Assembly type kiln oven and baking bin

Abstract

The invention relates to an assembled kiln oven and a baking bin, and belongs to the technical field of kiln ovens. The kiln oven adopts a modular design, comprises four core components, namely a supporting framework, a baking bin, a bottom bin and an operation table, and can be conveniently mounted and dismounted. The baking bin and the top bin form a main body structure through a fire-resistant base, and the top bin adopts an eight-layer composite layered design and sequentially comprises a metal shell bin shell, a self-adaptive expansion layer, an external bearing heat preservation layer, an aerogel plate layer, a supporting framework layer, a heat reflection shielding layer, a structure reinforcing layer and a refractory brick layer from outside to inside. The operation table integrates a baking inlet and outlet, an ash outlet and a firewood inlet and outlet, an internal arched channel communicates with the baking bin, an ash falling table and a drawer type ash box are arranged, and efficient ash collection is achieved. The supporting framework is of a double-frame structure of a circular frame and a U-shaped frame. The thermal insulation performance and the thermal efficiency are remarkably improved, the thermal shock resistance and the structural reliability are enhanced, meanwhile, the energy consumption and the maintenance cost are reduced, and the requirement for food baking uniformity is met.

Description

Technical Field

[0001] The present invention relates to the technical field of kiln baking ovens, and in particular to an assembled kiln baking oven and a baking chamber. Background Art

[0002] Kiln baking is a traditional method of baking food in a closed kiln structure to preserve its unique flavor. Most ovens used for kiln baking generate heat through open flame combustion, and use the heat storage and insulation properties of the kiln baking chamber to form a stable high-temperature environment inside. It can be used to bake a variety of ingredients such as bread, vegetables, pizza, meat, seafood, etc., and with the advantage of even heat distribution, it can give ingredients a unique flavor and taste. It is widely used in food processing scenarios that focus on traditional craftsmanship or batch baking.

[0003] Currently, most mainstream kiln baking ovens on the market are built in the form of buildings. These ovens must be constructed according to a building construction process, starting with site selection and foundation construction. Construction then continues with the laying of refractory bricks, pouring of insulation, and erection of a supporting framework. This entire process not only relies on a professional construction team but also requires a lengthy construction period, often taking weeks or even months from the preparation stage to commissioning. Furthermore, building-type kilns are fixed structures and cannot be moved or disassembled once constructed. Subsequent adjustments to the location, baking scale, or equipment relocation due to site planning adjustments require demolition and reconstruction. This not only results in significant material and financial waste, but also generates a significant amount of construction waste, which is not environmentally friendly. Furthermore, building-type kilns are expensive to manufacture. In addition to the cost of raw materials, they also include site rental, labor, and equipment commissioning. This creates a significant initial investment burden for small and medium-sized food processing companies or individual operators, severely hindering the widespread adoption and promotion of kiln baking technology. Precisely because existing building-type kiln baking furnaces have problems such as long construction period, fixed and immovable structure, high manufacturing cost, and difficulty in subsequent maintenance and transformation, the industry urgently needs a new type of equipment that can break through these limitations. Therefore, the design of assembled kiln baking furnaces has become an inevitable trend. Through modular design, the equipment is disassembled into core components that can be independently manufactured, transported and installed, which can greatly simplify the production and installation process, shorten the commissioning cycle, and facilitate mobility and subsequent maintenance, reduce costs, and promote the widespread application of kiln baking furnace technology.

[0004] The design of the baking chamber is a key aspect of the entire kiln oven. Existing kiln ovens often use simple, traditional refractory materials, such as ordinary refractory bricks paired with simple insulation felt. These structures have high thermal conductivity and significant heat loss, leading to low energy efficiency and increased energy costs. They also make it difficult to create a stable, uniform temperature field within the baking chamber, making it prone to large local temperature differences, impacting the quality and consistency of baked food. Furthermore, existing structures have poor thermal shock resistance. During frequent heating and cooling cycles, inconsistent thermal expansion coefficients can easily generate thermal stress, leading to cracks and spalling in the kiln body, shortening the equipment's service life and increasing maintenance costs. Existing kiln ovens often use simple, crude methods for connecting the various structural layers, often using ordinary mud bonding or direct splicing. These methods have low bonding strength and are prone to interlayer separation and loosening under prolonged high temperatures and mechanical vibration, impacting overall structural stability. Furthermore, interlayer gaps can lead to heat loss and smoke leakage, reducing insulation effectiveness and polluting the baking environment and food, posing a food safety risk. Furthermore, the material advantages of each layer cannot be fully utilized, limiting the overall performance of the equipment. In the existing technology, the supporting structure of kiln ovens is mostly a simple metal frame or brick support with limited bearing capacity, which makes it difficult to stably support the weight of core components such as the baking chamber. The strength of the supporting material further decreases under high temperature environment, and the structure is prone to deformation or even collapse risk. In the existing technology, the functional entrances and exits of the kiln oven operating table are scattered, and the location layout is inconvenient to operate. Operators need to move frequently when taking and placing food, adding fuel, and cleaning ash, which is labor-intensive and has low operating efficiency. In addition, the ash collection system of existing kiln ovens is imperfect, and most of them are open or semi-open. The ash is inconvenient to clean and is easy to scatter, polluting the operating environment and increasing the difficulty of cleaning and maintenance.

[0005] In view of the problems existing in the above-mentioned existing technologies, it is urgent to develop and implement assembled kiln ovens and baking chambers to improve the comprehensive performance and practicality of kiln ovens and meet the demand of the food processing field for efficient, energy-saving, safe and convenient kiln baking equipment, which is of great significance. Summary of the Invention

[0006] To solve the problems existing in the background technology, the present invention provides an assembled kiln oven, which includes a support frame and a baking chamber, a bottom chamber and an operating table installed on the support frame. The operating table is provided with a baking entrance and exit, an ash outlet and a firewood outlet, and an arched passage, an ash drop platform and an ash box are provided inside the operating table; wherein: The arched passage is connected to the baking entrance and exit and the baking chamber; the ash drop platform is arranged in the arched passage, the ash drop platform is provided with an ash drop opening, and an ash box is installed below the ash drop opening; A firewood box connected to the firewood inlet and outlet is provided in the bottom bin; Support legs are connected below the bottom bin.

[0007] In a preferred solution, the baking bin is installed above the supporting frame, the bottom bin is installed below the supporting frame, and the operating table is installed in front of the supporting frame.

[0008] In the preferred solution, the supporting frame includes a circular frame and a U-shaped frame, the baking bin is installed above the circular frame, and the bottom bin is installed below the circular frame; the U-shaped frame is connected to the bottom of the circular frame and is arranged in the bottom bin; the ash box is installed in the U-shaped frame.

[0009] In a preferred solution, a chimney is further provided, which is installed on the operating table, and the interior of the chimney is connected to the baking chamber through an arched passage.

[0010] In a preferred embodiment, the baking chamber comprises a refractory base and a top chamber mounted on the refractory base, wherein the top chamber is provided with: The silo shell is a metal shell that provides overall structural support; The adaptive expansion layer is located between the silo shell and the external load-bearing insulation layer. The adaptive expansion layer is made of a multi-walled nanotube-reinforced sodium sulfate-based structural material. The multi-walled nanotube-reinforced sodium sulfate-based structural material is formed into the main structure of the adaptive expansion layer by hot pressing. The external load-bearing insulation layer is composed of a new type of porous refractory ceramic material consisting of a high-purity alumina matrix, closed-pore hollow alumina microspheres, and silicon carbide whiskers; Aerogel board layer, using basalt fiber reinforced nitrogen-doped silicon carbide aerogel material as the main thermal barrier layer; The supporting skeleton layer is composed of an iron-chromium-aluminum heat-resistant alloy rib frame and a multi-phase lightweight magnesium-silicon system composite material filler, providing structural support and radiation management; The heat-reflecting shielding layer, which uses a zircon matrix layer embedded with micro-arc oxidized titanium foil, is provided on the outer surface of the structural reinforcement layer; The structural reinforcement layer, made of fiber-reinforced ceramic composite material, is attached to the outer surface of the refractory brick layer to bear the mechanical load, inhibit crack growth and evenly distribute thermal stress; The refractory brick layer is made of high-alumina bauxite-based refractory material. It is the innermost layer that directly contacts the open flame, and the inner surface is coated with a refractory coating.

[0011] Furthermore, the inner surface of the external load-bearing insulation layer is provided with a continuous trapezoidal corrugated groove array; the outer surface of the aerogel plate layer is provided with a matching trapezoidal corrugated protrusion array; the protrusion array is embedded in the groove array in a clearance fit manner; the inner surface of the aerogel plate layer is provided with a rectangular groove groove array; the outer surface of the supporting skeleton layer is provided with a rectangular protrusion array, and the rectangular protrusions of the rectangular protrusion array are pressed into the grooves with an interference fit; spherical protrusions are evenly distributed on the inner surface of the ribs of the supporting skeleton layer; corresponding spherical grooves are provided on the outer surface of the heat-reflecting shielding layer, and the spherical protrusions cooperate with the spherical grooves to form interlayer anchoring; the outer surface of the refractory brick layer is processed with a V-shaped groove array, and the inner surface of the structural reinforcement layer is provided with a V-shaped protrusion, and the tip of the V-shaped protrusion is embedded in the bottom of the groove.

[0012] Furthermore, the multi-walled nanotube-enhanced sodium sulfate-based structural material of the adaptive expansion layer is composed of the following components in parts by weight: 75-85 parts of sodium sulfate, 12-18 parts of multi-walled carbon nanotubes, and 3-8 parts of polyethylene glycol-400 fluidity improver; The adaptive expansion layer is provided with an Ω-shaped corrugated channel and an S-shaped microporous channel, and the S-shaped microporous channel is connected to the bottom of the Ω-shaped corrugated channel; The Ω-shaped corrugated channel and the S-shaped microporous channel are filled with a graphene-reinforced potassium nitrate-based composite material, wherein the graphene-reinforced potassium nitrate-based composite material comprises the following components in parts by weight: 78-85 parts of potassium nitrate, 5-8 parts of graphene nanosheets, and 4-7 parts of polyethylene glycol-600 fluidity improver; The new porous refractory ceramic material of the external load-bearing and heat-insulating layer includes, by weight: 70-85 parts of high-purity alumina, 20-30 parts of aluminum silicate fiber microspheres, and 3-5 parts of silicon carbide whiskers; The aerogel plate layer is made of basalt fiber reinforced nitrogen-doped silicon carbide aerogel material, and the materials include, by weight: 45-55 parts of polymethylsilane; 15-25 parts of basalt fiber; 8-12 parts of hexamethyldisilazane; 6-10 parts of colloidal silica binder; and 3-6 parts of polymethyl methacrylate.

[0013] Furthermore, the iron-chromium-aluminum heat-resistant alloy rib frame of the supporting skeleton layer is a three-dimensional cell in a crisscross shape, and the three-dimensional cell is filled with a high-strength cement-based composite material; the high-strength cement-based composite material comprises, by weight: 50-60 parts of Portland cement, 25-30 parts of silica sand, 4-7 parts of polypropylene fiber, 1-3 parts of sodium polynaphthalene formaldehyde sulfonate, and 4-8 parts of metakaolin; The zircon matrix layer of the heat reflective shielding layer comprises, by weight, 40-50 parts of zircon, 10-15 parts of chromium oxide, 15-20 parts of kaolin, 5-10 parts of titanium dioxide, 3-5 parts of calcium borate sintering aid, and 2-4 parts of sodium carboxymethyl cellulose; the micro-arc oxidation titanium foil is embedded in the zircon matrix layer; The fiber-reinforced ceramic composite material of the structural reinforcement layer comprises, by weight, 50-60 parts of mullite, 15-20 parts of silicon carbide fiber, 5-10 parts of activated alumina, and 5-8 parts of silica sol.

[0014] Furthermore, the high-alumina bauxite-based refractory material of the refractory brick layer includes, by weight: 45-50 parts of high-alumina bauxite, 15-20 parts of silicon carbide, 20-25 parts of mullite presynthetic material, 3-5 parts of microsilica powder, 2-3 parts of mixed rare earth oxides of ytterbium oxide and erbium oxide, and 1-2 parts of carboxymethyl cellulose organic cellulose binder; a coating is provided on the surface, and the coating includes, by weight: 40 parts of alumina micropowder, 25 parts of zirconium oxide, 20 parts of silica sol binder, 10 parts of aluminum titanate, 3 parts of butylated hydroxytoluene antioxidant, and 2 parts of sodium carboxymethyl cellulose rheology regulator.

[0015] Furthermore, the materials for preparing the refractory base include, by weight: 35-40 parts of fused white corundum; 25-30 parts of magnesium aluminum spinel; 20-25 parts of green silicon carbide; 5-8 parts of amorphous silicon dioxide; 2-3 parts of aluminum powder; 3-5 parts of aluminum dihydrogen phosphate; The surface of the refractory base is coated with an anti-stick coating, which includes an aluminum oxide-chromium oxide composite coating as a base layer and a ceramic coating as a surface layer. The aluminum oxide-chromium oxide composite coating as a base layer includes, by weight, 60 parts of aluminum oxide; 35 parts of chromium trioxide; and 5 parts of lanthanum oxide; and the ceramic coating as a surface layer includes, by weight, 30 parts of nano-silicon dioxide; 20 parts of methylphenyl silicone resin; and 5 parts of sodium dodecylbenzenesulfonate.

[0016] The beneficial effects achieved by the present invention are: First, the present invention utilizes a modular assembly design to achieve standardized production and convenient installation and maintenance of the kiln structure. The prefabricated kiln designed in this invention utilizes four core components: a support frame, baking chamber, bottom chamber, and operating table. Each component can be manufactured independently, significantly reducing manufacturing and transportation costs and simplifying on-site installation. The support frame's dual-frame design includes a circular frame and a U-shaped frame. The circular design enhances structural strength and promotes even heat distribution, while the bottom connection of the U-shaped frame effectively distributes the load and improves overall stability. The operating table's integrated baking, ash, and firewood inlets are strategically arranged, reducing operator workload and improving efficiency. The operating table features an arched channel structure, forming a continuous airflow path with the baking chamber and baking chamber, ensuring efficient heat transfer from the combustion area to the baking area. An ash dropout platform within the arched channel fully utilizes the channel space. Connected to the refractory base, it allows for efficient ash collection and, combined with the drawer-type ash bin design, allows for efficient ash removal.

[0017] Second, the baking chamber of this invention utilizes an eight-layer composite structure, achieving excellent thermal insulation and structural strength. The adaptive expansion layer utilizes a multi-walled nanotube-reinforced sodium sulfate-based structural material, which automatically adjusts its dimensions to reduce thermal stress during temperature fluctuations. Internally, the layer features Ω-shaped corrugated channels and S-shaped microporous channels, forming a three-dimensional air circulation network. The graphene-reinforced potassium nitrate-based composite filler exhibits excellent heat storage and thermal conductivity. The external load-bearing insulation layer utilizes a novel porous refractory ceramic material. The addition of closed-cell hollow alumina microspheres and silicon carbide whiskers significantly enhances thermal insulation and toughness. The aerogel sheet, serving as the primary thermal barrier, utilizes nitrogen-doped silicon carbide aerogel reinforced with basalt fibers, exhibiting extremely low thermal conductivity and excellent high-temperature resistance. The micro-arc titanium oxide foil embedded within the heat-reflecting shielding layer exhibits excellent heat reflection, effectively reducing radiative heat loss. The support skeleton layer's crisscross-shaped three-dimensional cell structure, filled with a high-strength cement-based composite material, provides reliable structural support and radiation management. The high-alumina bauxite-based refractory material used in the refractory brick layer incorporates mixed rare earth oxides, significantly improving the material's high-temperature performance and thermal shock resistance. The double-layer anti-stick coating on the refractory base, composed of an alumina-chromium oxide composite base layer and a nano-silica ceramic surface layer, offers excellent anti-stick properties and chemical inertness, ensuring the quality of baked goods and easy cleaning and maintenance of the equipment.

[0018] Third, the present invention achieves reliable connection and coordinated work between the functional layers through the interlayer matching structural design; the external load-bearing insulation layer and the aerogel plate layer adopt a trapezoidal corrugated concave-convex matching, which increases the contact area and improves the bonding strength and heat transfer efficiency. The aerogel plate layer and the supporting skeleton layer adopt an interference fit of rectangular protrusions and grooves, which can withstand mechanical loads and facilitate disassembly and replacement. The supporting skeleton layer and the heat-reflecting shielding layer adopt spherical protrusions and grooves to form an interlayer anchoring. The ball-and-socket connection can withstand thermal stress and mechanical loads, and can achieve a certain relative displacement to adapt to thermal expansion and deformation. The structural reinforcement layer and the refractory brick layer adopt a mechanical locking connection with V-shaped protrusions embedded in V-shaped grooves, which effectively inhibits crack propagation and evenly distributes thermal stress.

[0019] Fourth, the baking chamber of the present invention achieves significant improvements in multiple technical performance characteristics through the rational configuration of advanced materials and sophisticated structural design. In terms of thermal insulation, the eight-layer composite structure of the present invention significantly reduces thermal conductivity compared to traditional single-material structures through the synergistic effect of functional layers such as the adaptive expansion layer and aerogel sheet, effectively reducing heat loss and improving energy efficiency. In terms of structural reliability, the thermal shock resistance of the present invention significantly outperforms traditional structures. The significant increase in the number of thermal shock cycles indicates that the equipment can withstand more frequent heating and cooling cycles without damage, thereby extending the equipment's service life and reducing repair and replacement costs. In terms of load-bearing capacity, the present invention's compressive strength at both room and high temperatures significantly outperforms the comparative structure. The improved high-temperature strength retention ensures safe and reliable operation of the equipment under high-temperature operating conditions, meeting the requirements of heavy-duty operations. In terms of dimensional stability, the linear shrinkage of the present invention is significantly lower than that of traditional structures. The material exhibits excellent dimensional stability during high-temperature use, reducing equipment failures and maintenance requirements caused by thermal deformation, and improving the stability and reliability of the equipment's operation. The present invention's multi-layer composite structure design, advanced material formulation, and precise preparation process provide important technical support and application value for the development of prefabricated kiln baking oven technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 yes Figure 1 Schematic diagram of the local structure Figure 1 ; Figure 3 yes Figure 1 Schematic diagram of the local structure Figure 2 ; Figure 4 yes Figure 1 Schematic diagram of the local structure Figure 3 ; Figure 5 yes Figure 1 Schematic diagram of the local structure Figure 4 ; Figure 6 It is a schematic diagram of the cross-sectional structure of the baking chamber.

[0021] Numbers in the figure: 1. Top silo; 11. Adaptive expansion layer; 111. Ω-shaped corrugated channel; 112. S-shaped microporous channel; 12. External load-bearing insulation layer; 13. Aerogel plate layer; 14. Support skeleton layer; 15. Heat-reflecting shielding layer; 151. Micro-arc oxidation titanium foil; 16. Structural reinforcement layer; 17. Refractory brick layer; 171. Refractory coating; 18. Silo shell; 2. Refractory base; 3. Support skeleton; 31. Round rack; 32. U-shaped rack; 4. Bottom silo; 41. Firewood box; 5. Operating table; 51. Baking entrance and exit; 52. Ash outlet; 53. Firewood entrance and exit; 54. Ash drop platform; 55. Arched channel; 6. Chimney; 7. Support legs; 8. Ash box. DETAILED DESCRIPTION

[0022] The technical solutions of the present invention will be described clearly and completely below in conjunction with the drawings in the present invention. In addition, the forms of the various structures described in the following embodiments are merely examples. The present invention is not limited to the various structures described in the following embodiments. All other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0023] Reference Figures 1-6 The assembled kiln baking oven designed by the present invention is based on the design concept of easy installation and disassembly, and adopts a modular design. The overall structure is composed of four core components: a support frame 3, a baking bin, a bottom bin 4 and an operating table 5. The assembled structure is easy to transport, install and maintain, and has high structural stability and functional integrity.

[0024] The supporting skeleton 3 is the load-bearing foundation of the entire equipment. It adopts a double frame design and includes two main components: a circular frame 31 and a U-shaped frame 32. The circular frame 31 is the main load-bearing structure, bearing the weight of the baking bin. Its circular design enhances the structural strength and is conducive to the uniform distribution of heat. The U-shaped frame 32 is connected to the bottom of the circular frame 31 to form a stable support system, which can effectively disperse the load and improve the stability of the overall structure. In terms of spatial layout, the baking bin is installed above the circular frame 31, using the height advantage to achieve gravity-assisted hot air circulation. The bottom bin 4 is installed below the circular frame 31 to facilitate ash collection and fuel storage. The operating table 5 is installed in front of the supporting skeleton 3 to provide a convenient working interface for the operator. The U-shaped frame 32 is arranged inside the bottom bin 4 to save space. The ash box 8 is directly installed in the U-shaped frame 32, forming a compact and efficient layout.

[0025] Interaction with the kiln oven is conducted through the operating table 5, which integrates a baking entrance and exit 51. The baking entrance and exit 51 is located at the top of the operating table 5 and serves as the main passage for food entry and exit, meeting the entry and exit requirements of common baked foods. The baking entrance and exit 51 is equipped with a sealed door to ensure sealing performance and reduce heat loss. The ash outlet 52 is set below the baking entrance and exit 51 for ash cleaning. Its location design fully considers the convenience of operation while avoiding the risk of cross contamination with the food passage. The firewood entrance and exit 53 serves as a dedicated channel for adding fuel. It is directly connected to the firewood box 41 in the bottom bin 4, ensuring the convenience and continuity of fuel replenishment.

[0026] An arched passage 55 is constructed within the operating table 5. This arched passage 55, along with the baking inlet and outlet 51 and the baking chamber, forms a continuous airflow path, effectively transferring heat from the combustion area to the baking area. The arched design enhances structural strength, optimizes the flow characteristics of the hot air flow, reduces turbulence and heat loss, and ensures more uniform and efficient heat transfer.

[0027] An ash drop platform 54 is installed within the arched passage 55, making full use of the passage space. This platform 54 has an ash drop opening and is connected to the refractory base 2. After the firewood is completely burned on the refractory base 2, the ash is scooped out of the ash drop opening of the platform 54 using an ash scooping tool. The ash falls by gravity into the ash box 8, which is then collected. The ash box 8 adopts a drawer-type design and can be removed and cleaned at any time, keeping the equipment clean and hygienic.

[0028] The bottom bin 4 is mounted below the circular frame 31 and is fixedly connected to it. A firewood box 41 is located inside the bottom bin 4 and is connected to a firewood inlet and outlet 53. This allows operators to easily add and remove fuel, meeting the needs of long-term baking operations. Support legs 7 connected below the bottom bin 4 provide stable ground support for the entire equipment. These legs are designed to not only withstand the weight of the equipment and the operating load, but also adapt to varying ground conditions to ensure stability and safety during use. Universal wheels can be installed at the bottom of the legs 7 to enable the overall mobility of the equipment.

[0029] The kiln oven is also equipped with a chimney 6 smoke exhaust system. The chimney 6 is installed on the operating table 5. The interior of the chimney 6 is connected to the baking chamber through an arched channel 55, forming a complete smoke exhaust path. The smoke generated in the baking chamber first enters the arched channel 55, and then is guided into the chimney 6 through the arched channel 55, and finally discharged into the atmospheric environment, effectively preventing the accumulation and backflow of smoke inside the equipment, and ensuring the cleanliness and safety of the operating environment.

[0030] The entire prefabricated kiln oven integrates multiple functions, including baking, storage, operation, and smoke exhaust. Its modular design allows each major component to be independently manufactured and assembled, facilitating standardized production and reducing manufacturing costs. It also simplifies transportation and on-site installation, while also facilitating subsequent maintenance and component replacement. Through its rational structural layout and channel design, the equipment achieves efficient heat transfer and reasonable distribution. Furthermore, the rational arrangement of the baking inlet and outlet 51, ash outlet 52, and firewood inlet and outlet 53 reduces operator labor intensity and improves operational efficiency. Furthermore, the automated design of the ash collection system avoids potential safety hazards caused by ash accumulation. The coordinated use of the ash drop platform 54 and ash box 8 ensures a clean and safe working environment, meeting the hygienic requirements of modern food processing equipment. This prefabricated kiln oven meets the functional requirements for baking bread, vegetables, pizza, meat, and seafood, and offers significant advantages in terms of structural rationality, ease of operation, safety and reliability, and environmental performance.

[0031] The baking chamber consists of two main components: a refractory base 2 and a top chamber 1 mounted on the base. The refractory base 2, serving as the basic support structure of the baking chamber, is made of advanced composite refractory materials. The materials used in the refractory base 2 are composed, by weight, of 35-40 parts fused white corundum, 25-30 parts magnesia-alumina spinel, 20-25 parts green silicon carbide, 5-8 parts amorphous silica, 2-3 parts aluminum powder, and 3-5 parts aluminum dihydrogen phosphate. Fused white corundum, which exhibits exceptional refractoriness and thermal shock resistance, is produced by melting industrial alumina in an electric arc furnace at 2050-2100°C and then rapidly cooling and crystallizing it. Magnesia-alumina spinel is a synthetic refractory raw material, produced by mixing magnesium oxide and aluminum oxide in a 1:1 molar ratio and calcining at 1800-1900°C for 8-12 hours. It exhibits excellent thermal shock resistance and chemical stability. Green silicon carbide is produced by reacting quartz sand and petroleum coke in a resistance furnace at temperatures of 2200-2400°C. It exhibits exceptional hardness and excellent thermal conductivity. Amorphous silicon dioxide, a binder, forms a glassy bond at high temperatures, enhancing the overall structural density. Aluminum powder oxidizes at high temperatures to form alumina, which expands in volume and helps compensate for sintering shrinkage. Aluminum dihydrogen phosphate, a chemical binder, dehydrates during heating to form an aluminum phosphate binder, providing initial strength and high-temperature bonding.

[0032] The preparation process of the refractory base 2 includes the steps of raw material pretreatment, ingredient mixing, molding, drying and sintering. First, the fused white corundum and magnesium aluminum spinel are crushed to a particle size of 3-5 mm, the green silicon carbide is crushed to 0.5-1 mm, the amorphous silicon dioxide is ground to below 200 mesh, and the aluminum powder is controlled at 300 mesh. The components are dry-mixed in a forced mixer according to the ratio for 10-15 minutes, and then an aqueous solution of aluminum dihydrogen phosphate is added for wet mixing for 15-20 minutes, and the water content is controlled at 8-10%. The green body is prepared by vibration molding or compression molding, and the molding pressure is controlled at 15-25 MPa. The molded green body is dried at a temperature of 110-120 ° C for 24-48 hours, and then sintered in a tunnel kiln according to the heating curve, with the highest temperature of 1650-1700 ° C, the holding time of 4-6 hours, and the entire sintering cycle of 72-96 hours.

[0033] The surface of the refractory base 2 is coated with a special anti-stick coating, which adopts a double-layer structure design to enhance the protective effect. The base layer is an aluminum oxide-chromium oxide composite coating, which includes 60 parts of aluminum oxide, 35 parts of chromium trioxide, and 5 parts of lanthanum oxide by weight. Aluminum oxide provides basic fire resistance and chemical stability, chromium trioxide has excellent oxidation resistance and wear resistance, and lanthanum oxide as a rare earth oxide can significantly improve the high-temperature stability and thermal shock resistance of the coating. The surface layer is a ceramic coating, which includes 30 parts of nano-silica, 20 parts of methylphenyl silicone resin, and 5 parts of sodium dodecylbenzenesulfonate by weight. Nano-silica has excellent anti-stick properties and chemical inertness, methylphenyl silicone resin forms a ceramic structure at high temperature, providing a long-lasting protective effect, and sodium dodecylbenzenesulfonate acts as a surfactant to improve the wettability and uniformity of the coating.

[0034] The anti-stick coating is prepared by mixing the base material with an appropriate amount of water to form a slurry. This is then applied to the surface of the refractory base 2 by spraying or brushing, with a coating thickness of 0.3-0.5 mm. The coating is then dried at 300-350°C for 2-3 hours. The surface material is then dissolved in acetone or ethanol to form a solution with a concentration of 15-20%. The solution is then applied by dipping or spraying, with a coating thickness of 0.1-0.2 mm. The solution is then cured at 200-250°C for 1-2 hours, and finally sintered at 600-700°C.

[0035] The top chamber 1, the main structure of the baking chamber, adopts a multi-layer composite design to achieve excellent thermal insulation and structural strength. From the outside in, the top chamber 1 is arranged in eight functional layers, each layer of material and structure performs a specific function.

[0036] The outermost shell 18 is a metal shell, which is made of 304 stainless steel plate in one piece with a thickness of 2-3 mm. It provides overall structural support and outer surface protection, has good corrosion resistance and mechanical strength, and is easy to clean and maintain.

[0037] Adjacent to the inside of the silo shell 18 is the adaptive expansion layer 11, which is made of a multi-walled nanotube-reinforced sodium sulfate-based structural material. This multi-walled nanotube-reinforced sodium sulfate-based structural material is composed, by weight, of 75-85 parts sodium sulfate, 12-18 parts multi-walled carbon nanotubes, and 3-8 parts polyethylene glycol-400 flow improver. Sodium sulfate, as the matrix material, undergoes phase change expansion during heating, regulating thermal stress. Multi-walled carbon nanotubes have excellent thermal conductivity and mechanical strength. Polyethylene glycol-400, as a flow improver, improves the material's moldability and dispersibility.

[0038] The adaptive expansion layer 11 is prepared by first dispersing multi-walled carbon nanotubes in an ultrasonic disperser for 30-60 minutes, then mixing them evenly with polyethylene glycol-400, and then adding sodium sulfate powder. The layer is then hot-pressed at a temperature of 350-400°C, a pressure of 20-30 MPa, and a dwell time of 15-20 minutes. The resulting material exhibits a degree of flexibility and adaptability, automatically adjusting its dimensions in response to temperature changes to reduce thermal stress.

[0039] An Ω-shaped corrugated channel 111 and an S-shaped microporous channel 112 are provided in the adaptive expansion layer 11. The S-shaped microporous channel 112 is connected to the bottom of the Ω-shaped corrugated channel 111 to form a three-dimensional airflow circulation network. A prefabricated metal core rod is used in the hot pressing process, and the core rod is pulled out after forming to form the channel structure.

[0040] The Ω-shaped corrugated channel 111 and the S-shaped microporous channel 112 are filled with a graphene-reinforced potassium nitrate-based composite material. This material comprises, by weight, 78-85 parts potassium nitrate, 5-8 parts graphene nanosheets, and 4-7 parts polyethylene glycol-600 (PEG-600) as a flow improver. Potassium nitrate, a phase-change thermal storage material, has a melting point of 334°C and a high thermal density. The graphene nanosheets are prepared by using a modified Hummers method to prepare graphene oxide, followed by reduction with hydrazine hydrate. The thickness is controlled to be 1-5 nanometers, and they exhibit excellent thermal conductivity. PEG-600 improves the material's flowability and compatibility. The filling material is prepared by first ultrasonically dispersing the graphene nanosheets in acetone, then mixing them with PEG-600. Finally, potassium nitrate powder is added and mixed thoroughly, and the mixture is then filled into the channels via vacuum impregnation.

[0041] The external load-bearing insulation layer 12, located inside the adaptive expansion layer 11, is composed of a novel porous refractory ceramic material consisting of 70-85 parts by weight of high-purity alumina, 20-30 parts of aluminum silicate fiber microspheres, and 3-5 parts of silicon carbide whiskers. High-purity alumina, with a purity exceeding 99%, is the primary material, offering excellent refractory properties and mechanical strength. The aluminum silicate fiber microspheres are a lightweight, porous material produced through spray drying, with a diameter of 50-200 microns and a hollow interior, exhibiting excellent thermal insulation properties. Silicon carbide whiskers, produced through a vapor-liquid-solid mechanism at 1400-1600°C, have a diameter of 0.1-1 micron and a length of 10-100 microns, significantly enhancing the material's toughness and thermal shock resistance.

[0042] The preparation process of the external load-bearing insulation layer 12 is to mix the various components in proportion, add an appropriate amount of organic binder and water to make a plastic blank, and use casting or pressing to form it. The thickness is controlled at 30-50 mm. After drying, it is sintered at a temperature of 1500-1550°C. During the sintering process, aluminum silicate fiber microspheres and silicon carbide whiskers are evenly distributed in the alumina matrix to form a porous structure.

[0043] The inner surface of the external load-bearing insulation layer 12 is provided with a continuous array of trapezoidal corrugated grooves, which is prepared through precise mechanical processing and can increase the contact area with the next layer, thereby improving the bonding strength and heat transfer efficiency.

[0044] The aerogel plate layer 13 is located inside the external load-bearing insulation layer 12 and is made of nitrogen-doped silicon carbide aerogel material reinforced with basalt fiber, serving as the main thermal barrier. The material comprises, by weight, 45-55 parts of polymethylsilane, 15-25 parts of basalt fiber, 8-12 parts of hexamethyldisilazane, 6-10 parts of colloidal silica binder, and 3-6 parts of polymethyl methacrylate. Polymethylsilane is used as a silicon source precursor to prepare the silicon carbide aerogel skeleton through pyrolysis. Basalt fiber is prepared by drawing molten basalt and has a diameter of 5-15 microns, exhibiting excellent high-temperature resistance and mechanical strength. Hexamethyldisilazane is used as a nitrogen source to introduce nitrogen doping during the pyrolysis process, improving the thermal conductivity and chemical stability of the aerogel. The colloidal silica binder provides crosslinking points for the gel network, and polymethyl methacrylate acts as an organic template to control the formation of the pore structure.

[0045] The preparation process of the aerogel plate layer 13 is to first dissolve polymethylsilane in a toluene solvent, add hexamethyldisilazane and colloidal silica, stir evenly, add dispersed basalt fibers, pour into a mold for a sol-gel reaction, gel at room temperature for 24-48 hours, then perform solvent replacement and supercritical drying, and finally pyrolyze in a nitrogen atmosphere at 1200-1400°C for 2-4 hours to obtain a nitrogen-doped silicon carbide aerogel plate.

[0046] The outer surface of the aerogel sheet 13 is provided with an array of trapezoidal corrugated protrusions that match the groove array of the external load-bearing insulation layer 12. These protrusions are molded and inserted into the groove array with a clearance fit of 0.5-1 mm to ensure good contact. The inner surface of the aerogel sheet 13 is provided with an array of rectangular grooves, produced through precision machining or laser processing, which provide positioning and locking functions for the installation of the next layer.

[0047] The support skeleton layer 14, located inside the aerogel sheet 13, is composed of an iron-chromium-aluminum heat-resistant alloy ribbed frame and a multiphase lightweight magnesium-silicon composite filler, providing structural support and radiation management. The iron-chromium-aluminum heat-resistant alloy ribbed frame forms a three-dimensional lattice structure in a crisscross pattern. The alloy composition is 72-78 parts iron, 18-22 parts chromium, and 4-6 parts aluminum, resulting in excellent high-temperature resistance and oxidation resistance. The three-dimensional cells are fabricated using laser cutting and welding to form a regular grid structure.

[0048] The three-dimensional grid is filled with a high-strength cement-based composite material, consisting of 50-60 parts by weight of Portland cement, 25-30 parts of silica sand, 4-7 parts of polypropylene fiber, 1-3 parts of sodium polynaphthalene sulfonate, and 4-8 parts of metakaolin. The Portland cement is grade 42.5 ordinary Portland cement, and the silica sand is natural river sand with a quartz content greater than 95% and a particle size of 0.1-0.5 mm. The polypropylene fiber is 12-18 mm long and 15-25 microns in diameter, enhancing the material's toughness and crack resistance. Sodium polynaphthalene sulfonate acts as a high-efficiency water reducer, improving the mix's performance. Metakaolin, an active admixture made from calcined kaolin, improves the density and durability of the cementitious material.

[0049] The preparation process of high-strength cement-based composite materials is to first mix the dry materials evenly according to the proportion, then add an appropriate amount of water and stir, control the water-cement ratio at 0.28-0.35, and stir for 3-5 minutes to obtain a mixture with good fluidity. The mixture is filled into the three-dimensional cells by pouring or pumping, and after vibrating and compacting, it is cured for 28 days to reach the design strength.

[0050] The outer surface of the support skeleton layer 14 is equipped with an array of rectangular protrusions that match the rectangular grooves of the aerogel sheet layer 13. The rectangular protrusions are pressed into the grooves with an interference fit of 0.2-0.5 mm. This connection can withstand certain mechanical loads while facilitating removal and replacement. The inner surface of the ribs of the support skeleton layer 14 is evenly distributed with spherical protrusions, produced by machining or press molding, which provide positioning and anchoring for the installation of the next layer.

[0051] The heat-reflective shielding layer 15 is located inside the supporting skeleton layer 14. It utilizes a zircon matrix layer embedded with micro-arc oxidized titanium foil 151 and is applied to the outer surface of the structural reinforcement layer 16. The zircon matrix layer comprises, by weight, 40-50 parts zircon, 10-15 parts chromium oxide, 15-20 parts kaolin, 5-10 parts titanium dioxide, 3-5 parts calcium borate as a sintering aid, and 2-4 parts sodium carboxymethyl cellulose. Zircon has excellent refractory properties and thermal stability, chromium oxide provides oxidation resistance and wear resistance, kaolin, as a plastic raw material, improves formability, titanium dioxide has excellent heat-reflective properties, calcium borate acts as a sintering aid to lower the sintering temperature, and sodium carboxymethyl cellulose acts as a temporary binder to improve green body strength.

[0052] Micro-arc oxidation titanium foil 151 is a special material prepared by micro-arc oxidation technology. It uses pure titanium foil as the substrate and undergoes micro-arc oxidation treatment in an alkaline electrolyte solution with a voltage of 300-400V and a treatment time of 20-30 minutes. A porous titanium oxide coating with a thickness of 10-20 microns is formed on the surface of the titanium foil, which has excellent heat reflection properties and corrosion resistance.

[0053] The preparation process of the heat-reflecting shielding layer 15 is to mix the zircon matrix material according to a certain ratio, add an appropriate amount of water to make a plastic mud, and use pressing or casting to prepare a plate with a thickness of 5-8 mm. During the forming process, the micro-arc oxidation titanium foil 151 is embedded in the matrix, and the embedding depth is controlled to be 1 / 3-1 / 2 of the coating thickness. After drying, it is sintered at a temperature of 1300-1350°C. During the sintering process, the titanium foil and the matrix form a good bond.

[0054] Corresponding spherical grooves are set on the outer surface of the heat-reflecting shielding layer 15. The grooves have a diameter of 9-13 mm and a depth of 2-4 mm. They cooperate with the spherical protrusions of the supporting skeleton layer 14 to form interlayer anchoring. The ball-and-socket connection can withstand thermal stress and mechanical loads while allowing a certain relative displacement.

[0055] The structural reinforcement layer 16, located inside the heat-reflecting shielding layer 15, is made of a fiber-reinforced ceramic composite material and adhered to the outer surface of the refractory brick layer 17. It bears mechanical loads, inhibits crack propagation, and evenly distributes thermal stress. This material, by weight, comprises 50-60 parts mullite, 15-20 parts silicon carbide fiber, 5-10 parts activated alumina, and 5-8 parts silica sol. Mullite has excellent refractory properties and thermal stability. Silicon carbide fiber is produced by chemical vapor deposition and exhibits high strength and modulus. Activated alumina is produced by rapid dehydration, resulting in a large specific surface area and high reactivity. Silica sol acts as an inorganic binder, forming a silicate binding phase at high temperatures.

[0056] The preparation process of the structural reinforcement layer 16 is to mix mullite powder and activated alumina evenly, then add dispersed silicon carbide fiber, and finally add silica sol binder and stir to form a slurry, which is formed by pouring or spraying, and sintered at 1400-1450°C after drying to form a dense fiber-reinforced ceramic composite material.

[0057] The inner surface of the structural reinforcement layer 16 is provided with a V-shaped protrusion, the tip of the V-shaped protrusion is embedded in the bottom of the V-shaped groove on the outer surface of the refractory brick layer 17, forming a mechanical locking connection.

[0058] The refractory brick layer 17, serving as the innermost layer, is constructed from high-alumina bauxite-based refractory materials and is the innermost structure that comes into direct contact with open flames. This material comprises, by weight, 45-50 parts high-alumina bauxite, 15-20 parts silicon carbide, 20-25 parts mullite pre-synthetic material, 3-5 parts microsilica, 2-3 parts of a mixed rare earth oxide of ytterbium oxide and erbium oxide, and 1-2 parts of a carboxymethyl cellulose organic cellulose binder. High-alumina bauxite is high-quality bauxite with an Al2O3 content greater than 85%. Silicon carbide provides thermal conductivity and wear resistance. Mullite pre-synthetic material is produced by mixing and firing kaolin and aluminum oxide in a stoichiometric ratio and exhibits excellent thermal stability. Microsilica is a byproduct of ferrosilicon production, with a particle size of less than 1 micron, capable of filling micropores and improving density. Ytterbium oxide and erbium oxide, as rare earth oxides, can significantly improve the high-temperature performance and thermal shock resistance of the material. The preparation method is to precipitate and calcine the corresponding rare earth nitrate solution to obtain oxides with a purity greater than 99.9%.

[0059] The preparation process of the refractory brick layer 17 is to dry-mix the components according to the proportion in a high-intensity mixer for 20-30 minutes, then add an appropriate amount of water for wet mixing, and control the moisture content at 6-8%. The bricks are prepared by high-pressure molding with a molding pressure of 50-80 MPa. After drying, they are sintered at a temperature of 1600-1650°C and the insulation time is 6-8 hours to obtain high-strength, high-refractory refractory bricks.

[0060] The outer surface of the refractory brick layer 17 is machined with an array of V-shaped grooves, the angle of which matches the V-shaped protrusions of the structural reinforcement layer 16. It is prepared by diamond cutting or grinding, and the processing accuracy is controlled within ±0.2 mm to ensure precise fit with the structural reinforcement layer 16.

[0061] The inner surface of the refractory brick layer 17 is coated with a dedicated refractory coating 171. This coating comprises, by weight, 40 parts alumina powder, 25 parts zirconium oxide, 20 parts colloidal silica binder, 10 parts aluminum titanate, 3 parts butylated hydroxytoluene antioxidant, and 2 parts sodium carboxymethyl cellulose rheology modifier. The alumina powder, with a particle size of less than 5 microns, provides basic refractory properties. Zirconia offers excellent refractory properties and chemical stability. The colloidal silica binder forms a glassy bond at high temperatures. The aluminum titanate has an extremely low coefficient of thermal expansion and excellent thermal shock resistance. Butylated hydroxytoluene acts as an antioxidant to prevent oxidative degradation of organic components, while sodium carboxymethyl cellulose acts as a rheology modifier to improve the coating's coating properties and smoothness.

[0062] The preparation and application process of the refractory coating 171 is to mix the various components according to the proportions, add an appropriate amount of water to prepare the coating, control the viscosity to 3000-5000mPa·s, and apply it by spraying or brushing. The coating thickness is 0.5-1 mm. After application, it is baked at 300-400℃ for 2-4 hours to fully cure and ceramicize the coating.

[0063] The entire top silo 1 preparation and installation process strictly adheres to process requirements. First, the materials and components for each functional layer are prepared, then installed layer by layer from the inside out. The installation process strictly controls the fit and connection quality between each layer. High-temperature sealant is used between each layer to ensure overall airtightness and thermal insulation.

[0064] The installation process for the top silo 1 is a layer-by-layer installation method from the inside out. First, preparations for installation are carried out, and all components undergo comprehensive quality inspection and pretreatment during the installation preparation phase. The dimensional accuracy and surface quality of the refractory brick layer 17 are checked to ensure that the machining accuracy of the V-groove array meets the design requirements. The dimensions of the V-shaped protrusions of the structural reinforcement layer 16 are checked to ensure that they precisely match the V-grooves of the refractory brick layer 17, with the interference fit within the range of 0.1-0.3 mm. At the same time, a dedicated high-temperature sealant is prepared. Silicone high-temperature sealant with an operating temperature range of -60°C to +350°C is used, or ceramic-based high-temperature sealant is used. The appropriate sealant type is selected based on the operating temperature between different layers.

[0065] The first step is to install the refractory brick layer 17, and install the refractory brick layer 17 as the innermost layer first. Before installation, clean the inner surface of the refractory brick layer 17 to ensure that the refractory coating 171 is intact, check the uniformity of the coating thickness, and control the thickness deviation within ±0.1 mm. The refractory brick layer 17 is assembled in sections, and the prefabricated curved bricks are spliced ​​according to the section plan. Each section of bricks is sealed and connected with refractory mud. The formula of the refractory mud is 60 parts of high-alumina cement, 30 parts of silica powder, and 10 parts of expanded perlite. Add water to make a paste, apply it to the joints and smooth it with special tools. During the installation process, a laser level and three-coordinate measuring equipment are used to control the geometric accuracy of the brick layer to ensure that the roundness error of the inner surface is controlled within ±2 mm and the surface flatness is controlled within ±1 mm. After installation, it is naturally dried for 48 hours, and then low-temperature baking is carried out with the temperature controlled at 200-250℃ for 4-6 hours to remove moisture and organic binders in the brick layer.

[0066] The second step is to install the structural reinforcement layer 16 and attach it to the outer surface of the refractory brick layer 17. Before installation, apply a special bonding adhesive to the V-shaped groove on the outer surface of the refractory brick layer 17. Use a silicate-based high-temperature adhesive with a coating thickness of 0.2-0.3 mm to ensure that the adhesive layer is uniform and free of bubbles. Align the V-shaped protrusion of the structural reinforcement layer 16 with the V-shaped groove of the refractory brick layer 17, and use a hydraulic press to press the protrusion into the groove. The pressing force is controlled at 200-300N / cm. 2 During the press-fitting process, monitor the press-fitting depth to ensure that the protruding tip is fully embedded in the groove bottom. After press-fitting, check the tightness of each connection point, using a tapping test to check for looseness or gaps. After the structural reinforcement layer 16 is installed, apply a ceramic-based high-temperature sealant to the interlayer joints. The sealant should be 3-5 mm wide and 1-2 mm thick. Use a dedicated glue application tool to ensure continuity and uniformity of the sealant.

[0067] The third step is to install the heat-reflecting shielding layer 15, which is provided on the outer surface of the structural reinforcement layer 16. Before installation, check the processing quality of the spherical grooves on the outer surface of the heat-reflecting shielding layer 15 to ensure that the groove depth and position accuracy meet the design requirements. Apply a thin layer of high-temperature sealant on the surface of the spherical protrusion of the structural reinforcement layer 16 with a coating thickness of 0.1-0.15 mm, and then lightly press the heat-reflecting shielding layer 15 into place so that the spherical protrusion and the spherical groove are precisely matched. Apply pressure slowly during the matching process to avoid damage to the micro-arc oxidized titanium foil 151, and ensure that each matching point is in place at the same time. After the installation is completed, check the reliability of the interlayer anchoring and use a slight pull-out test to verify the connection strength. The pull-out force should be greater than 100N / cm 2 An annular sealant is applied to the outer peripheral edge of the heat reflective shielding layer 15. The sealant is a silicone high-temperature sealant containing aluminum oxide filler. After curing, a flexible sealing layer is formed, which can adapt to thermal expansion and deformation.

[0068] The fourth step is to install the supporting skeleton layer 14, which is composed of an iron-chromium-aluminum heat-resistant alloy rib frame and a filled high-strength cement-based composite material. Before installation, the rib frame is surface treated to remove oil and scale from the processing process. After cleaning with acetone, the surface is roughened to improve the bonding strength with the sealant. Align the rib frame with the positioning mark of the heat-reflecting shielding layer 15, and slowly press down to make the spherical protrusions on the inner surface of the rib fit with the spherical grooves of the heat-reflecting shielding layer 15. During the fitting process, ensure that each protrusion enters the corresponding groove at the same time to avoid deflection or jamming. After the rib frame is in place, the pre-prepared high-strength cement-based composite material slurry is poured into the three-dimensional cell. The pouring is carried out in layers, with each layer being 10-15 mm thick. After each layer is poured, it is vibrated with a vibrator at a vibration frequency of 50-80 Hz and a vibration time of 2-3 minutes to ensure that the slurry fully fills the cell and eliminates bubbles. After all the pouring is completed, the surface is leveled and the surface flatness is controlled within ±0.5 mm. Then it is covered with plastic film for moisturizing maintenance. During the maintenance period, the ambient temperature is controlled at 20-25℃, the relative humidity is greater than 90%, and the maintenance time is not less than 72 hours.

[0069] The fifth step is to install the aerogel plate layer 13, which serves as the main thermal barrier layer. The installation quality directly affects the overall thermal insulation effect. Before installation, carefully check the integrity of the aerogel plate layer 13 to ensure that there are no cracks or defects, and especially check the geometric accuracy of the trapezoidal corrugated protrusion array. Apply a special flexible sealant in the rectangular groove on the outer surface of the supporting skeleton layer 14. The sealant is made of low-modulus silicone glue, which has good flexibility after curing and can adapt to the deformation characteristics of the aerogel material. Align the rectangular protrusions of the aerogel plate layer 13 with the rectangular grooves of the supporting skeleton layer 14, and press them in one by one using an interference fit. The pressing force is controlled at 50-80N / cm 2 Apply even force during the press-in process to avoid damaging the brittle aerogel material. After installation, check the tightness of each connection point using a feeler gauge to check the gap, which should be less than 0.2 mm. Apply a thin layer of sealant (0.05-0.1 mm thick) to the trapezoidal corrugated protrusions on the outer surface of aerogel sheet 13, preparing for the installation of the next layer.

[0070] The sixth step is to install the external load-bearing insulation layer 12, which undertakes important load-bearing and heat-insulating functions. Before installation, check the processing quality of the trapezoidal corrugated groove array on the inner surface of the external load-bearing insulation layer 12 to ensure that the depth, angle and spacing of the grooves meet the design requirements. Slowly lower the external load-bearing insulation layer 12 to align the trapezoidal corrugated groove array with the trapezoidal corrugated protrusion array of the aerogel plate layer 13, and embed them in a clearance fit manner, with the fitting clearance controlled at 0.5-1 mm. During the installation process, ensure that each protrusion enters the corresponding groove at the same time to avoid local stress concentration. After the installation is completed, inject a high-temperature sealant with good fluidity into the gap between the layers. The sealant is made of modified silicone material with good fluidity and filling properties. It has good fluidity and filling properties, can completely fill the gap and form a continuous sealing layer. After the injection is completed, let it stand for 24-48 hours to allow the sealant to fully cure. During the curing process, the ambient temperature is controlled at 25-30°C and the relative humidity is controlled at 40-60%.

[0071] The seventh step involves installing the adaptive expansion layer 11, which features specialized thermal adaptability and a complex internal channel structure. Before installation, the adaptive expansion layer 11 undergoes a comprehensive inspection to ensure the integrity and connectivity of the Ω-shaped corrugated channels 111 and the S-shaped microporous channels 112. The graphene-reinforced potassium nitrate-based composite material filling the channels is inspected for fullness and voids. The contact surface between the adaptive expansion layer 11 and the external load-bearing insulation layer 12 is cleaned to remove dust and oil. A special flexible sealant with excellent fatigue resistance is then applied to the contact surface to accommodate the deformation characteristics of the expansion layer. Installation is performed in sections, with each section ranging in length from 500 to 800 mm. Expansion joints of 2 to 3 mm are reserved between sections and filled with flexible sealing material. Each section is temporarily secured after installation, and overall adjustments and final securing are performed after all sections are installed.

[0072] The final step is to install the silo shell 18. As the outermost metal protective shell, the silo shell 18 provides overall structural support and external surface protection. Before installation, the inner surface of the silo shell 18 is treated for corrosion and sprayed with a high-temperature anti-corrosion paint that has good adhesion and high-temperature resistance. The silo shell 18 is fitted onto the outside of the adaptive expansion layer 11 and secured with flanges or bolts. A rubber sealing ring is installed at the joint to ensure the sealing and reliability of the connection. The gap between the silo shell 18 and the adaptive expansion layer 11 is controlled to 3-5 mm. The gap can be filled with lightweight insulation material, such as aluminum silicate fiber felt, to further enhance the insulation effect.

[0073] Quality control measures throughout the installation process include geometric accuracy testing after each layer is installed, using laser rangefinders and three-dimensional coordinate measuring machines to check the position and shape accuracy of each layer. The quality of interlayer connections is inspected using non-destructive testing methods such as ultrasonic testing and infrared thermal imaging to ensure reliable and defect-free connections. The construction quality of the sealant is verified through visual inspection and air tightness testing. The air tightness test uses a positive pressure method with a test pressure of 500-1000Pa and a leakage rate of less than 0.1L / min·m 2 .

[0074] Dedicated measuring tools and positioning devices are used to control the fit accuracy between each layer. Dedicated groove depth and angle measuring devices are used to precisely control the fit of trapezoidal corrugations, ensuring that the fit meets design requirements. The interference fit between rectangular protrusions and grooves is achieved using dedicated press-fit equipment, with the press-fit force and depth precisely controlled by a CNC system. Three-dimensional coordinate measurement is used to ensure positional accuracy between spherical protrusions and grooves. The contact area after mating should exceed 85% of the theoretical area.

[0075] The selection and use of high-temperature sealants are optimized based on the operating temperature and stress state between different layers. For the outer layer, which operates at lower temperatures, a high-temperature silicone sealant is used. This sealant offers excellent flexibility and sealing properties, with a curing time of 12-24 hours. For the inner layer, which operates at higher temperatures, a ceramic-based inorganic sealant is used. This sealant is based on a silicate matrix and contains refractory fillers and curing agents. It can withstand temperatures exceeding 1000°C and cures in 48-72 hours, forming a ceramic structure.

[0076] The sealant application process requires strict control of the construction environment and operating procedures. The application temperature should be maintained between 15-30°C and the relative humidity between 30-70%. Avoid application in rainy or high-humidity environments. Use a dedicated sealant gun or scraper to apply the sealant to a uniform thickness, avoiding bubbles and breakage. After application, use specialized tools to trim the sealant surface to ensure a smooth, even surface and a secure bond with the substrate.

[0077] To ensure the overall airtightness and thermal insulation effect, a comprehensive performance test is carried out after installation. The airtightness test uses the tracer gas method, filling the top chamber 1 with helium, controlling the pressure at 1000-1500Pa, and using a helium mass spectrometer to detect leaks. The leakage rate should be less than 1×10 -6 Pa·m³ / s. The thermal insulation effect test uses the steady-state heat flow method to heat the top chamber 1 to the designed working temperature, measure the temperature distribution on the outer surface, and calculate the heat transfer coefficient. The heat transfer coefficient should be less than 0.5W / (m 2 ·K).

[0078] Process control points during the installation process include controlling the moisture content of each layer of material. Before installation, the moisture content of all materials should be less than 0.5% to prevent the generation of water vapor during use, which can affect performance. Regarding temperature control, the ambient temperature must be strictly controlled during the sealant application and curing process to prevent temperature fluctuations from affecting curing quality. Regarding time control, the intervals between each process must be strictly implemented according to process requirements, ensuring the full completion of the previous process while preventing excessive intervals from affecting material performance.

[0079] After installation, quality inspection includes a visual inspection to check the smoothness of each layer, the continuity and integrity of the sealant, and the strength and reliability of each joint. Dimensional accuracy is verified using specialized measuring equipment to check key parameters such as overall dimensions, layer thickness, and clearances. Performance testing includes pressure resistance, sealing, thermal insulation, and thermal cycling tests to ensure that all performance indicators of Top Chamber 1 meet design requirements.

[0080] The entire installation process, through precise coordination, reliable connections, effective sealing measures, and rigorous process control and quality inspection, ensures that the top chamber 1 possesses excellent structural integrity, thermal insulation, and operational reliability, providing a solid technical foundation for the efficient and stable operation of the kiln. After the above-mentioned process, the installed top chamber 1 forms an organic whole with its various functional layers, maintaining the unique properties of each layer while achieving synergy through rational connections and sealing, thus achieving the intended technical objectives of the design.

[0081] The top chamber 1 and the refractory base 2 are connected by flanges. A metal flange is installed on the edge of the refractory base 2, and a corresponding flange is installed on the bottom of the top chamber 1. The two flanges are connected by high-temperature bolts. High-temperature resistant sealing gaskets are installed at the joint to ensure the reliability and sealing of the connection. After the entire baking chamber is installed, the overall airtightness test and heating test are carried out to ensure that all performance indicators meet the design requirements.

[0082] Through detailed structural design, material formulation and preparation process, the baking chamber has excellent thermal insulation performance, mechanical strength and service life. The synergistic effect of each layer of material achieves efficient heat management and structural stability, fully meeting the technical requirements of high-temperature baking operations. At the same time, the detailed description of the preparation process ensures the feasibility and reproducibility of the technical solution.

[0083] The present invention is directed to a technical solution for a kiln baking furnace baking chamber, and three specific embodiments are used to verify the feasibility of the technical solution of the present invention.

[0084] Example 1. In this embodiment, the multi-walled nanotube-reinforced sodium sulfate-based structural material of the adaptive expansion layer 11 includes 85 parts sodium sulfate, 18 parts multi-walled carbon nanotubes, and 8 parts polyethylene glycol-400. The filler materials are 85 parts potassium nitrate, 8 parts graphene nanosheets, and 7 parts polyethylene glycol-600. The new porous refractory ceramic material of the external load-bearing and thermal insulation layer 12 is composed of 85 parts high-purity alumina, 30 parts aluminum silicate fiber microspheres, and 5 parts silicon carbide whiskers. The aerogel plate layer 13 uses basalt fiber-reinforced nitrogen-doped silicon carbide aerogel material, containing 55 parts polymethylsilane, 25 parts basalt fiber, 12 parts hexamethyldisilazane, 10 parts colloidal silica binder, and 6 parts polymethyl methacrylate. The high-strength cement-based composite material of the supporting skeleton layer 14 is composed of 60 parts silicate cement, 30 parts silica sand, 7 parts polypropylene fiber, 3 parts sodium polynaphthalene formaldehyde sulfonate, and 8 parts metakaolin. The zircon matrix layer of the heat-reflecting shielding layer 15 comprises 50 parts zircon, 15 parts chromium oxide, 20 parts kaolin, 10 parts titanium dioxide, 5 parts calcium borate sintering aid, and 4 parts sodium carboxymethyl cellulose. The fiber-reinforced ceramic composite material of the structural reinforcement layer 16 contains 60 parts mullite, 20 parts silicon carbide fiber, 10 parts activated alumina, and 8 parts silica sol. The high-alumina bauxite-based refractory material of the refractory brick layer 17 is composed of 50 parts high-alumina bauxite, 20 parts silicon carbide, 25 parts mullite pre-synthetic material, 5 parts microsilica, 3 parts mixed rare earth oxide of ytterbium oxide and erbium oxide, and 2 parts carboxymethyl cellulose organic cellulose binder. The refractory base 2 is made of 40 parts fused white corundum, 30 parts magnesia-aluminum spinel, 25 parts green silicon carbide, 8 parts amorphous silica, 3 parts aluminum powder, and 5 parts aluminum dihydrogen phosphate. The preparation process adopts hot pressing molding technology, the molding temperature is set at 400℃, the pressure is controlled at 30MPa, the pressure holding time is 20 minutes, and each layer is installed layer by layer from the inside to the outside. The layers are sealed with ceramic-based high-temperature sealant.

[0085] Example 2. In this embodiment, the adaptive expansion layer 11 comprises 80 parts sodium sulfate, 15 parts multi-walled carbon nanotubes, and 5.5 parts polyethylene glycol-400. The filler material comprises 81.5 parts potassium nitrate, 6.5 parts graphene nanosheets, and 5.5 parts polyethylene glycol-600. The external load-bearing insulation layer 12 is composed of 77.5 parts high-purity alumina, 25 parts aluminum silicate fiber microspheres, and 4 parts silicon carbide whiskers. The aerogel plate layer 13 comprises 50 parts polymethylsilane, 20 parts basalt fiber, 10 parts hexamethyldisilazane, 8 parts colloidal silica binder, and 4.5 parts polymethyl methacrylate. The support skeleton layer 14 comprises 55 parts silicate cement, 27.5 parts silica sand, 5.5 parts polypropylene fiber, 2 parts sodium polynaphthalene formaldehyde sulfonate, and 6 parts metakaolin. The heat-reflecting shielding layer 15 comprises 45 parts zircon, 12.5 parts chromium oxide, 17.5 parts kaolin, 7.5 parts titanium dioxide, 4 parts calcium borate, and 3 parts sodium carboxymethyl cellulose. The structural reinforcement layer 16 contains 55 parts mullite, 17.5 parts silicon carbide fiber, 7.5 parts activated alumina, and 6.5 parts silica sol. The refractory brick layer 17 is composed of 47.5 parts high-alumina bauxite, 17.5 parts silicon carbide, 22.5 parts mullite pre-synthetic material, 4 parts microsilica, 2.5 parts rare earth oxide, and 1.5 parts carboxymethyl cellulose. The refractory base 2 contains 37.5 parts fused white corundum, 27.5 parts magnesia alumina spinel, 22.5 parts green silicon carbide, 6.5 parts amorphous silica, 2.5 parts aluminum powder, and 4 parts aluminum dihydrogen phosphate. The preparation process adopts medium parameters, molding temperature 375℃, pressure 25MPa, and holding time 17.5 minutes.

[0086] Example 3. In this embodiment, the adaptive expansion layer 11 comprises 75 parts sodium sulfate, 12 parts multi-walled carbon nanotubes, and 3 parts polyethylene glycol-400. The filler material comprises 78 parts potassium nitrate, 5 parts graphene nanosheets, and 4 parts polyethylene glycol-600. The external load-bearing insulation layer 12 is composed of 70 parts high-purity alumina, 20 parts aluminum silicate fiber microspheres, and 3 parts silicon carbide whiskers. The aerogel plate layer 13 comprises 45 parts polymethylsilane, 15 parts basalt fiber, 8 parts hexamethyldisilazane, 6 parts colloidal silica binder, and 3 parts polymethyl methacrylate. The support skeleton layer 14 comprises 50 parts silicate cement, 25 parts silica sand, 4 parts polypropylene fiber, 1 part sodium polynaphthalene formaldehyde sulfonate, and 4 parts metakaolin. The heat-reflecting shielding layer 15 comprises 40 parts zircon, 10 parts chromium oxide, 15 parts kaolin, 5 parts titanium dioxide, 3 parts calcium borate, and 2 parts sodium carboxymethyl cellulose. The structural reinforcement layer 16 contains 50 parts mullite, 15 parts silicon carbide fiber, 5 parts activated alumina, and 5 parts silica sol. The refractory brick layer 17 is composed of 45 parts high-alumina bauxite, 15 parts silicon carbide, 20 parts mullite pre-synthetic material, 3 parts microsilica powder, 2 parts rare earth oxide, and 1 part carboxymethyl cellulose. The refractory base 2 contains 35 parts fused white corundum, 25 parts magnesia-aluminum spinel, 20 parts green silicon carbide, 5 parts amorphous silica, 2 parts aluminum powder, and 3 parts aluminum dihydrogen phosphate. The manufacturing process uses relatively low parameters: a molding temperature of 350°C, a pressure of 20 MPa, and a holding time of 15 minutes.

[0087] Comparative Example 1: This comparative example adopts a traditional single refractory material structure with a formula of 70 parts of high-alumina bauxite, 25 parts of clay, and 5 parts of silica powder. The preparation process adopts dry pressing molding, a molding pressure of 15 MPa, and a sintering temperature of 1450°C.

[0088] Comparative Example 2 adopts a traditional inner and outer double-layer structure. The inner layer is ordinary refractory bricks composed of 60 parts of high-alumina bauxite and 40 parts of clay. The outer layer is ordinary thermal insulation material, using aluminum silicate fiber felt with a density of 128kg / m³. The preparation process is layered preparation and there is no special connection structure.

[0089] Comparative Example 3 adopts a traditional three-layer structure, with the inner layer being a refractory brick layer 17 composed of 65 parts of high-alumina bauxite and 35 parts of clay, the middle layer being ordinary insulation bricks, using lightweight clay bricks with a density of 0.8g / cm³, and the outer layer being insulation felt, using aluminum silicate fiber felt with a density of 96kg / m³.

[0090] The comparative experiment was carried out strictly in accordance with national standards. The thermal insulation performance test was based on GB / T5990-2006 "Test method for thermal conductivity of refractory materials", the thermal shock resistance test was based on GB / T3997-2017 "Test method for thermal shock resistance of refractory materials", the compressive strength test was based on GB / T5072.1-2008 "Test method for compressive strength of refractory materials at room temperature", the refractoriness test was based on GB / T7322-2017 "Test method for refractoriness of refractory materials", and the linear expansion coefficient test was based on GB / T7320-2008 "Test method for thermal expansion of refractory materials".

[0091] The thermal conductivity coefficient was measured under conditions ranging from room temperature to 800°C using a flat plate thermal conductivity meter with a sample size of 100mm×100mm×25mm. The thermal shock resistance test conditions were cycled between 1100°C and room temperature, and the number of cycles was recorded until the sample was damaged. The evaluation indicators were the number of thermal shock cycles and the crack length. The loading speed of the room temperature compressive strength test was controlled between 0.5-2.0MPa / s, and the sample size was 50mm×50mm×50mm. The high temperature compressive strength test was carried out at 1000°C with a holding time of 30 minutes. The post-use linear shrinkage test was carried out at a temperature of 1200°C for 3 hours.

[0092] During the preparation of experimental materials, baking chamber samples were prepared according to the recipes of Examples 1-3 and Comparative Examples 1-3. The sample dimensions were uniformly 300 mm long and 200 mm wide, and the thickness was determined according to design requirements. Five parallel samples were prepared for each group, and the average value was taken. For the thermal conductivity test, the sample was placed on a flat plate thermal conductivity tester, with the hot surface temperature set at 800°C and the cold surface temperature at room temperature. After stabilization, the heat flux and temperature gradient were measured, and the thermal conductivity was calculated according to the formula λ = q × d / ΔT. For the thermal shock resistance test, the sample was heated in a muffle furnace at 1100°C for 30 minutes, then quickly transferred to room temperature water for cooling. The sample surface cracks were inspected and the cycle was repeated until the sample failed. For the compressive strength test, the sample was placed on a pressure testing machine at room temperature and loaded at a rate of 1.0 MPa / s until failure. The maximum failure load was recorded and the compressive strength was calculated. For the high-temperature compressive strength test, the sample was heated to 1000°C and kept at this temperature for 30 minutes. The compressive strength test was performed at high temperature and the value was recorded. The linear shrinkage test measures the specimen's length, L0, before heating. The specimen is then held at 1200°C for three hours. After cooling, the length, L1, is measured. The linear shrinkage is calculated using the formula (L0 - L1) / L0 × 100%. The experimental results are shown in Table 1.

[0093] Table 1 Experimental results of Examples 1-3 and Comparative Examples 1-3

[0094] Performance indicators Example 1 Comparative Example 1 Example 2 Comparative Example 2 Example 3 Comparative Example 3 Thermal conductivity (W / m·K) 0.35 1.40 0.42 1.20 0.48 1.05 Thermal shock cycles 85 30 78 35 72 40 Compressive strength at room temperature (MPa) 95.2 65.8 88.6 58.9 82.1 62.3 High temperature compressive strength (MPa) 78.5 35.2 72.8 32.8 68.5 38.1 High temperature strength retention rate (%) 82.5 53.5 82.2 55.7 83.4 61.2 Linear shrinkage (%) 0.15 1.00 0.18 0.96 0.22 0.88

[0095] As can be seen from Table 1, in terms of thermal insulation performance, the thermal conductivity of Example 1 is 0.35 W / m·K, which is 75.0% lower than the 1.40 W / m·K of Comparative Example 1. The thermal conductivity of Examples 2 and 3 are improved by 70.0% and 65.7% respectively compared to the corresponding comparison, indicating that the multi-layer composite structure design significantly improves the thermal insulation effect. In terms of thermal shock resistance, the number of thermal shock cycles of Example 1 reached 85 times, an increase of 183.3% compared to 30 times of Comparative Example 1. Examples 2 and 3 are improved by 160.0% and 140.0% respectively compared to the corresponding comparison, indicating that the application of the adaptive expansion layer 11 and the aerogel plate layer 13 effectively alleviates thermal stress and significantly improves the thermal stability of the material. In terms of mechanical strength, Example 1 has a room-temperature compressive strength of 95.2 MPa, a 44.7% increase over Comparative Example 1. The high-temperature compressive strength is 78.5 MPa, a 123.0% increase over Comparative Example 1. The high-temperature strength retention rate reaches 82.5%, a 54.2% increase over Comparative Example 1. This demonstrates that the fiber-reinforced ceramic composite and the well-shaped three-dimensional cell structure effectively enhance the material's load-bearing capacity and high-temperature stability. In terms of dimensional stability, the linear shrinkage of Example 1 is only 0.15%, an 85.0% improvement over Comparative Example 1. Examples 2 and 3 show improvements of 81.3% and 77.1%, respectively, demonstrating that the multilayer composite structure effectively controls thermal deformation of the material.

[0096] The multi-layer composite structure design of the present invention achieves excellent comprehensive performance through the synergistic effect of eight layers of functional materials. The thermal conductivity coefficient is reduced by 65.7%-75.0% compared with the traditional structure, and the energy consumption is significantly reduced; the thermal shock resistance is strong, and the number of thermal shock cycles is increased by 140%-183.3% compared with the traditional structure, and the service life is greatly extended; the mechanical strength is high, and the compressive strength at both room temperature and high temperature is significantly better than that of the traditional structure, and the bearing capacity is significantly enhanced; the dimensional stability is good, and the linear shrinkage rate is improved by 77.1%-85.0% compared with the traditional structure, and the maintenance cost is significantly reduced; the structural design is reasonable and adopts a modular design concept, which is easy to manufacture, transport and install. At the same time, the precise coordination between the layers ensures the overall reliability and a long service life.

[0097] The process of baking food using the assembled kiln oven of the present invention is as follows: 1. Residual Heat Baking Mode: Before commencing baking operations, the operator must first conduct a comprehensive pre-operational inspection of the prefabricated kiln, confirming the secure connections between the support frame 3, baking chamber, bottom chamber 4, and operating platform 5. The operator must also check the tightness of the flange connection between the top chamber 1 and the refractory base 2, ensuring that the high-temperature bolts are not loose and that the high-temperature sealing gaskets are intact and undamaged. The operator must place pre-prepared, dry firewood into the firewood box 41 in the bottom chamber 4 through the firewood inlet 53 in front of the operating platform 5. Hardwoods with moderate density and a moisture content below 20%, such as oak, beech, or fruitwood, should be preferred. These woods have a high calorific value and a long combustion duration, providing a stable and sufficient heat source for the baking chamber.

[0098] The operator opens the sealed door of the baking entrance 51 and uses a long-handled tool to remove an appropriate amount of firewood from the firewood box 41 and place it on the refractory base 2 in the baking chamber. The placement of the firewood follows scientific combustion principles: coarser wood is placed on the bottom layer as the base fuel, and finer fire starter materials are stacked on the top layer. Appropriate gaps are maintained between the firewood to ensure air circulation and sufficient combustion. The double-layer anti-stick coating on the surface of the refractory base 2 consists of an aluminum oxide-chromium oxide composite base layer and a nano-silica ceramic surface layer. It has excellent fire resistance and anti-stick properties, can withstand direct contact with open flames, and facilitates subsequent cleaning and maintenance.

[0099] The ignition process uses a dedicated long-handled ignition tool to simultaneously ignite the ignition material from multiple locations, ensuring the flames spread rapidly throughout the firewood pile. During combustion, the multi-walled nanotube-reinforced sodium sulfate-based structural material within the adaptive expansion layer 11 undergoes phase change expansion as the temperature rises, automatically adjusting its size to reduce thermal stress. The internal Ω-shaped corrugated channels 111 and S-shaped microporous channels 112 form a three-dimensional air circulation network, and the graphene-reinforced potassium nitrate-based composite material, acting as a phase change heat storage material, begins to absorb and store heat. The new porous refractory ceramic material of the external load-bearing insulation layer 12, due to its closed-cell hollow alumina microsphere structure, has extremely low thermal conductivity, effectively preventing heat loss. The aerogel layer 13, serving as the primary thermal barrier, utilizes basalt fiber-reinforced nitrogen-doped silicon carbide aerogel material. It has extremely low thermal conductivity and excellent high-temperature resistance, maintaining a stable thermal barrier even under high-temperature conditions. The support skeleton layer 14's three-dimensional, crisscross-shaped cells are filled with a high-strength cement-based composite material, providing both structural support and radiant heat management. The iron-chromium-aluminum heat-resistant alloy ribbed frame maintains excellent mechanical properties even in high-temperature environments. The micro-arc-oxidized titanium foil 151 embedded in the heat-reflecting shielding layer 15 exhibits excellent heat reflection properties, reflecting most of the radiant heat back into the baking chamber, effectively reducing radiant heat loss.

[0100] Combustion continues for approximately 60-90 minutes, depending on the type and quantity of firewood and environmental conditions. During this time, the combustion status is monitored through observation holes to ensure full combustion. When the firewood is essentially consumed, leaving only a small amount of charcoal, the preheating phase is nearly complete, and the temperature inside the baking chamber has reached the ideal baking temperature of 450-500°C. Chimney 6 connects to the baking chamber via arched passage 55, forming a complete flue gas exhaust path. The flue gas generated by combustion first enters arched passage 55, is then guided through arched passage 55 into chimney 6, and is ultimately discharged into the atmosphere, effectively preventing flue gas accumulation within the equipment.

[0101] When the firewood is essentially burned, the operator performs ash removal to create a clean environment for baking. The operator uses a dedicated long-handled ash removal tool to remove the remaining firewood ash from the surface of the refractory base 2 through the baking opening 51. The ash removal tool should be made of high-temperature resistant material, and the handle should be well insulated to prevent burns to the operator. The removed firewood ash is collected by an ash dropper 54 located within the arched passage 55. The ash dropper 54 has an ash drop opening connected to the refractory base 2, and gravity allows the firewood ash to fall through the ash drop opening into the ash box 8 below.

[0102] The ash box 8, a drawer-style design, is mounted within the U-shaped frame 32 and can be conveniently removed from the ash outlet 52 of the operating table 5 for cleaning. The operator pulls the handle of the ash box 8 to completely remove the filled ash box 8, empty the ash box, and then push it back into place after cleaning. This avoids the fly ash and dust problems associated with traditional kiln cleaning, maintains a clean and hygienic operating environment, and meets the hygienic requirements of modern food processing equipment. After cleaning, the operator can simply clean the surface of the refractory base 2 as needed. The excellent anti-stick properties and chemical inertness of the surface coating make cleaning relatively simple.

[0103] After the dust removal operation is completed, the temperature inside the baking chamber remains very high. At this time, the eight-layer composite structure of the top chamber 1 has exerted its excellent heat insulation and heat storage properties, creating a uniform and stable baking environment throughout the baking chamber. The operator places the pre-prepared food into the baking chamber to ensure that all ingredients reach the appropriate baking temperature.

[0104] After the food is placed, the operator immediately closes the sealed door of the baking entrance and exit 51, and relies on the excellent heat preservation performance of the baking chamber and the heat stored in the early stage to complete the baking of the food, allowing the food to slowly mature in a relatively stable temperature environment to obtain better taste and flavor.

[0105] Baking time depends on the type and quantity of food. Generally, bread takes 15-25 minutes, meat takes 30-45 minutes, and vegetables take 10-20 minutes. The operator can regularly check the baking status of the food through the observation window in the sealed door, judging the baking progress by the color changes and aroma release on the food surface. The heat-reflecting shielding layer 15 in the top chamber 1 reflects most of the radiant heat back into the baking chamber, achieving extremely efficient heat utilization during baking and evenly heating the food, avoiding localized overheating or underheating.

[0106] 2. Direct Bake Mode: In direct bake mode, food is baked simultaneously with the burning of firewood. This method is suitable for foods that require strong heat, such as pizza and barbecue. The operator first places the firewood on the refractory base 2 according to the above method and stacks it strategically to ensure that the firewood can burn fully and produce a stable flame. The amount of firewood is precisely calculated according to the type of food and the baking time, ensuring sufficient heat supply while avoiding excessive combustion that affects food quality.

[0107] After ignition is complete, the operator controls the intensity of the combustion according to the desired baking requirements. By adjusting the ventilation of the arched passage 55, the operator can control the combustion speed and flame temperature. This allows for precise control of the combustion process by fully utilizing the air circulation characteristics of the arched passage 55, which connects the baking inlet 51, and the baking chamber. Once the firewood is burning steadily and the temperature in the baking chamber reaches the desired baking temperature, the operator can place the food directly into the baking chamber. The food can then be baked simultaneously with the burning firewood, utilizing both direct radiant heat and convection heat from the open flame.

[0108] During the direct baking process, the eight-layer composite structure of the top chamber 1 also plays a vital role. The refractory brick layer 17, made of high-alumina bauxite-based refractory materials, directly withstands the open flame. The surface refractory coating 171 protects the bricks from flame damage. The fiber-reinforced ceramic composite material of the structural reinforcement layer 16 bears the mechanical load and inhibits crack propagation caused by temperature gradients. The other layers work together to ensure the structural stability of the baking chamber and the efficient use of heat in high-temperature environments. Operators adjust the placement of firewood or add small amounts of firewood to maintain the appropriate temperature according to the baking requirements. The entire baking process is closely monitored to ensure food quality.

[0109] The direct baking mode's ash cleaning process is interspersed with the food baking process. Once the food is baked and removed, the operator immediately uses a long-handled ash removal tool to clean the wood ash from the refractory base 2. Because the refractory base 2's anti-stick coating utilizes a nano-silica ceramic surface layer, which offers excellent anti-stick properties and chemical inertness, the ash does not adhere to the base surface, making cleaning relatively simple. The removed wood ash is collected into the ash box 8 through the ash drop opening of the ash drop platform 54. The ash drop platform 54 fully utilizes the space within the arched passage 55, ensuring efficient ash collection and preventing ash residue and accumulation within the baking chamber.

[0110] The operator draws out the ash box 8 from the ash outlet 52 of the operating table 5 for cleaning. After cleaning, the operator pushes the empty ash box 8 back into the installation position in the U-shaped frame 32 to prepare for the next baking operation.

[0111] The prefabricated kiln oven utilizes a modular assembly design, allowing maintenance work on each major component to be performed separately, greatly simplifying the maintenance process. Specifically, after each use, the operator should first thoroughly clean the operating table 5, removing food debris and dust from the baking inlet and outlet 51, ash outlet 52, and firewood outlet 53. The operator should also check the sealed doors of each inlet and outlet for proper opening and closing and sealing. Any signs of aging or damage should be promptly replaced to ensure heat does not leak from these areas during the baking process. The arched passage 55 should be cleaned and maintained regularly, using specialized cleaning tools to remove any ash and food debris that may have accumulated within the passage. Maintenance of the ash platform 54 includes regularly cleaning the platform and checking the ash outlet for unobstructed access. Any blockage should be promptly cleared to ensure that ash can fall smoothly into the ash box 8 without accumulating within the passage. Maintenance of the bottom bin 4 and firewood box 41 includes removing any remaining firewood debris and inspecting the integrity of the box structure. Maintenance of the outriggers 7 includes checking the firmness of the connection and the stability of the ground contact. If universal wheels are installed, the wheels should be lubricated and maintained regularly to ensure the stability and safety of the equipment when moving.

[0112] As the innermost layer exposed to open flames, the refractory brick layer 17 should be regularly inspected for cracks, flaking, or wear. Particular attention should be paid to the integrity of the refractory coating 171. If any localized peeling or severe wear is observed, the coating should be repaired or reapplied. The refractory coating 171 repair process involves preparing a coating according to the original formula: alumina powder, zirconium oxide, colloidal silica binder, aluminum titanate, butylated hydroxytoluene antioxidant, and sodium carboxymethyl cellulose rheology modifier are mixed in proportions by weight. The coating is then used to perform local repairs on damaged areas.

[0113] Maintenance of the structural reinforcement layer 16 mainly involves checking the tightness of the connection between the V-shaped protrusion and the V-shaped groove of the refractory brick layer 17. Long-term high-temperature use may cause the connection to loosen. Regular inspections and re-pressing when necessary are required to ensure the reliability of the mechanical locking connection. Maintenance of the heat-reflecting shielding layer 15 focuses on the integrity of the micro-arc oxidation titanium foil 151, checking for oxidation or corrosion. The heat-reflecting performance of the titanium foil directly affects the thermal efficiency of the baking chamber. If severe oxidation is found, replace the titanium foil with a new one. Maintenance of the supporting skeleton layer 14 includes checking whether the iron-chromium-aluminum heat-resistant alloy rib frame is deformed or cracked, and checking whether the high-strength cement-based composite material filled in the three-dimensional cell is cracked or detached. If damaged, the material is re-prepared according to the original formula for repair. Due to the special nature of the material, the aerogel plate layer 13 is protected from mechanical damage. The main inspection is for breakage or detachment. Due to the brittleness of the aerogel material, the entire piece should be replaced if any damage is found. The maintenance and inspection of the external load-bearing insulation layer 12 focuses on whether the porous structure is intact, whether there are microcracks caused by thermal cycles, whether the trapezoidal corrugated groove array maintains a good geometric shape, and whether the fit with the aerogel plate layer 13 is still tight. The maintenance of the adaptive expansion layer 11 is to check whether the Ω-shaped corrugated channel 111 and the S-shaped microporous channel 112 are unobstructed, and whether the filled graphene-reinforced potassium nitrate-based composite material is lost or deteriorated. Since the material will undergo phase change when the temperature changes, its phase change performance should be checked regularly to ensure normal. As the outermost protective structure, the silo shell 18 has relatively simple maintenance work, which mainly involves cleaning the outer surface and checking for corrosion or deformation. If necessary, the anti-corrosion coating can be re-applied. The maintenance of the sealant between the layers is also an important link. The sealant may age or crack during high-temperature use. Regular inspection and timely replacement are required to ensure the sealing performance between the layers and the overall thermal insulation effect.

[0114] The assembled kiln baking oven of the present invention can operate stably and efficiently for a long time, providing users with high-quality baking effects and a good user experience. At the same time, the convenient maintenance characteristics achieved through the modular assembly design greatly reduce the full life cycle use cost of the equipment, reflecting the technical advantages and practical value of modern food processing equipment.

[0115] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An assembled kiln oven, characterized in that: It includes a supporting frame and a baking bin, a bottom bin and an operating table installed on the supporting frame. The operating table is provided with a baking entrance and exit, an ash outlet and a firewood outlet. The operating table is provided with an arched passage, an ash drop platform and an ash box. The arched passage is connected to the baking entrance and exit and the baking chamber; the ash drop platform is arranged in the arched passage, the ash drop platform is provided with an ash drop opening, and an ash box is installed below the ash drop opening; A firewood box connected to the firewood inlet and outlet is provided in the bottom bin; Support legs are connected below the bottom bin.

2. The kiln oven according to claim 1, characterized in that: The baking bin is installed above the supporting frame, the bottom bin is installed below the supporting frame, and the operating table is installed in front of the supporting frame.

3. The kiln oven according to claim 2, characterized in that: The supporting frame includes a circular frame and a U-shaped frame. The baking bin is installed above the circular frame and the bottom bin is installed below the circular frame. The U-shaped frame is connected to the bottom of the circular frame and is arranged in the bottom bin. The ash box is installed in the U-shaped frame.

4. The kiln oven according to claim 1, characterized in that: A chimney is also provided, which is installed on the operating table. The inside of the chimney is connected with the baking chamber through an arched passage.

5. The kiln oven according to claim 1, characterized in that: The baking chamber includes a refractory base and a top chamber mounted on the refractory base. The top chamber is provided with the following components from the outside to the inside: The silo shell is a metal shell that provides overall structural support; The adaptive expansion layer is located between the silo shell and the external load-bearing insulation layer. The adaptive expansion layer is made of a multi-walled nanotube-reinforced sodium sulfate-based structural material. The multi-walled nanotube-reinforced sodium sulfate-based structural material is formed into the main structure of the adaptive expansion layer by hot pressing. The external load-bearing insulation layer is composed of a new type of porous refractory ceramic material consisting of a high-purity alumina matrix, closed-pore hollow alumina microspheres, and silicon carbide whiskers; Aerogel board layer, using basalt fiber reinforced nitrogen-doped silicon carbide aerogel material as the main thermal barrier layer; The supporting skeleton layer is composed of an iron-chromium-aluminum heat-resistant alloy rib frame and a multi-phase lightweight magnesium-silicon system composite material filler, providing structural support and radiation management; The heat-reflecting shielding layer, which uses a zircon matrix layer embedded with micro-arc oxidized titanium foil, is provided on the outer surface of the structural reinforcement layer; The structural reinforcement layer, made of fiber-reinforced ceramic composite material, is attached to the outer surface of the refractory brick layer to bear the mechanical load, inhibit crack growth and evenly distribute thermal stress; The refractory brick layer is made of high-alumina bauxite-based refractory material. It is the innermost layer that directly contacts the open flame, and the inner surface is coated with a refractory coating.

6. The kiln oven according to claim 5, characterized in that: The inner surface of the external load-bearing insulation layer is provided with a continuous trapezoidal corrugated groove array; the outer surface of the aerogel plate layer is provided with a matching trapezoidal corrugated protrusion array; the protrusion array is embedded in the groove array in a clearance fit manner; the inner surface of the aerogel plate layer is provided with a rectangular groove groove array; the outer surface of the supporting skeleton layer is provided with a rectangular protrusion array, and the rectangular protrusions of the rectangular protrusion array are pressed into the grooves with an interference fit; spherical protrusions are evenly distributed on the inner surface of the ribs of the supporting skeleton layer; corresponding spherical grooves are provided on the outer surface of the heat-reflecting shielding layer, and the spherical protrusions cooperate with the spherical grooves to form interlayer anchoring; the outer surface of the refractory brick layer is processed with a V-shaped groove array, and the inner surface of the structural reinforcement layer is provided with a V-shaped protrusion, and the tip of the V-shaped protrusion is embedded in the groove bottom.

7. The kiln oven according to claim 5, characterized in that: The multi-walled nanotube-enhanced sodium sulfate-based structural material of the adaptive expansion layer is composed of the following components in parts by weight: 75-85 parts of sodium sulfate, 12-18 parts of multi-walled carbon nanotubes, and 3-8 parts of polyethylene glycol-400 fluidity improver; The adaptive expansion layer is provided with an Ω-shaped corrugated channel and an S-shaped microporous channel, and the S-shaped microporous channel is connected to the bottom of the Ω-shaped corrugated channel; The Ω-shaped corrugated channel and the S-shaped microporous channel are filled with a graphene-reinforced potassium nitrate-based composite material, wherein the graphene-reinforced potassium nitrate-based composite material comprises the following components in parts by weight: 78-85 parts of potassium nitrate, 5-8 parts of graphene nanosheets, and 4-7 parts of polyethylene glycol-600 fluidity improver; The new porous refractory ceramic material of the external load-bearing and heat-insulating layer includes, by weight: 70-85 parts of high-purity alumina, 20-30 parts of aluminum silicate fiber microspheres, and 3-5 parts of silicon carbide whiskers; The aerogel plate layer is made of basalt fiber reinforced nitrogen-doped silicon carbide aerogel material, and the materials include, by weight: 45-55 parts of polymethylsilane; 15-25 parts of basalt fiber; 8-12 parts of hexamethyldisilazane; 6-10 parts of colloidal silica binder; and 3-6 parts of polymethyl methacrylate.

8. The kiln oven according to claim 5, characterized in that: The iron-chromium-aluminum heat-resistant alloy rib frame of the supporting skeleton layer is a three-dimensional cell in a crisscross shape, and the three-dimensional cell is filled with a high-strength cement-based composite material; A high-strength cement-based composite material comprising, by weight, 50-60 parts of Portland cement, 25-30 parts of silica sand, 4-7 parts of polypropylene fiber, 1-3 parts of sodium polynaphthalene sulfonate, and 4-8 parts of metakaolin; The zircon matrix layer of the heat reflective shielding layer comprises, by weight, 40-50 parts of zircon, 10-15 parts of chromium oxide, 15-20 parts of kaolin, 5-10 parts of titanium dioxide, 3-5 parts of calcium borate sintering aid, and 2-4 parts of sodium carboxymethyl cellulose; the micro-arc oxidation titanium foil is embedded in the zircon matrix layer; The fiber-reinforced ceramic composite material of the structural reinforcement layer comprises, by weight, 50-60 parts of mullite, 15-20 parts of silicon carbide fiber, 5-10 parts of activated alumina, and 5-8 parts of silica sol.

9. The kiln oven according to claim 5, characterized in that: The high-alumina bauxite-based refractory material of the refractory brick layer comprises, by weight, 45-50 parts of high-alumina bauxite, 15-20 parts of silicon carbide, 20-25 parts of mullite presynthetic material, 3-5 parts of microsilica powder, 2-3 parts of mixed rare earth oxides of ytterbium oxide and erbium oxide, and 1-2 parts of carboxymethyl cellulose organic cellulose binder; a coating is provided on the surface, and the coating comprises, by weight, 40 parts of aluminum oxide micropowder, 25 parts of zirconium oxide, 20 parts of silica sol binder, 10 parts of aluminum titanate, 3 parts of butylated hydroxytoluene antioxidant, and 2 parts of sodium carboxymethyl cellulose rheology regulator.

10. The kiln oven according to claim 5, characterized in that: The materials for preparing the refractory base include, by weight: 35-40 parts of fused white corundum; 25-30 parts of magnesium aluminum spinel; 20-25 parts of green silicon carbide; 5-8 parts of amorphous silicon dioxide; 2-3 parts of aluminum powder; and 3-5 parts of aluminum dihydrogen phosphate. The surface of the refractory base is coated with an anti-stick coating, which includes an aluminum oxide-chromium oxide composite coating as a base layer and a ceramic coating as a surface layer. The aluminum oxide-chromium oxide composite coating as a base layer includes, by weight, 60 parts of aluminum oxide; 35 parts of chromium trioxide; and 5 parts of lanthanum oxide; and the ceramic coating as a surface layer includes, by weight, 30 parts of nano-silicon dioxide; 20 parts of methylphenyl silicone resin; and 5 parts of sodium dodecylbenzenesulfonate.

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