Installation method of engineering black body element in industrial heating furnace

Abstract

The invention discloses a mounting method of an engineering blackbody element in an industrial heating furnace, which comprises the following steps: three positioning holes are symmetrically formed in an element mounting surface in a triangular shape, a semicircular diversion trench is formed between every two adjacent positioning holes, and the mounting surface is subjected to sand blasting treatment; manufacturing a positioning gasket according to the curvature of the inner wall of the hearth, wherein the positioning gasket is arranged between the element mounting surface and the inner wall of the hearth; coating or spraying a high-temperature-resistant permeation type adhesive on the element mounting surface and the inner wall of the hearth, adhering the element to the inner wall of the hearth, and screwing the element on the inner wall of the hearth by adopting a screw through a positioning hole and a positioning gasket; high-temperature-resistant fastening screws are evenly distributed on the periphery of the element and vertically screwed into refractory bricks or concrete base materials on the inner wall of a hearth to lock the position of the element. According to the method, the defects of traditional engineering black body element installation are overcome, high-strength, long-acting and stable connection between the engineering black body element and the inner wall of the hearth is achieved, the problem that the element is prone to displacement and falling off under the high-temperature working condition is effectively solved, and the continuous effectiveness of kiln energy-saving transformation is guaranteed.

Description

Technical Field

[0001] This invention relates to the field of equipment installation technology, and in particular to a method for installing engineering blackbody elements in industrial heating furnaces and kilns. Background Technology

[0002] In the field of industrial heating, industrial heating furnaces and kilns are core energy-consuming equipment, and energy conservation and efficiency improvement have always been a key focus of the industry. Engineering blackbody elements, as a novel energy-saving technology, effectively improve energy utilization efficiency by optimizing the heat transfer process within the furnace or kiln. Engineering blackbody elements are energy-saving devices used in industrial heating furnaces and kilns. By enhancing radiative heat transfer efficiency, they significantly improve heating uniformity, reduce energy consumption (gas / electricity) and carbon emissions, and are widely used in industries such as steel and building materials. In the operation of heating furnaces in industries such as steel and machinery manufacturing, traditional furnace chambers suffer from problems such as diffuse reflection of thermal rays, low heat transfer efficiency, and uneven temperature, leading to energy waste and product quality fluctuations. To solve this problem, engineering blackbody elements, as a technology that enhances radiative heat transfer, have been proposed and widely applied. Based on the principle of blackbody radiation, an ideal blackbody can efficiently absorb and re-emit heat energy. By installing engineering blackbody elements with high emissivity on the furnace top or furnace wall, the originally lost heat energy is directionally reflected to the surface of the steel billet, achieving more efficient heat transfer. This can significantly enhance the intensity of radiative heat transfer inside the furnace, making the heat transfer to the heated workpiece more uniformly and quickly, thereby shortening the heating cycle and reducing energy waste.

[0003] In practical applications, the installation of engineering blackbody elements does not require large-scale modifications to existing furnace structures. Energy-saving goals can be achieved simply by rationally arranging the element positions and quantities according to the furnace type. In high-temperature environments, engineering blackbody elements can increase the effective radiant energy utilization rate within the furnace by more than 20%, while simultaneously reducing exhaust gas temperature and waste heat loss. Furthermore, the improved heating uniformity enhances the heating quality of workpieces, reduces scrap rates, and indirectly lowers production costs.

[0004] The traditional mounting methods for blackbody components and their main drawbacks are as follows: Pre-embedded installation (embedded into the furnace wall during the masonry period) involves a complex construction process, and once the components are damaged, repairs are extremely difficult and often require damage to the furnace structure.

[0005] External installation (added to the outer surface after the furnace body is completed), such as Figure 1As shown, single-point positioning installation is typically used. The furnace substrate 4 has a process hole, and the mounting surface of component 1 has a through hole 2. A screw 3 is inserted through the through hole 2 and screwed into the process hole. The screw 3 is then screwed into a nut 31 to secure the component 1. Adhesive 5 is applied between the mounting surface of component 1 and the furnace substrate 4. Single-point fixing cannot constrain the multidimensional displacement of the component during the bonding and solidification process (such as thermal expansion and contraction, vibration displacement), leading to stress concentration and bonding failure, resulting in uncontrolled component freedom. Furthermore, the bonding on the mounting surface of the component is prone to cracking due to uneven local stress, especially under high-frequency vibration or sudden temperature changes, leading to a high component detachment rate.

[0006] Embedded installation (installation in a pre-reserved location on the furnace wall) requires extremely high sealing technology during installation to prevent heat loss or air leakage, and at the same time, the convenience of maintenance and repair is relatively poor. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to provide a method for installing engineering blackbody elements in industrial heating furnaces. This method overcomes the defects of traditional engineering blackbody element installation, realizes a high-strength and long-term stable connection between the engineering blackbody element and the inner wall of the furnace, effectively solves the problem of easy displacement and detachment of elements under high-temperature conditions, and ensures the continuous effectiveness of furnace energy-saving transformation.

[0008] To solve the above-mentioned technical problems, the installation method of the engineering blackbody element in the industrial heating furnace of the present invention includes the following steps: Step 1: Three positioning holes are symmetrically arranged in a triangle on the component mounting surface. Semi-circular guide grooves are provided between adjacent positioning holes and along the radial outward of each positioning hole on the mounting surface. The mounting surface is sandblasted to make its roughness 3.2 micrometers to increase mechanical interlocking force. A 0.1mm protrusion is provided at the edge of the mounting surface to prevent adhesive overflow. Step 2: Make positioning shims according to the curvature of the furnace inner wall. The front of the positioning shim is set with three positioning holes, and the curvature of the back is consistent with the curvature of the furnace inner wall. Mounting holes matching the positions of the three positioning holes are set at the component mounting positions on the furnace inner wall. Step 3: Apply or spray high-temperature penetrating adhesive to the component mounting surface and the component mounting position on the inner wall of the furnace, respectively, and then bond the component to the inner wall of the furnace. The adhesive is spread to the component mounting surface through the semi-circular guide groove, and air is discharged and stress is released through the semi-circular guide groove. Screws are inserted into the three positioning holes and positioning washers to screw the component into the mounting holes on the inner wall of the furnace. Step 4: Arrange 4 to 6 high-temperature resistant fastening screws evenly around the component and screw them vertically into the refractory bricks or concrete substrate on the inner wall of the furnace to quickly lock the component in place. This prevents the component from shifting due to airflow disturbance or vibration in the furnace before the adhesive cures, and provides a stable environment for the penetration and curing of the adhesive.

[0009] Furthermore, the three positioning holes on the component mounting surface are evenly distributed at 120° to form a statically determinate structure with minimal constraints, eliminating the risk of over-constraint during assembly.

[0010] Furthermore, the height tolerance of the semi-circular guide channel is ±0.05mm, the inclined guide angle is 15°, and the semi-circular guide channel forms an anchoring structure for bonding the element to the inner wall of the furnace.

[0011] Furthermore, the positioning pad is made of high-temperature resistant ceramic or silicon carbide material, and has a temperature resistance of ≥1200℃.

[0012] Furthermore, the high-temperature resistant fastening screws are made of 310S stainless steel and have a temperature resistance of ≥1300℃, with torque controlled between 15 and 20 N·m to ensure uniform force distribution on each screw.

[0013] Furthermore, the high-temperature penetrating adhesive is an inorganic silica sol-based adhesive, which has a temperature resistance of ≥1000℃ after curing.

[0014] The method for installing engineering blackbody elements in industrial heating furnaces according to this invention employs the aforementioned technical solution. Specifically, this method involves symmetrically arranging three positioning holes in a triangular pattern on the element mounting surface, with semi-circular guide grooves between adjacent positioning holes. The mounting surface is sandblasted. Positioning shims are fabricated according to the curvature of the furnace inner wall and placed between the element mounting surface and the furnace inner wall. A high-temperature resistant penetrating adhesive is coated or sprayed onto the element mounting surface and the furnace inner wall to bond the element to the furnace inner wall. Screws are then used to tighten the element to the furnace inner wall through the positioning holes and shims. High-temperature resistant fastening screws are evenly distributed around the element and vertically screwed into the refractory bricks or concrete substrate of the furnace inner wall to lock the element's position. This method overcomes the defects of traditional engineering blackbody element installation, achieving a high-strength, long-term stable connection between the engineering blackbody element and the furnace inner wall. It effectively solves the problem of element displacement and detachment under high-temperature conditions, ensuring the continuous effectiveness of furnace energy-saving renovations. Attached Figure Description

[0015] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments: Figure 1 A schematic diagram of a traditional engineering blackbody component external mounting structure; Figure 2 This diagram illustrates the positioning holes and guide grooves on the component mounting surfaces in this installation method. Detailed Implementation

[0016] Implementation, for example Figure 2 As shown, the installation method of the engineering blackbody element in the industrial heating furnace of the present invention includes the following steps: Step 1: Three positioning holes 12 are symmetrically arranged in a triangle on the mounting surface 11 of component 1. Semi-circular guide grooves 13 are provided between adjacent positioning holes 12 and along the radial outward of each positioning hole 12 on the mounting surface 11. The mounting surface 11 is sandblasted to make its roughness 3.2 micrometers to increase the mechanical interlocking force. A 0.1mm protrusion 14 is provided on the edge of the mounting surface 11 to prevent adhesive overflow. Step 2: Make positioning shims according to the curvature of the furnace inner wall. The front of the positioning shim is set with three positioning holes, and the curvature of the back is consistent with the curvature of the furnace inner wall. Mounting holes matching the positions of the three positioning holes are set at the component mounting positions on the furnace inner wall. Step 3: Apply or spray high-temperature penetrating adhesive to the component mounting surface and the component mounting position on the inner wall of the furnace, respectively, and then bond the component to the inner wall of the furnace. The adhesive is spread to the component mounting surface through the semi-circular guide groove, and air is discharged and stress is released through the semi-circular guide groove. Screws are inserted into the three positioning holes and positioning washers to screw the component into the mounting holes on the inner wall of the furnace. Step 4: Arrange 4 to 6 high-temperature resistant fastening screws evenly around the component and screw them vertically into the refractory bricks or concrete substrate on the inner wall of the furnace to quickly lock the component in place. This prevents the component from shifting due to airflow disturbance or vibration in the furnace before the adhesive cures, and provides a stable environment for the penetration and curing of the adhesive.

[0017] Preferably, the three positioning holes on the mounting surface of the component are evenly distributed at 120° to form a statically determinate structure with minimal constraints, eliminating the risk of over-constraint during assembly.

[0018] Preferably, the height tolerance of the semi-circular guide channel is ±0.05mm, the inclined guide angle is 15°, and the semi-circular guide channel forms an anchoring structure for bonding the element to the inner wall of the furnace.

[0019] Preferably, the positioning pad is made of high-temperature resistant ceramic or silicon carbide material, and has a temperature resistance of ≥1200℃.

[0020] Preferably, the high-temperature resistant fastening screws are made of 310S stainless steel and have a temperature resistance of ≥1300℃, with the torque controlled between 15 and 20 N·m to ensure uniform force distribution on each high-temperature resistant fastening screw.

[0021] Preferably, the high-temperature penetrating adhesive is an inorganic silica sol-based adhesive with a temperature resistance of ≥1000℃ after curing.

[0022] This method addresses the issue of component detachment caused by single-point positioning by employing a three-point positioning method. This method uses non-collinear fastening screws to secure the component to the furnace wall, significantly improving the reliability of component installation. The three-point positioning constrains the component's spatial degrees of freedom; the three non-collinear fastening screws form a stable plane, restricting the component's six degrees of freedom (three translations + three rotations), ensuring uniform stress distribution. Simultaneously, it achieves stress dispersion; the three fastening screws are arranged in a triangular pattern (e.g., evenly distributed at 120° angles), decomposing the external load into multi-directional components and preventing localized stress exceeding limits.

[0023] This method employs a composite fixing system consisting of three-point limiting, multi-screw mechanical fixing, and high-temperature penetrating adhesive. Through step-by-step synergistic action, it achieves a high-strength, long-term stable connection between the engineering blackbody element and the inner wall of the furnace, effectively solving the problem of easy displacement and detachment of the element under high-temperature conditions, and ensuring the continuous effectiveness of energy-saving renovation.

[0024] 1. Three-point positioning method: Precise positioning ensures a perfect fit. Three-point symmetrical positioning pads were designed to address the geometric dimensions of the engineering blackbody element and the curvature of the furnace inner wall. Limiting reference points were set at the top, left, and right sides of the element mounting surface. By tightly fitting the positioning pads to the furnace inner wall, the element was forced to maintain a completely parallel installation posture with the furnace inner wall substrate, eliminating local stress concentration caused by installation deviations and laying the foundation for subsequent fixing steps.

[0025] 2. Multi-screw mechanical fastening: Provides initial structural stability. Four to six high-temperature fastening screws are evenly arranged around the component after it has been positioned. The screws are vertically screwed into the refractory bricks or concrete substrate on the inner wall of the furnace, with the torque controlled at 15 to 20 N·m to ensure that each screw is subjected to uniform force. The purpose of mechanical fastening is to quickly lock the position of the component and prevent it from shifting due to airflow disturbance or vibration in the furnace before the adhesive cures, thus providing a stable environment for the penetration and curing of the adhesive.

[0026] 3. High-temperature penetrating adhesive: fills pores and forms a double bond. An inorganic silica sol-based high-temperature adhesive is selected, possessing excellent thermal stability and penetrating bonding characteristics. It is applied evenly between the component mounting surface and the furnace inner wall using a brush or spray. Leveraging its high permeability, the adhesive penetrates the microporous structure (pore size approximately 0.1–1 mm) of the furnace substrate (such as refractory concrete), creating a mechanical interlocking effect. Simultaneously, the active silica oxygen groups (-Si-OH) in the adhesive undergo condensation reactions with the hydroxyl groups (-OH) on the furnace substrate surface and the metal oxides on the component mounting surface (such as the alumina coating of engineering blackbody components), forming chemical covalent bonds. This dual effect of "mechanical interlocking + chemical bonding" significantly enhances the connection strength between the component and the furnace substrate, effectively filling interfacial gaps and reducing the risk of interfacial delamination due to thermal expansion differences at high temperatures.

[0027] 4. Synergistic effect: Improves stability and ensures energy-saving effect The three-point limiting method ensures precise positioning of the components, multi-screw mechanical fixing provides initial structural support, and high-temperature penetrating adhesive achieves long-term interface stability through penetration and filling. The synergistic effect of these three factors improves the connection strength between the engineering blackbody components and the furnace inner wall by 40%–60% (based on thermal shock cycling tests, after 50 cycles from 1000℃ to room temperature, the detachment rate is ≤1%), effectively maintaining the component's radiation efficiency (blackbody emissivity ≥0.9), reducing heat loss within the furnace (thermal efficiency improved by 8%–12%), and ensuring the continued effectiveness of energy-saving renovations.

[0028] This method, through practical application, not only solves the problems of easy detachment and poor stability of traditional single fixing methods (such as using only screws or adhesives) under high-temperature conditions, but also optimizes the interface structure through the penetration and filling of adhesives, further improving the radiation performance of engineering blackbody elements, and providing reliable technical support for energy-saving transformation of industrial furnaces and kilns.

Claims

1. A method for installing engineering blackbody elements in an industrial heating furnace, characterized in that... Includes the following steps: Step 1: Three positioning holes are symmetrically arranged in a triangle on the component mounting surface. Semi-circular guide grooves are provided between adjacent positioning holes and along the radial outward of each positioning hole on the mounting surface. The mounting surface is sandblasted to make its roughness 3.2 micrometers to increase mechanical interlocking force. A 0.1mm protrusion is provided at the edge of the mounting surface to prevent adhesive overflow. Step 2: Make positioning shims according to the curvature of the furnace inner wall. The front of the positioning shim is set with three positioning holes, and the curvature of the back is consistent with the curvature of the furnace inner wall. Mounting holes matching the positions of the three positioning holes are set at the component mounting positions on the furnace inner wall. Step 3: Apply or spray high-temperature penetrating adhesive to the component mounting surface and the component mounting position on the inner wall of the furnace, respectively, and then bond the component to the inner wall of the furnace. The adhesive is spread to the component mounting surface through the semi-circular guide groove, and air is discharged and stress is released through the semi-circular guide groove. Screws are inserted into the three positioning holes and positioning washers to screw the component into the mounting holes on the inner wall of the furnace. Step 4: Arrange 4 to 6 high-temperature resistant fastening screws evenly around the component and screw them vertically into the refractory bricks or concrete substrate on the inner wall of the furnace to quickly lock the component in place. This prevents the component from shifting due to airflow disturbance or vibration in the furnace before the adhesive cures, and provides a stable environment for the penetration and curing of the adhesive.

2. The method for installing engineering blackbody elements in industrial heating furnaces and kilns according to claim 1, characterized in that: The three positioning holes on the component mounting surface are evenly distributed at 120° to form a statically determinate structure with minimal constraints, eliminating the risk of over-constraint during assembly.

3. The method for installing engineering blackbody elements in industrial heating furnaces and kilns according to claim 1, characterized in that: The height tolerance of the semi-circular guide channel is ±0.05mm, the inclined guide angle is 15°, and the semi-circular guide channel forms an anchoring structure for bonding the element to the inner wall of the furnace.

4. The method for installing engineering blackbody elements in industrial heating furnaces and kilns according to claim 1, characterized in that: The positioning pad is made of high-temperature resistant ceramic or silicon carbide material, and has a temperature resistance of ≥1200℃.

5. The method for installing engineering blackbody elements in industrial heating furnaces and kilns according to claim 1, characterized in that: The high-temperature resistant fastening screws are made of 310S stainless steel and have a temperature resistance of ≥1300℃. The torque is controlled between 15 and 20 N·m to ensure that each high-temperature resistant fastening screw is subjected to uniform force.

6. The method for installing engineering blackbody elements in industrial heating furnaces and kilns according to claim 1, characterized in that: The high-temperature penetrating adhesive is an inorganic silica sol-based adhesive, which has a temperature resistance of ≥1000℃ after curing.

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