External replacement construction method for preheater system of rotary cement kiln

Abstract

The invention relates to an external replacement construction method for a preheater system of a rotary cement kiln. The external replacement construction method is characterized by comprising the following steps that S1, a double-row scaffold is erected on the outer portion of a shell of a part to be replaced; s2, cutting off the outer shell according to the burnt part; s3, anchoring parts are subjected to repair welding on the cut-off iron plates and the shell hole interval iron plates, heat insulation materials are pasted and fixed according to design requirements, then a template is cut according to the hole cutting size, and the template extends into each part of the individual to be fixed; s4, the contact portion of the periphery and the old castable is plugged to prevent slurry leakage, then the cut iron plate is firmly welded and reinforced row by row, and a refractory material is poured from the upper portion; and S5, the refractory material replacement requirement is met through layer-by-layer construction in the steps. According to the method, the scaffold erection amount of the decomposing furnace can be greatly reduced, the safety operation risk of scaffold erection personnel and refractory material construction personnel in the decomposing furnace is completely eradicated, skin alkali erosion and burn of materials to the personnel are reduced, safety accidents are reduced, and the production economic benefits are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of cement rotary kiln, in particular to a cement rotary kiln preheater system external replacement construction method. BACKGROUND

[0002] At present, the cement rotary kiln combustion system is usually configured with solid waste disposal, waste incineration, alternative fuel and chlorine removal, etc. The preheater system often has serious skinning and high alkali content. When the system is shut down for maintenance, the internal refractory of the decomposing furnace needs to be repaired, the skinning needs to be cleaned, and then the scaffold is erected for dismantling and repairing, so there are two problems: first, the scaffold erection volume is large and the erection cost is high; second, the skinning, delamination and peeling of the refractory material in the internal decomposing furnace pose safety risks such as object impact and material alkali corrosion of the skin, which can easily cause safety accidents and economic losses. SUMMARY

[0003] The purpose of the present application is to provide a cement rotary kiln preheater system external replacement construction method, which solves the construction method of the preheater system decomposing furnace under the condition of ensuring safety, and at the same time reduces the difficulty of scaffold erection, improves safety, reduces the cost of scaffold erection and maintenance, and reduces the loss caused by safety accidents.

[0004] The technical scheme adopted by the present application to solve the technical problems is: a cement rotary kiln preheater system external replacement construction method, characterized by: including the following steps:

[0005] S1: erecting a double-row scaffold outside the shell at the planned replacement position;

[0006] S2: cutting off the outer shell according to the burning loss position;

[0007] S3: supplementing the anchor fastener for the cut-off iron plate and the shell hole interval iron plate, sticking the heat insulation material and fixing it according to the design requirements, then cutting the template according to the hole size, and fixing the template into each part;

[0008] S4: filling the contact part between the periphery and the old castable to prevent slurry leakage, then restoring the cut-off iron plate to be firmly welded and reinforced, and pouring refractory material from the top;

[0009] S5: the above steps are sequentially performed to complete the replacement of the refractory material.

[0010] The specific steps of S2 are:

[0011] S21: the cutting-off size is about 300*400mm in length and width,

[0012] S22: the interval between holes is 300mm,

[0013] S23: the transverse hole cutting position is spaced apart from the bottom non-replacement position by 200-300mm,

[0014] S25: the upper and lower hole spacing is 200-300mm,

[0015] S26: after cutting off 2-3 rows of transverse holes.

[0016] The heat insulation material in S3 is any one of ceramic micro-bead heat insulation coating, alkali-resistant castable, high-alumina castable and corundum castable.

[0017] The present application has the following beneficial effects: according to the construction scheme, the amount of scaffold erection of the decomposition furnace can be greatly reduced, the safety operation risk of scaffold erection personnel and refractory material construction personnel in the decomposition furnace can be eliminated, the skin alkali erosion and burn of the personnel by the material can be reduced, the safety accidents can be reduced, and the production economic benefits can be improved.

[0018] The present application will be described in more detail below in combination with the drawings and examples. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 It is a current decomposition furnace construction scaffold erection diagram.

[0020] Figure 2 It is a current construction effect diagram.

[0021] Figure 3 It is a current construction effect diagram.

[0022] Figure 4 It is a final repair effect diagram for implementing the present application. DETAILED DESCRIPTION

[0023] The terms "upper", "lower", "inner", "outer", "front end", "rear end", "two ends", "one end", "the other end" and the like in the application text indicate the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. In addition, the terms "first" and "second" are only for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0024] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0025] like Figures 1-2 As shown, the preheater system often suffers from severe scaling and high alkali content. When the system is shut down for maintenance, the refractory materials inside the decomposition furnace need to be repaired, requiring the scaling to be cleaned and then scaffolding to be erected for dismantling and repair. This presents two problems: First, the scaffolding is large in size and expensive to erect; second, the scale, voids, and peeling refractory materials that are not completely cleaned inside the decomposition furnace pose safety risks to personnel entering the furnace, such as being struck by objects and having their skin corroded by alkali materials, which can easily lead to safety accidents and economic losses.

[0026] Based on the environmental characteristics of the decomposition furnace, the workload of cleaning scale buildup caused by refractory material maintenance in the decomposition furnace can be reduced, as can the workload and cost of scaffolding erection. This will reduce the safety risks to personnel working inside the decomposition furnace, prevent safety accidents during furnace operations, and minimize economic losses.

[0027] Example 1, as Figures 3-4 As shown, the external replacement construction method for the cement rotary kiln preheater system, specifically for a 5000T rotary kiln preheater, includes the following steps:

[0028] S1: The shell of the planned replacement section; after confirming the repair location of the refractory material in the decomposition furnace, double-row scaffolding will be erected using the preheater tower's floor platform.

[0029] S2: Cut off the outer casing according to the burned area; the cutting dimensions are approximately 300*400mm horizontally and vertically, with a spacing of approximately 300mm between holes. The horizontal cut holes should be approximately 200-300mm from the bottom non-repair interval, and the vertical hole spacing should be approximately 200-300mm. After cutting off 2-3 rows of horizontal hole plates, weld anchors (remove nails) to the cut iron plates and the iron plates separating the casing holes.

[0030] S3: Weld anchors to the cut iron plates and the iron plates between the shell holes, attach and fix the heat insulation material according to the design requirements, then determine the template according to the size of the cut hole, and insert the template into each part of the individual for fixing;

[0031] S4: Seal the edges where they contact the old castable to prevent grout leakage. Then, reinforce each row of cut iron plates by welding them back together, and pour refractory material in from above; seal the edges where they contact the old castable to prevent grout leakage.

[0032] S5: The above steps are carried out layer by layer to complete the replacement of refractory materials.

[0033] The specific steps of S2 are as follows:

[0034] S21: Cutting dimensions approximately 300*400mm (horizontal and vertical).

[0035] S22: The spacing between holes is 300mm.

[0036] S23: The horizontal cut hole should be positioned 200mm from the bottom non-replacement area.

[0037] S25: The distance between the upper and lower holes is 200mm.

[0038] S26: After cutting off 2-3 rows of horizontally perforated iron plates.

[0039] The heat insulation material in S3 is any one of ceramic microsphere heat insulation coating, alkali-resistant castable, high-alumina and corundum castable.

[0040] Example 2, as Figures 3-4 As shown, the external replacement construction method for the cement rotary kiln preheater system, for rotary kiln preheaters of 5000T and above, includes the following steps:

[0041] S1: The shell of the planned replacement section; after confirming the repair location of the refractory material in the decomposition furnace, double-row scaffolding will be erected using the preheater tower's floor platform.

[0042] S2: Cut off the outer casing according to the burned area; the cutting dimensions are approximately 400mm horizontally and vertically, with a spacing of approximately 300mm between holes. The horizontal cut holes should be approximately 300mm from the bottom non-repair interval, and the vertical hole spacing should be approximately 300mm. After cutting off 2-3 rows of horizontal hole plates, weld anchors (remove nails) to the cut iron plates and the iron plates separating the casing holes.

[0043] S3: Weld anchors to the cut iron plates and the iron plates between the shell holes, attach and fix the heat insulation material according to the design requirements, then determine the template according to the size of the cut hole, and insert the template into each part of the individual for fixing;

[0044] S4: Seal the edges where they contact the old castable to prevent grout leakage. Then, reinforce each row of cut iron plates by welding them back together, and pour refractory material in from above; seal the edges where they contact the old castable to prevent grout leakage.

[0045] S5: The above steps are carried out layer by layer to complete the replacement of refractory materials.

[0046] The specific steps of S2 are as follows:

[0047] S21: Cutting dimensions approximately 300*400mm (horizontal and vertical).

[0048] S22: The spacing between holes should be 300-200mm.

[0049] S23: The horizontal cut hole should be positioned 200-300mm from the bottom non-replacement area.

[0050] S25: The spacing between the upper and lower holes is 200-300mm.

[0051] S26: After cutting off 2-3 rows of horizontally perforated iron plates.

[0052] The heat insulation material in S3 is any one of ceramic microsphere heat insulation coating, alkali-resistant castable, high-alumina and corundum castable.

[0053] This construction plan can significantly reduce the amount of scaffolding erected for the decomposition furnace, eliminate the safety risks for scaffolding erectors and refractory material workers operating inside the decomposition furnace, reduce the workload of cleaning scale buildup caused by refractory material maintenance, reduce the risk of skin erosion and burns from materials, lower the incidence of safety accidents, and improve production and economic efficiency.

[0054] The above embodiments are merely descriptions of preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

[0055] All parts not covered in this invention are the same as or can be implemented using existing technologies.

Claims

1. A method for external replacement of a cement rotary kiln preheater system, characterized in that, This includes the following steps: S1: Erect double-row scaffolding outside the shell of the planned replacement section; S2: Cut off the outer shell according to the burned area; S3: Weld anchors to the cut iron plates and the iron plates between the shell holes, attach and fix the heat insulation material according to the design requirements, then determine the template according to the size of the cut hole, and insert the template into each part of the individual for fixing; S4: Seal the area where the old castable material is in contact with the surrounding area to prevent grout leakage. Then, reinforce the cut iron plates row by row by welding them back together and pour refractory material from above. S5: The above steps are carried out layer by layer to complete the replacement of refractory materials.

2. The external replacement construction method for the cement rotary kiln preheater system as described in claim 1, characterized in that, The specific steps of S2 are as follows: S21: Cutting dimensions approximately 300*400mm (horizontal and vertical). S22: The spacing between holes is 300mm. S23: The horizontal cut hole should be positioned 200-300mm from the bottom non-replacement area. S25: The spacing between the upper and lower holes is 200-300mm. S26: After cutting off 2-3 rows of horizontally perforated iron plates.

3. The external replacement construction method for the cement rotary kiln preheater system as described in claim 1, characterized in that: The heat insulation material in S3 is any one of ceramic microsphere heat insulation coating, alkali-resistant castable, high-alumina and corundum castable.

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