and weld it, and the flue online opening and docking is completed.

[0014] Furthermore, in step 2, the vertical and horizontal center lines of the hole are marked with ink lines, and the center line of the opening is marked with a triangle using red paint.

[0015] Furthermore, in step 2, the allowable deviation of the basic marking is 20 mm for the coordinate position, ±20 mm for the plane dimension, and -20 to 0 mm for the elevation of different planes.

[0016] Furthermore, in step 2, the cross-sectional area of ​​the opening = daily flue gas volume / (3600*7); wherein, the daily theoretical flue gas volume = daily heavy oil consumption × 12.9 × 1000 × 21÷13.

[0017] Furthermore, in step four, the ring beam is made of 12Cr1MoV heat-resistant steel plate material.

[0018] Furthermore, in step five, the steel flue is made into a square flue using Q235B steel plate with a thickness of 6 mm.

[0019] Furthermore, in step six, the temporary gate is L-shaped.

[0020] Furthermore, in steps six and seven, a hand winch is used to control the lifting and lowering of the steel gate.

[0021] Compared with the background technology, this technical solution has the following advantages:

[0022] The present invention aims at the problems that the flue wall or flue arch may collapse when the flue is opened online during the construction of the environmental protection backup system, and the float glass kiln pressure may fluctuate greatly during the construction process, affecting the production stability, and even causing harm to the construction personnel due to high temperature and harmful exhaust gas during the opening process. By designing a float glass kiln flue online opening construction method, the difficulties encountered during the construction process are avoided, so as to solve the problem of ensuring the long-term stability of the flue wall after the opening, and smoothly connecting with the environmental protection backup system interface, so that the environmental protection backup system can normally lead the "smoke" into the environmental protection treatment and stably operate, so as to achieve the purpose of the float glass enterprise meeting the emission standards.

[0023] The method for online hole drilling of the flue of a glass kiln of the present invention is to find the flue design drawings, take precise positioning, and after gradually drilling holes, first use a high-temperature resistant ring beam to reinforce the brick structure of the hole, and then use channel steel to weld the end of the cross beam to support the inner flue clay bricks to prevent the inner clay bricks from collapsing. Finally, a temporary gate is gradually lowered, which is not only conducive to the damage to the human body caused by high-temperature radiation and harmful gases during the removal of internal clay bricks, but also reduces the outside air entering the flue to cause fluctuations in the kiln pressure of the production line, thereby causing production losses. Through the present invention, the main flue of the glass kiln can not only open the gate at any time to drill holes online to "introduce smoke" and connect to the environmental protection system, but also can be used to drill holes to clean up dust accumulation in the flue, etc., improve the glass production process, improve the glass quality, and thus enhance the core competitiveness of the enterprise. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0025] Figure 1 This is a schematic diagram of the masonry thickness structure of the flue wall. 100- Flue bottom paving bricks 200- Clay brick wall 300- Lightweight insulation red bricks 400- Flue insulation layer of 1+1 mode of aluminum silicate wool and rock wool 500- Flue arch

[0026] Figures 2 to 8 It is a schematic diagram of the process of the present invention.

[0027] Figure 2 Schematic diagram of removing surface insulation wool and insulation bricks.

[0028] Figure 3 Schematic diagram of the installation and fixing of the ring beam.

[0029] Figure 4 Schematic diagram of full welding of steel flue and ring beam.

[0030] Figure 5 Schematic diagram of temporary gate installation.

[0031] Figure 6 Schematic diagram of wall brick removal.

[0032] Figure 7 Schematic diagram of wall removal and temporary gate adjustment.

[0033] Figure 8 Schematic diagram of the temporary gate being fully lowered. DETAILED DESCRIPTION

[0034] A float glass furnace flue online opening construction method comprises the following steps:

[0035] 1. Check the original flue design drawings to understand the thickness of the flue wall, the brick materials used for the construction, the distribution of refractory materials such as the flue structure, etc. Figure 1 As shown: For example, in the existing float glass production line of Zhangzhou Qibin Glass Co., Ltd., the standard design of the wall of the float glass kiln flue is to lay ordinary clay bricks inside with a wall thickness of 240mm, lay lightweight thermal insulation red bricks in the middle with a wall thickness of 240mm, and lay the surface in a 1+1 mode of aluminum silicate wool and rock wool, and then brush a layer of thermal insulation mud on the surface for insulation.

[0036] 2. Positioning and laying out:

[0037] Referring to the flue structure design construction drawing, combined with the basic positioning axis and reference points required by the environmental protection backup system, use instruments to locate the openings on the flue, then pop out the vertical and horizontal center lines of the holes with ink lines, and mark the center lines of the openings with triangles using red paint. The allowable deviation of the basic marking is shown in Table 1.

[0038] Table 1 Error allowable values

[0039] project Allowable deviation (mm) Coordinate position (vertical and horizontal axis) 20 Plane dimensions ±20 Elevations of different planes -20～0

[0040] 3. Remove the surface insulation cotton and insulation bricks

[0041] Arrange bricklayers to remove the surface insulation cotton layer and lightweight insulation red bricks of the flue according to the markings, and clean up the brick slag around the opening. Figure 2 shown.

[0042] 4. Install ring beams around the opening and pour with high temperature resistant concrete

[0043] According to the size of the flue opening, a ring beam similar to a door frame is made in advance with 12Cr1MoV heat-resistant steel plate material. After the surface insulation cotton and lightweight insulation red bricks of the flue are removed, the pre-made ring beam is installed at the opening position according to the designed opening size. The gap between the ring beam and the lightweight insulation red brick is sealed by pouring high-temperature resistant concrete. After the high-temperature concrete hardens, the ring beam is fixed on the flue to form a whole. Figure 3 shown.

[0044] 5. Steel flue connection

[0045] After the ring beam is installed, the pre-made steel flue (the steel flue is made of Q235B, 6mm thick steel plate to form a square flue) is fully welded to the ring beam. Figure 4 shown.

[0046] 6. Temporary gate installation

[0047] In order to reduce air leakage and protect the drillers during drilling, a temporary steel gate is installed near the ring beam of the steel flue, and the steel gate is raised and lowered by a hand winch. When the operator begins to dismantle the brick flue, the temporary steel gate adjusts its height according to the progress of brick removal, which not only reduces air leakage and utilizes the "kiln pressure stability" of the four small stability of float production, but also isolates the high-temperature harmful flue gas in the flue from harming the operators. Figure 5 As shown in the figure, the temporary steel gate is L-shaped. The horizontal section of the L-shape is inserted inwards into the opening.

[0048] 7. Brick flue opening

[0049] 7.1 Arrange bricklayers to use prefabricated sharp picks, hammers and long hooks to remove 2 layers of clay bricks inside. Figure 6 shown.

[0050] 7.2 Since float glass production uses heavy oil as fuel, the exhaust gas produced after the heavy oil is burned at high temperature in the kiln contains harmful substances such as sulfur dioxide, nitrogen oxides and dust. The SO2 concentration in the flue gas is about 1000mg / m3, and the NOx concentration is about 1500mg / m 3 , dust concentration is about 300mg / m 3 In addition, the smoke temperature in the flue is about 500℃. Therefore, when removing bricks from the brick flue, each time a layer of bricks is removed, the temporary gate is lowered to cover it, which not only prevents the high-temperature smoke from overflowing and scalding and poisoning the operators, but also avoids the flue gas fluctuations that cause the kiln pressure fluctuations to affect production. Figure 7 shown.

[0051] 7.3 Repeat the steps in 7.2, remove and hook out the clay bricks layer by layer, and gradually lower the temporary gate. Continue to repeat the operation until all the clay bricks inside are removed and hooked out, and all the temporary gates fall down. Figure 8 shown.

[0052] 8. Weld the prefabricated steel flue firmly and install the gate door. After the gate door is installed, cut off the bottom horizontal plate of the temporary gate, weld the temporary manhole door, and after the flue is connected, drop the gate door completely, take out the temporary gate, fill the upper gap with steel plate and weld it, and the flue online opening is completed.

[0053] Example 1

[0054] In line with the national environmental protection needs, Zhangzhou Kibing Glass Co., Ltd. began to build an environmental protection backup system on lines 1# and 2# in January 2021, named A environmental protection backup system. In October 2021, the main construction of A environmental protection backup system was completed and it is about to be put into commissioning and operation, but it requires online drilling of the main flue of the 1# production line to connect to the environmental protection backup system. After consulting the line construction drawings and on-site analysis and research, the above-mentioned "online drilling construction method for the flue of the float glass kiln" docking process was adopted to successfully complete the drilling and commissioning. Subsequently, the same method was used to complete the online drilling docking and commissioning and operation on line 2#. The implementation process is described as follows:

[0055] ①、Calculation of theoretical flue gas volume of 1# production line (daily exhaust volume of 1# production line is 1000t / d):

[0056] Theoretical daily flue gas volume of float glass production line = daily heavy oil consumption × 12.9 × 1000 × 21 ÷ 13

[0057] 12.9—Empirical constants for conversion into flue gas when heavy oil is used as fuel in float production line

[0058] 13—Refers to the 8% residual oxygen conversion factor in flue gas

[0059] 21—refers to the oxygen content in the air of 21%

[0060] Theoretical daily flue gas volume of production line 1# = 130 × 12.9 × 1000 × 21 ÷ 13 = 2709000m 3 / D

[0061] Smoke volume per hour = 2709000 ÷ 24 = 112875 m3 / h

[0062] ②. The size of the brick flue opening is based on:

[0063] a. Because float glass flue gas contains a large amount of harmful gases such as sulfur dioxide and nitrogen oxides, low-porosity clay bricks are used in the main flue of the kiln, which are not only highly corrosion-resistant but also low in cost;

[0064] b. The environmentally friendly flue is made of 6-8mm thick Q235B carbon steel, which has strong corrosion resistance:

[0065] C. According to the test results, the flow rate of float glass smoke is about 7m / s

[0066] Flue gas volume Q = flow rate U * opening cross-sectional area S * 3600:

[0067] Opening cross-sectional area S = amount of smoke passing through (m 3 / h) / (3600*wind speed(m / s))

[0068] Calculation shows: Opening cross-sectional area = smoke volume / (3600*7) = 112875÷3600÷7 = 4.48m 2

[0069] According to the on-site conditions of the 1# production line, the opening length is 3.7m and the width is 1.5m, with a total opening area of ​​3.7×1.5=5.5m 2 In this way, the actual opening area is larger than the theoretical area, ensuring that there is room for the increase in flue gas volume caused by the increase in fuel volume due to the increase in kiln age in the later stage of the kiln.

[0070] First, remove the insulation cotton on the surface of the flue to expose the insulation red bricks on the wall surface. Use red spray paint to mark the size of the hole to be opened 3.7m×1.5m in advance, and then arrange the bricklayer to gradually remove the insulation red bricks to expose the main clay bricks of the flue.

[0071] Clean up the brick scraps and other debris around the opening, and organize the fitter to insert the ring beam made of 12Cr1MoV heat-resistant steel plate into the door frame. The gap between the ring beam and the lightweight insulation red brick is sealed with high-temperature resistant concrete. After the high-temperature concrete hardens, the ring beam is fixed on the flue to form a whole.

[0072] After the high-temperature cement around the ring beam solidifies the next day, organize fitters to connect the flue. Fully weld the flue and ring beam prefabricated in advance according to size, install a temporary steel gate near the ring beam of the steel flue, and use a hand winch to control the lifting of the steel gate. After everything is ready, arrange the bricklayers to start removing bricks. Bricklayers need to wear gas masks and heat-insulating masks to prevent high-temperature burns and smoke poisoning. Every time a layer of clay bricks is removed, the temporary gate falls down through the hand winch until all the walls are removed. After the wall is removed, immediately organize fitters to install a steel gate on the other side of the steel flue to control the size of the smoke. The steel gate is required to meet remote operation and control the gate opening accuracy of 1%.

[0073] Example 2

[0074] In March 2021, Zhangzhou Qibin Glass Co., Ltd. began to build an environmental protection backup system on lines 3#-8#, named B environmental protection backup system. It is an environmental protection system that uses high-temperature ceramic tube dust removal and humidification for desulfurization. In January 2022, the main construction of the B environmental protection backup system was completed and it will be put into commissioning and operation soon, but it requires the main flue of the 6# production line to be opened online to connect to the environmental protection backup system. After on-site analysis and research, the above flue online opening and docking process was adopted to successfully complete the opening and commissioning. Subsequently, the same method was used to complete the online opening and docking and commissioning and operation were successful in other 3-8# lines. The implementation process is described as follows:

[0075] ①、Calculation of theoretical flue gas volume of 6# production line (daily exhaust volume of 1# production line is 900t / d):

[0076] Theoretical daily flue gas volume of float glass production line = daily heavy oil consumption × 12.9 × 1000 × 21 ÷ 13

[0077] 12.9—Empirical constants for conversion into flue gas when heavy oil is used as fuel in float production line

[0078] 13—Refers to the 8% residual oxygen conversion factor in flue gas

[0079] 21—refers to the oxygen content in the air of 21%

[0080] Theoretical daily flue gas volume of 1# production line = 130×12.9×1000×21÷13=2500615m3 / D

[0081] Smoke volume per hour = 2709000 ÷ 24 = 104192 m3 / h

[0082] ②. The size of the brick flue opening is based on:

[0083] a. Because float glass flue gas contains a large amount of harmful gases such as sulfur dioxide and nitrogen oxides, low-porosity clay bricks are used in the main flue of the kiln, which are not only highly corrosion-resistant but also low in cost;

[0084] b. The environmentally friendly flue is made of 6-8mm thick Q235B carbon steel, which has strong corrosion resistance:

[0085] C. According to the test results, the flow rate of float glass smoke is about 7m / s

[0086] Flue gas volume Q = flow rate U * opening cross-sectional area S * 3600:

[0087] Opening cross-sectional area S = amount of smoke passing through (m 3 / h) / (3600*wind speed(m / s))

[0088] Calculation shows: Opening cross-sectional area = smoke volume / (3600*7) = 104192÷3600÷7 = 4.14m2

[0089] According to the on-site conditions of the 6# production line, the opening length is 2.2m and the width is 2.2m, with a total opening area of ​​2.2×2.2=4.84m 2 In this way, the actual opening area is larger than the theoretical area, ensuring that there is room for the increase in flue gas volume caused by the increase in fuel volume due to the increase in kiln age in the later stage of the kiln.

[0090] First, remove the insulation cotton on the surface of the flue to expose the insulation red bricks on the wall surface. Use red spray paint to mark the size of the hole to be opened 2.2m×2.2m in advance, and then arrange the bricklayer to gradually remove the insulation red bricks to expose the main clay bricks of the flue.

[0091] Clean up the brick scraps and other debris around the opening, and organize the fitter to insert the ring beam made of 12Cr1MoV heat-resistant steel plate into the door frame. The gap between the ring beam and the lightweight insulation red brick is sealed with high-temperature resistant concrete. After the high-temperature concrete hardens, the ring beam is fixed on the flue to form a whole.

[0092] After the high-temperature cement around the ring beam solidifies the next day, the fitters are organized to connect the flue. The flue prefabricated in advance according to the size is fully welded to the ring beam, and a temporary steel gate is installed near the ring beam of the steel flue. The steel gate is controlled by a hand winch to rise and fall. After everything is ready, the bricklayers are arranged to start removing bricks. The bricklayers need to wear gas masks and heat-insulating masks to prevent high-temperature burns and smoke poisoning. Every time a layer of clay bricks is removed, the temporary gate is lowered by a hand winch until all the walls are removed.

[0093] After the wall was demolished, fitters were immediately organized to install a steel gate on the other side of the steel flue to control the size of the smoke. The steel gate is required to meet the requirements of remote operation and control the gate opening accuracy of 1%.

[0094] The above description is only a preferred embodiment of the present invention, and therefore cannot be used to limit the scope of the present invention. That is, equivalent changes and modifications made according to the patent scope of the present invention and the contents of the specification should still fall within the scope of the present invention.

Claims

1. A float glass furnace flue online opening construction method, comprising the following steps: Step 1: Check the original flue design drawings to understand the masonry thickness of the flue wall, masonry brick materials and the distribution of the flue structure; Step 2: Refer to the flue structure design drawing, combine the basic positioning axis and reference points required by the environmental protection backup system, and use instruments to locate the openings on the flue; Step 3: Remove the surface insulation cotton and insulation bricks in the opening area and keep the inner layer; Step 4: After the surface insulation cotton and insulation bricks of the flue are removed, the pre-made ring beam is installed at the opening position according to the designed opening size; the gap between the ring beam and the lightweight insulation red brick is sealed with high-temperature resistant concrete, and after the high-temperature concrete hardens, the ring beam is fixed on the flue to form a whole; Step 5: After the ring beam is installed, weld the pre-made steel flue to the ring beam; Step 6: Install a temporary steel gate plate near the ring beam of the steel flue; Step 7: Remove the inner layer of the opening area from top to bottom. After each layer of bricks is removed, lower the temporary gate to cover the removal position. Remove and hook out the clay bricks layer by layer, and gradually lower the temporary gate. Repeat the operation until all the clay bricks inside are removed and hooked out, and all the temporary gates fall down. Step eight, weld the prefabricated steel flue firmly and install the gate door; after the gate door is installed, cut off the lowest horizontal plate of the temporary gate, weld the temporary manhole door, and after the flue is connected, fully drop the gate door, take out the temporary gate, fill the upper gap with steel plate and weld it, and the flue online opening and docking is completed.

2. The method for online opening and construction of a flue of a float glass furnace according to claim 1, characterized in that: In step two, the vertical and horizontal center lines of the hole are marked with ink lines, and the center line of the opening is marked with a triangle using red paint.

3. The method for online opening and construction of a flue of a float glass furnace according to claim 1, characterized in that: In step 2, the allowable deviation of the foundation marking is 20mm for the coordinate position, ±20mm for the plane dimension, and -20 to 0mm for the elevation of different planes.

4. The method for online opening and construction of a flue of a float glass furnace according to claim 1, characterized in that: In step 2, the calculation method of the opening cross-sectional area is: opening cross-sectional area = daily smoke volume / (3600*7); wherein, daily smoke volume = daily heavy oil consumption × 12.9 × 1000 × 21÷13.

5. The method for online opening and construction of a flue of a float glass furnace according to claim 1, characterized in that: In step 4, the ring beam is made of 12Cr1MoV heat-resistant steel plate material.

6. The method for online opening and construction of a flue of a float glass furnace according to claim 1, characterized in that: In step five, the steel flue is made into a square flue using Q235B steel plate with a thickness of 6 mm.

7. The method for online opening and construction of a flue of a float glass furnace according to claim 1, characterized in that: In steps six and seven, use a hand winch to control the lifting and lowering of the steel gate.

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