On-line brick binding operation method for large ultra-white glass kiln pool wall of thousand tons or above

Abstract

The invention relates to the technical field of float glass production, in particular to an online brick binding operation method for a pool wall of a large ultra-white glass kiln with thousand tons or more, which comprises the following steps: S1, inserting an L-shaped water hook into the kiln through an operation window, and placing the horizontal section of the water hook in molten glass and attaching the horizontal section to the inner surface of a pool wall brick to be replaced; cooling water is introduced into the water hook to cool and solidify local molten glass; s2, removing a pool wall brick to be replaced on one side, facing the pool wall brick, of the solidified molten glass; and S3, new pool wall binding bricks are installed at the vacated positions after the pool wall bricks to be replaced are dismantled and fixed. The method has the beneficial effects that the L-shaped water hook is directly inserted into the molten glass for controllable cooling and solidification, so that the brick binding operation is carried out on the premise that the glass liquid level of the kiln is not lowered at all and normal production is not interrupted, and the yield loss, quality fluctuation and safety risk caused by a traditional liquid level lowering method are thoroughly avoided.

Description

Technical Field

[0001] This invention relates to the field of float glass production technology, specifically to an online brick-binding method for the walls of large-scale ultra-clear glass kilns with a capacity of over 1,000 tons. Background Technology

[0002] The bricks on the walls of a glass melting furnace gradually thin under the long-term erosion of molten glass at high temperatures, especially in the upper, hotter areas of the molten glass. To extend the furnace's lifespan, "brick binding" is necessary on the outside of the furnace walls. This involves fixing new bricks to the outside of the old bricks to reinforce the furnace walls without interrupting production. The furnace's lifespan directly impacts production line costs; each year of extension significantly reduces production costs.

[0003] There are various existing methods for binding bricks to pool walls, but each has its limitations: (1) Technology of attaching or binding bricks to the outside of the pool wall: For example, Chinese invention patent application with publication number CN110294588A discloses a method of binding bricks, which directly attaches new bricks to the outside of old bricks. However, it is necessary to insert cooling water pipes to solidify the glass liquid. During the operation, a large amount of water vapor is easily generated. For ultra-white glass (low iron content and thin glass liquid), water vapor can easily cause bubbles and microbubbles to be generated in the glass plate. In addition, iron water pipes may introduce impurities, affecting product quality.

[0004] (2) Liquid level reduction and brick binding technology: As mentioned above, production needs to be stopped or the liquid level needs to be significantly reduced, resulting in production losses.

[0005] (3) Water-cooled slab freezing technology with external brick binding inside the pool wall: A water-cooled slab (cooler) is inserted inside the pool wall to solidify the molten glass. This method is acceptable for ordinary glass, but for ultra-clear photovoltaic glass, the molten glass is thinner and has different heat conduction. Water-cooled slab freezing carries the risk of local overcooling or uneven freezing of the molten glass. More importantly, ultra-clear glass has extremely strict control over iron content. The entry of iron products such as stainless steel water slabs into the kiln is not allowed by the process and will contaminate the molten glass. With the popularization of large-tonnage ultra-clear float glass and photovoltaic glass kilns of over 1,000 tons, the above technology is no longer able to meet the production process requirements of "online, no liquid level drop, no iron contamination, safe and efficient". Large-tonnage kilns have large heat loads and complex molten glass flow. If simple cooling operations are not properly controlled, they can easily cause safety accidents (such as molten glass splashing) or cause drastic fluctuations in the working conditions inside the kiln.

[0006] Therefore, there is an urgent need for an online brick-binding operation method specifically designed for large-scale ultra-white glass kilns with a capacity of over 1,000 tons, which can achieve multiple brick binding operations on the pool walls without cooling, liquid level drop, or affecting the quality of glass production, while ensuring absolute safety. Summary of the Invention

[0007] The technical problem to be solved by this invention is to provide an online brick-binding operation method for the tank walls of large-scale ultra-clear glass kilns with a capacity of over 1,000 tons. This method can safely and efficiently complete multiple brick-binding operations on the tank walls under the normal high-temperature operation of large-tonnage kilns, without lowering the glass molten level, and has minimal impact on the kiln temperature and glass quality.

[0008] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A method for online brick-binding operation of the pool wall of a large-scale ultra-white glass kiln with a capacity of over 1000 tons is provided, comprising the following steps: S1: Remove the gap brick above the wall brick to be replaced to form an operating window; insert the L-shaped water hook into the kiln through the operating window, so that the horizontal section of the water hook is placed in the molten glass and close to the inner surface of the wall brick to be replaced; pass cooling water into the water hook to cool and solidify the local molten glass. S2: Remove the pool wall bricks to be replaced from the side of the pool wall bricks facing the solidified glass liquid; S3: Install new pool wall cladding bricks in the empty space after removing the pool wall bricks to be replaced, and secure them.

[0009] The beneficial effects of this invention are as follows: In the online brick-binding operation method for the walls of large-scale ultra-clear glass kilns with a capacity of over 1000 tons, L-shaped water hooks are directly inserted into the molten glass for controlled cooling and solidification. This allows for brick-binding operations without lowering the molten glass level or interrupting normal production, completely avoiding the production losses, quality fluctuations, and safety risks associated with traditional methods of lowering the molten glass level. The method uses non-ferrous tools such as seamless steel pipes throughout the process, ensuring precise and localized cooling, eliminating the risk of iron contamination, and having minimal impact on the overall thermal regime and molten glass quality within the kiln. This perfectly meets the stringent requirements of ultra-clear and photovoltaic glass for high purity and stable melting processes. This invention provides a standardized and repeatable operating procedure, enabling safe multiple online brick-binding operations on the kiln walls. This significantly overcomes the limitations of the original kiln design maintenance cycle, maximizing the kiln's service life and bringing substantial long-term economic benefits to enterprises. Attached Figure Description

[0010] Figure 1 This is a schematic diagram of the relevant parts of the kiln before brick binding in the online brick binding operation method of a specific embodiment of the present invention; Figure 2 This is a schematic diagram of the relevant parts of the kiln after brick binding, as described in a specific embodiment of the online brick binding operation method of the present invention. Figure 3 A diagram showing the distribution of water hooks in a kiln according to a specific embodiment of the online brick-binding method of the present invention. Figure 4 A schematic diagram of the water distributor structure of a kiln in an online brick-binding operation method according to a specific embodiment of the present invention; Label Explanation: 1. Hook bricks; 2. Breast wall support plate; 3. Water hooks; 4. Handles; 5. Valves; 6. Quick connectors; 7. Metal hoses; 8. Original pool wall bricks; 9. Insulating bricks; 10. Old binding bricks; 11. Eroded parts of pool wall binding bricks; 12. Diverter; 13. Gap bricks; 14. Replacement binding brick material; 15. Steel grating; 16. Iron bars; 17. Top screws. Detailed Implementation

[0011] To explain in detail the technical content, objectives, and effects of the present invention, the following description is provided in conjunction with the embodiments and accompanying drawings.

[0012] This invention provides an online brick-binding operation method for the pool wall of a large-scale ultra-clear glass kiln with a capacity of over 1,000 tons, comprising the following steps: S1: Remove the gap brick above the wall brick to be replaced to form an operating window; insert the L-shaped water hook into the kiln through the operating window, so that the horizontal section of the water hook is placed in the molten glass and close to the inner surface of the wall brick to be replaced; pass cooling water into the water hook to cool and solidify the local molten glass. S2: Remove the pool wall bricks to be replaced from the side of the pool wall bricks facing the solidified glass liquid; S3: Install new pool wall cladding bricks in the empty space after removing the pool wall bricks to be replaced, and secure them.

[0013] Furthermore, in the above-mentioned online brick-binding operation method for the pool wall of a large ultra-white glass kiln with a capacity of over 1,000 tons, in step S1, three or more water hooks are inserted at even intervals along the surface of the pool wall bricks to be replaced.

[0014] As described above, for large-tonnage kilns with high heat loads, the use of multiple water hooks for synchronous and uniform cooling ensures the sufficiency and consistency of glass molten solidification within the width of a single brick, completely eliminating the major safety hazard of local glass molten leakage caused by uneven cooling, and is the core guarantee for safe operation.

[0015] Furthermore, in the above-mentioned online brick-binding operation method for the pool wall of large ultra-white glass kilns with a capacity of over 1,000 tons, in step S1, the flow rate of cooling water introduced through the water hook is controlled by a valve with flow rate regulation, and a flow control program of small to large is executed: first, water is introduced at an initial low flow rate, and then the flow rate is increased to the working flow rate for cooling the glass liquid.

[0016] As described above, the initial low flow rate avoids the risk of splashing caused by violent vaporization when the water hook comes into instantaneous contact with the high-temperature molten glass; increasing the flow rate after stabilization ensures cooling intensity. This procedure greatly improves the safety and controllability of the operation.

[0017] Furthermore, in the above-mentioned online brick-binding operation method for the pool wall of a large ultra-white glass kiln with a capacity of over 1,000 tons, the initial low flow rate is 20%-30% of the working flow rate, and the working flow rate is 60%-80% of the flow rate when the valve is fully open.

[0018] As described above, the aforementioned constraints are key quantitative indicators that enable the flow control strategy to achieve optimal results while balancing security and efficiency.

[0019] Furthermore, in the above-mentioned online brick-binding operation method for the furnace wall of large-scale ultra-white glass with a capacity of over 1,000 tons, an emergency cooling gun is configured next to the operation window while step S1 is being performed; in step S2, if signs of local glass melt remelting are found, the emergency cooling gun is activated to spray cooling water for reinforced cooling.

[0020] As described above, the emergency cooling gun acts as a dynamic safety barrier, capable of responding in real time to any unexpected localized melting that may occur during dismantling, instantly eliminating safety hazards. This significantly improves the safety redundancy and reliability of the entire method when facing complex kiln conditions.

[0021] Furthermore, in the above-mentioned online brick-binding operation method for the pool wall of large ultra-white glass kilns with a capacity of over 1,000 tons, before step S2, a drain outlet is opened along the upper edge of the old bricks to be removed.

[0022] As described above, the drain outlet can promptly discharge condensate or trace amounts of seepage generated during the cooling process, preventing it from accumulating in the high-temperature zone of the kiln and suddenly vaporizing. This effectively avoids potential steam splashing accidents and is a necessary design to ensure the safety of personnel and equipment.

[0023] Furthermore, in the above-mentioned online brick-binding operation method for the pool wall of a large ultra-white glass kiln with a capacity of over 1,000 tons, after step S3, the method further includes: gradually reducing the flow rate of cooling water to the water hook in stages; after the solidified glass melt softens, removing the water hook and resealing the operation window using gap bricks and sealing materials.

[0024] As described above, the phased withdrawal prevented the newly bonded bricks from cracking due to thermal stress caused by a sudden cessation of cooling. The closed-loop operation of withdrawal and sealing ensured the immediate restoration of the kiln structure, which is crucial for maintaining the stability of the kiln's thermal regime and guaranteeing the quality of subsequent production.

[0025] Furthermore, in the above-mentioned online brick-binding operation method for the pool wall of large-scale ultra-white glass kilns with a capacity of over 1,000 tons, the water hook is made of seamless steel pipe bent into shape.

[0026] As described above, seamless steel pipes possess excellent pressure resistance, heat resistance, and corrosion resistance. The L-shaped design allows them to penetrate deep into the molten glass for efficient heat exchange while also facilitating operation and fixation outside the kiln.

[0027] Furthermore, in the above-mentioned online brick-binding operation method for the furnace wall of large-scale ultra-white glass kilns with a capacity of over 1,000 tons, in step S1, while inserting the water hook into the kiln, refractory fiber cotton is used to temporarily seal the gaps around the operation window.

[0028] As described above, temporary sealing can effectively block the flames from being ejected and the cold air from being drawn into the kiln, protecting the operators and reducing disturbances to the kiln pressure and temperature, reflecting a thorough consideration of operational details and overall working conditions.

[0029] Example 1 Please refer to Figures 1 to 4 In this embodiment, an ultra-white photovoltaic glass melting furnace with a daily melting capacity of over 1,000 tons is used as the implementation object, and the bricks binding the furnace wall with an erosion depth of 700mm are replaced online.

[0030] Step 1: Pre-construction preparation Near the brick-binding work area, install a booster pump to stabilize the on-site water pressure at approximately 6 kg / m². Set up a water distributor 12 with multiple outlets equipped with quick-connect fittings 6. Prepare at least 5 specially made water hooks 3 and 2 emergency water guns (each with a handle 4). The water hooks 3 are made of seamless steel pipe (3mm wall thickness) bent into an L-shape, with a horizontal section length of 250mm based on the width of the pool wall bricks and a vertical section length greater than 800mm (greater than the erosion depth of 700mm). Simultaneously, prepare aluminum silicate fiber cotton, gap bricks 13 of the same width as the operating window, steel grating 15, guardrails 16, top screws 17, and sealing mud. Position the air compressor, pneumatic angle grinder, and pneumatic shovel. Additionally, install two cooling fans to improve working conditions in high-temperature environments. Before the operation, a special long-handled stainless steel measuring hook is used to insert into the gap of the original gap bricks to accurately measure the remaining thickness and erosion depth of the original pool wall brick 8 and the old binding brick 10, so as to confirm the scope and size of the binding bricks that need to be replaced.

[0031] Step 2: Open the window, insert the water hook, and allow controlled cooling for solidification. First, use specialized tools to safely remove the gap bricks 13 above the area to be replaced (above which are hook bricks 1 and breast wall support plates 2), creating an operating window of sufficient width. Three operators, each holding a water hook 3, two holding fire-resistant fiber cotton, and two holding emergency water guns, stand by.

[0032] Synchronous insertion and temporary sealing: The operator connects the vertical section of the water hook 3 to the metal hose 7, and then to the outlet of the water distributor 12. A quick-connect fitting 6 and a graduated valve 5 are provided at the connection point between the vertical section of the water hook 3 and the metal hose 7. Simultaneously, the three water hooks 3 are vertically inserted into the kiln from the operating window, with the end of their L-shaped horizontal section close to the old brick binding 10. Figure 1The side of the old brickwork 10 is the eroded part of the pool wall brickwork 11, and the lower part is the insulation brick 9). At the same time, the auxiliary personnel quickly used fire-resistant fiber cotton to seal all the gaps around the operating window to achieve a temporary seal.

[0033] The "small-to-large" flow control procedure: After confirming the water hook is in place, three operators simultaneously open their respective valves 5 to approximately 25% of the scale (initial flow rate) to ensure water flow in the pipeline. After waiting approximately 10 seconds for the water hook to initially adapt to the molten glass, they simultaneously open valves 5 to approximately 70% of the scale (working flow rate) to begin main body cooling. This "small-to-large" procedure effectively prevents the potential risk of splashing caused by sudden and intense heat exchange. In this embodiment, the initial flow rate is approximately 30% of the working flow rate, and the working flow rate is 70% of the full flow rate.

[0034] Multiple hooks evenly cover the cooling area: such as Figure 3 As shown, the three water hooks 3 are evenly arranged along the width of a single pool wall brick to ensure that their horizontal sections can cover most of the inner area of ​​the brick, achieving efficient and uniform solidification.

[0035] Step 3: Safety verification, drainage, and removal of old bricks; Cooling lasts approximately 40-60 minutes, during which observation and tool testing confirm that the molten glass has fully solidified into a robust "protective shell." Before dismantling, a crucial step is to use a chisel to create a small drain hole along the upper edge of the old binding brick 10, near the innermost brick layer. This allows any small amount of condensate that may form during cooling to be promptly drained from the kiln, eliminating the risk of water vaporization.

[0036] Subsequently, using pneumatic shovels and hammers, the old 10 binding bricks were divided, broken, and cleaned. During this high-risk phase, emergency cooling guns remained on standby. The solidification interface was closely monitored throughout the dismantling process; if any area of ​​the molten glass turned red (indicating heat or signs of localized melting), the on-duty emergency water guns were immediately aimed at that point for precise, brief, and reinforcing cooling, instantly mitigating the risk.

[0037] Step 4: Installation and phased fixing of new bricks; After cleaning the work surface, quickly install the prefabricated replacement brick binding material 14 into the designated position. After installation, immediately attach a steel grating 15 tightly to the outer surface of the new brick and temporarily reinforce it with simple clamps to prevent displacement or tipping. After completing the installation of new bricks for a work section (such as half of a small furnace), use long iron bars 16 and top screws 17 to perform final, rigid overall reinforcement of all new brick bindings.

[0038] Step 5: The cooling device is "softly withdrawn" and sealed to the kiln body; After the new bricks are fixed in place, the cooling system is removed. Directly closing the valves is strictly prohibited. The operator, in three stages with approximately 10-minute intervals, slowly reduces the water hook valve 5 from 70% to 40%, then to 15%, and finally closes it completely. This process allows the solidified glass "protective shell" to gradually and evenly soften from the outside in, preventing stress impact on the new bricks. When the water hook can be felt to wiggle slightly, the three operators simultaneously and quickly and smoothly pull the water hook 3 out of the kiln. Finally, using pre-prepared gap bricks 13 and high-temperature sealing mud, the operating windows are tightly sealed and smoothed, restoring the kiln's integrity and insulation.

[0039] Through the implementation of the above complete embodiment, the severely corroded pool wall bricks were successfully and safely replaced without lowering the glass liquid level or interrupting production.

[0040] In summary, the online brick-binding method for the furnace wall of large-scale ultra-white glass kilns with a capacity of over 1,000 tons, according to the present invention, has the following beneficial effects: 1. This invention completely avoids molding process fluctuations, production losses and quality risks caused by liquid level drops, and achieves true online hot repair.

[0041] 2. This invention employs L-shaped water hooks inserted directly into the molten glass for heat exchange, which is far more efficient than placing cooling water pipes above the surface of the molten glass. The unique multi-hook synchronization, small-to-large flow rate control, and emergency mechanism make the solidification process more uniform, controllable, and safe, making it particularly suitable for ultra-clear photovoltaic glass furnaces with thinner molten glass and stronger convection.

[0042] 3. The evenly distributed water hooks ensure reliable solidification; the small-to-large flow rate program and emergency cooling gun form a dual safety barrier combining active and passive measures; and the drainage outlet eliminates a major safety hazard that is easily overlooked. These features work together to greatly ensure the safety of personnel and equipment when this method is applied to large kilns with a capacity of thousands of tons.

[0043] 4. This invention uses seamless steel pipes, eliminating the presence of any iron components inside the kiln and preventing iron contamination of the ultra-clear photovoltaic glass. Localized, precise cooling has minimal impact on the overall thermal regime within the kiln, protecting the melting quality and energy consumption of the glass.

[0044] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent modifications made based on the content of the present invention specification and drawings, or direct or indirect applications in related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for online brick-binding operation of the pool wall of a large-scale ultra-white glass kiln with a capacity of over 1,000 tons, characterized in that, Includes the following steps: S1: Remove the gap brick above the wall brick to be replaced to form an operating window; insert the L-shaped water hook into the kiln through the operating window, so that the horizontal section of the water hook is placed in the molten glass and close to the inner surface of the wall brick to be replaced; pass cooling water into the water hook to cool and solidify the local molten glass. S2: Remove the pool wall bricks to be replaced from the side of the pool wall bricks facing the solidified glass liquid; S3: Install new pool wall cladding bricks in the empty space after removing the pool wall bricks to be replaced, and secure them.

2. The online brick-binding operation method for the pool wall of a large-scale ultra-white glass kiln with a capacity of over 1,000 tons, as described in claim 1, is characterized in that... In step S1, insert three or more water hooks at even intervals along the surface of the pool wall bricks to be replaced.

3. The online brick-binding operation method for the pool wall of a large-scale ultra-white glass kiln with a capacity of over 1,000 tons, as described in claim 1, is characterized in that... In step S1, the flow rate of cooling water entering the water hook is controlled by a valve with flow regulation, and a flow control program of small to large flow rate is executed: water is first introduced at an initial low flow rate, and then increased to the working flow rate for cooling the molten glass.

4. The online brick-binding operation method for the pool wall of a large-scale ultra-white glass kiln with a capacity of over 1,000 tons, as described in claim 3, is characterized in that... The initial low flow rate is 20%-30% of the working flow rate, and the working flow rate is 60%-80% of the flow rate when the valve is fully open.

5. The online brick-binding operation method for the pool wall of a large-scale ultra-white glass kiln with a capacity of over 1,000 tons, as described in claim 1, is characterized in that... While step S1 is being performed, an emergency cooling gun is positioned next to the operation window; in step S2, if signs of localized remelting of the molten glass are detected, the emergency cooling gun is activated to spray cooling water for reinforced cooling.

6. The online brick-binding operation method for the pool wall of a large-scale ultra-white glass kiln with a capacity of over 1,000 tons, as described in claim 1, is characterized in that... Before step S2, a drain outlet is opened along the upper edge of the old binding bricks to be removed.

7. The online brick-binding operation method for the pool wall of a large-scale ultra-white glass kiln with a capacity of over 1,000 tons, as described in claim 1, is characterized in that... Step S3 is followed by: gradually reducing the flow rate of cooling water to the water hook in stages; after the solidified molten glass softens, removing the water hook and resealing the operating window with gap bricks and sealing material.

8. The online brick-binding operation method for the pool wall of a large-scale ultra-white glass kiln with a capacity of over 1,000 tons, as described in claim 1, is characterized in that... The water hook is made of seamless steel pipe.

9. The online brick-binding operation method for the pool wall of a large-scale ultra-white glass kiln with a capacity of over 1,000 tons, as described in claim 1, is characterized in that... In step S1, while inserting the water hook into the kiln, refractory fiber cotton is used to temporarily seal the gaps around the operating window.

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