Production process of electrically fused recombined magnesite-chrome brick with excellent thermal shock stability

Abstract

The application belongs to the technical field of brick embryo production and processing, and particularly relates to a production process of fused recoupling magnesite-chrome brick with excellent thermal shock stability. In view of the problem that batch firing cannot realize continuous production and cannot guarantee the drying quality of the brick embryo when the brick embryo is dried at present, the following scheme is proposed, which comprises a conveying assembly. The conveying assembly comprises a conveying machine box and a top machine box. An arrayed feeding assembly is further arranged on the top of the conveying machine box. A drying assembly is further arranged in the conveying machine box. A control module is further arranged on the side wall of the conveying machine box. The control module comprises a processor. The application realizes continuous drying of the brick embryo, replaces the traditional batch processing, greatly improves the production efficiency, accurately controls the drying degree through real-time weight and crack detection combined with dynamic gas adjustment, effectively avoids the problems of incomplete drying or excessive carbonization, significantly improves the drying qualified rate of the brick embryo, adjusts the gas consumption on demand, reduces energy waste, and reduces the production energy consumption.

Description

Technical Field

[0001] This invention relates to the field of brick blank production and processing technology, and in particular to a production process for electrofused rebonded magnesia-chrome bricks with excellent thermal shock stability. Background Technology

[0002] Magnesia-chrome bricks are alkaline refractory materials with magnesium oxide and chromium trioxide as the main components. With their excellent resistance to slag erosion, good thermal stability and high load softening temperature, they are widely used in high-temperature industrial kilns such as open-hearth furnace tops, electric furnace tops, ladle refining furnaces and non-ferrous metal smelting furnaces in the metallurgical industry. They are a key basic material to ensure the stable operation of high-temperature equipment. In the production process of magnesia-chrome bricks, the firing and drying process of the brick blanks is an important step.

[0003] For example, Chinese patent document CN118705844A discloses a brick blank drying device for producing bricks for waste incinerators, including a base, a frame above the base, an mounting platform above the base, a tank above the mounting platform, a fan in the middle of the air inlet pipe, a box below the tank, a connecting pipe below the box, a hollow shaft tube inside one side of the tank, a heating box on one side of the tank, a moving mechanism below the frame, a clamping mechanism below the moving mechanism, a rotating mechanism inside the tank, a transmission mechanism on one side of the tank, and a connecting block on one side of the clamping mechanism. The above-disclosed technology has the following problems: current brick blank drying processes involve batch firing, which cannot ensure continuous production and the quality of brick blank drying. Existing technologies do not easily solve these problems. Therefore, there is an urgent need for an electro-fused and combined magnesia-chrome brick production process with excellent thermal shock stability to solve the above problems. Summary of the Invention

[0004] Based on the current technical problems of batch firing during brick blank drying, which makes continuous production impossible and fails to guarantee the quality of brick blank drying, this invention proposes a production process for electrofused rebonded magnesia-chrome bricks with excellent thermal shock stability.

[0005] The present invention proposes a production process for electrofused rebonded magnesia-chrome bricks with excellent thermal shock stability, including a conveying assembly. The conveying assembly includes a conveyor box and a top box. The top of the conveyor box is also provided with an array of feeding components. The inside of the conveyor box is also provided with a drying component. The side wall of the conveyor box is also provided with a control module, which includes a processor.

[0006] Drying assembly: includes a main air pipe fixed to the inner wall of the conveyor box, an array of drying fire plates installed on the top of the main air pipe, and flame nozzles provided on the circumference of the drying fire plates;

[0007] Feeding assembly: including the feeding rod installed on the inner wall of the conveyor box.

[0008] Preferably, the drying assembly further includes a gas distribution valve fixed to the outer wall of the conveyor box. The gas distribution valve is sleeved with the internal main air pipe. An air inlet head is provided at the bottom of the gas distribution valve. A stepper motor is installed on the side wall of the gas distribution valve to control the opening and closing of the gas distribution valve.

[0009] Preferably, the outer circumference of the feeding rod is provided with five equally spaced brick isolation rings, and the feeding rod is divided into four conveying areas by the five brick isolation rings.

[0010] Preferably, both ends of the feeding rod are provided with feeding rod end shafts, and the feeding rod end shafts are fixed to the inner wall of the conveyor box by bearings.

[0011] Preferably, the conveying assembly is further provided with a weight detection assembly and a crack detection assembly.

[0012] Preferably, the weight detection component includes a support plate fixed to the inner walls of both sides of the conveyor box. Four sets of detection structures are fixed to the top of the support plate. Each detection structure includes two fixed columns fixed to the top of the support plate. Each of the two fixed columns is fitted with a movable sleeve on its top. A top frame is fixed to the top of the two movable sleeves. A rotating roller is installed on the top of the top frame.

[0013] Preferably, a distance sensor is fixed at the top position inside the movable sleeve, and a limit spring is installed between the bottom of the movable sleeve and the top of the support plate.

[0014] Preferably, the crack detection assembly includes a mounting top box that snaps onto the top of the top chassis, and multiple mounting top boxes are arranged in an array. Four ultrasonic sensors arranged in an array are fixed at the bottom of the mounting top box.

[0015] Preferably, the control module includes a distance detection module for detecting distance changes caused by the brick pressing against the rotating roller and transmitting the detected data to the processor. The control module also includes a crack detection module for detecting crack status data within the brick and transmitting the detected data to the processor.

[0016] Preferably, the control module further includes a data processing module for collecting distance change data transmitted by the distance detection module and crack state data transmitted by the crack detection module, and analyzing and processing multiple sets of data to obtain a final logical decision. This logical decision controls the next stepper motor through the processor to control the opening and closing degree of the gas distribution valve of the drying component at the position where the brick is about to be conveyed, and controls the size of the drying flame to adjust the drying effect of the brick.

[0017] The beneficial effects of this invention are as follows:

[0018] 1. This electro-fused magnesia-chrome brick production process with excellent thermal shock stability enables continuous drying of brick blanks, replacing traditional batch processing and significantly improving production efficiency. By combining real-time weight and crack detection with dynamic gas regulation, the degree of drying can be precisely controlled, effectively avoiding incomplete drying or excessive carbonization, significantly improving the qualified rate of brick blank drying, and adjusting gas consumption as needed to reduce energy waste and lower production energy consumption. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of an electrofused rebonded magnesia-chrome brick production process with excellent thermal shock stability proposed in this invention.

[0020] Figure 2 This is a schematic diagram of the feeding rod structure for an electrofused recombinant magnesia-chrome brick production process with excellent thermal shock stability proposed in this invention.

[0021] Figure 3 This is a partial cross-sectional view of the overall structure of the electrofused rebonded magnesia-chrome brick production process with excellent thermal shock stability proposed in this invention.

[0022] Figure 4 This is a schematic diagram of the drying component structure for an electrofused rebonded magnesia-chrome brick production process with excellent thermal shock stability proposed in this invention.

[0023] Figure 5 This is a schematic diagram of the weight detection component structure for an electrofused rebonded magnesia-chrome brick production process with excellent thermal shock stability proposed in this invention.

[0024] Figure 6 This is a schematic diagram of the distance sensor structure for an electrofused rebonded magnesia-chrome brick production process with excellent thermal shock stability proposed in this invention.

[0025] Figure 7 This is a partial structural diagram of a crack detection component for an electrofused rebonded magnesia-chrome brick production process with excellent thermal shock stability, as proposed in this invention.

[0026] Figure 8 This is a schematic diagram illustrating the quality inspection and control principle of an electrofused rebonded magnesia-chrome brick production process with excellent thermal shock stability proposed in this invention.

[0027] In the picture:

[0028] 100. Conveying assembly; 101. Conveyor housing; 102. Top housing; 103. Conveying bracket; 104. Partition plate; 105. Brick conveying port; 106. Sealing end plate;

[0029] 200. Feeding assembly; 201. Feeding rod; 202. Brick isolation ring; 203. Conveying area; 204. Feeding rod end shaft;

[0030] 300. Drying assembly; 301. Main air pipe; 302. Drying burner; 303. Gas distribution valve; 304. Air inlet head; 305. Stepper motor; 306. Flame nozzle;

[0031] 400. Weight detection component; 401. Support plate; 402. Fixed column; 403. Movable sleeve; 404. Limit spring; 405. Top frame; 406. Rotary roller; 407. Nested chamber; 408. Distance sensor;

[0032] 500. Crack detection assembly; 501. Mounting top box; 502. Ultrasonic sensor. Detailed Implementation

[0033] Reference Figure 1 A process for producing electrofused magnesia-chrome bricks with excellent thermal shock stability includes a conveying assembly 100, which includes a conveyor housing 101 and a top housing 102. The top of the conveyor housing 101 is also provided with an array of feeding assemblies 200. The interior of the conveyor housing 101 is also provided with a drying assembly. The side wall of the conveyor housing 101 is also provided with a control module, which includes a processor.

[0034] Reference Figure 1 Sealing end plates 106 are also bolted to both ends of the conveyor box 101 to seal both ends of the conveyor box 101, forming a closed space inside the conveyor box 101 to prevent the rapid loss of heat during the drying process.

[0035] Reference Figure 1 Conveying brackets 103 are bolted to both ends of the conveyor box 101. The top plane of the conveying bracket 103 is flush with the top of the feeding rod 201, ensuring that the bricks can enter the feeding rod 201 for conveying from the top of the conveying bracket 103. Five partitions 104 are also fixed to the top of the conveying bracket 103, forming brick conveying ports 105 between the partitions 104. The side walls of the partitions 104 are designed with an arc-shaped structure, which can guide the bricks to the brick conveying port 105 in the middle position and keep the conveyed bricks in the same position for feeding and discharging, which helps the brick drying process.

[0036] Drying assembly: includes a main air pipe 301 fixed to the inner wall of the conveyor box 101, an array of drying fire plates 302 installed on the top of the main air pipe 301, and a nozzle 306 is provided on the circumference of the drying fire plate 302. Combustion gas is introduced into the main air pipe 301, and the multiple drying fire plates 302 on the top introduce combustion gas. The combustion gas ejected from the nozzle 306 is ignited by electronic ignition to dry the bricks on the top.

[0037] Reference Figure 1 , Figure 3 and Figure 4 In the drying process of brick production, the drying process is continuous, and each drying component is equipped with a brick status detection structure to detect the weight and internal cracks of the bricks, and to detect the degree of dryness of the bricks. Based on the detected degree of dryness, the drying flame of the next drying position is adjusted. This dynamic drying process saves drying costs and improves the drying effect of the bricks.

[0038] Reference Figure 1 and Figure 2 The feeding assembly includes a feeding rod 201 installed on the inner wall of the conveyor housing 101. Five equally spaced brick isolation rings 202 are provided on the outer circumference of the feeding rod 201. The feeding rod 201 is divided into four conveying areas 203 by the five brick isolation rings 202. The four conveying areas 203 are aligned with the four brick conveying ports 105 at the inlet and outlet ends of the conveyor housing 101. The bricks conveyed by the brick conveying ports 105 enter each conveying area 203. Both ends of the feeding rod 201 are provided with feeding rod end shafts 204. The feeding rod end shafts 204 are fixed to the inner wall of the conveyor housing 101 by bearings, so that the feeding rod 201 can rotate freely. The material of the feeding rod 201 is refractory ceramic.

[0039] Reference Figure 1 , Figure 3 and Figure 4 Furthermore, the drying assembly also includes a gas distribution valve 303 fixed to the outer wall of the conveyor housing 101. The gas distribution valve 303 is fitted with the internal main gas pipe 301. The gas distribution valve 303 has an internal component for adjusting the intake air volume, driven and controlled by a stepper motor 305. The control signal for the stepper motor 305 comes from a processor. An intake pipe head 304 is located at the bottom of the gas distribution valve 303. Multiple intake pipe heads 304 are connected to an external combustion gas source. A stepper motor 305 is installed on the side wall to control the opening and closing of the air distribution valve 303. After the brick blank enters from the feed end of the conveyor box 101, the stepper motor 305 of the first drying component controls the air distribution valve 303 to be fully opened to dry the brick blank. After the brick blank leaves, it enters the detection position to detect the weight and internal cracks of the brick blank. The data is fed back to the processor, and then the processor sends a signal to the stepper motor 305 of the next drying component to control the opening degree of the air distribution valve 303.

[0040] Reference Figures 1-6 Furthermore, the conveying assembly 100 is also equipped with a weight detection assembly 400 and a crack detection assembly 500.

[0041] Reference Figure 3 , Figure 5 and Figure 6Furthermore, the weight detection component 400 includes support plates 401 fixed to the inner walls of both sides of the conveyor housing 101. The support plates 401 are strong enough to ensure that they do not shift when the brick blanks pass over them. Four sets of detection structures are fixed to the top of the support plates 401. The four sets of detection structures correspond to the positions of the four conveying areas 203 of the feeding component 200. The detection structure includes two fixed columns 402 fixed to the top of the support plates 401. Each fixed column 402 has a movable sleeve 403 fitted on its top, allowing the movable sleeve 403 to move within the fixed column 402. The outer wall slides up and down without shifting. The top of the two movable sleeves 403 is fixed with a top frame 405. A rotating roller 406 is installed on the top of the top frame 405. The top of the rotating roller 406 is higher than the top of the feeding rod 201. This structural design will generate a downward pressure force when the brick blank passes through the rotating roller 406. A distance sensor 408 is fixed at the top position inside the movable sleeve 403. The distance sensor 408 is used to detect the relative downward distance of the movable sleeve 403 when the brick blank passes through the top. A limit spring 404 is installed between the bottom of the movable sleeve 403 and the top of the support plate 401.

[0042] Reference Figure 3 , Figure 7 Furthermore, the crack detection component 500 includes a mounting top box 501 that is snapped onto the top of the top housing 102, and multiple mounting top boxes 501 are arranged in an array. Four ultrasonic sensors 502 arranged in an array are fixed at the bottom of the mounting top box 501, wherein the detection end of the ultrasonic sensor 502 faces the bottom, and the bottom of the four ultrasonic sensors 502 corresponds to the four conveying areas 203 of the conveying component 100, respectively, to detect cracks in the brick blanks conveyed at the top of the four conveying areas 203.

[0043] Reference Figures 1-7 Furthermore, the control module includes a distance detection module. This module collects detection data from the distance sensor 408 to detect the distance change data caused by the brick pressing against the roller 406. The detection data from the distance detection module reflects the current brick weight. Different brick weights result in different pressing distances. The distance sensor 408 detects the distance change data caused by the brick passing by and generates a distance change coefficient K. The distance detection module transmits the distance change coefficient K to the processor. Based on the difference between the initial distance of the roller 406 without a brick and the actual distance when the brick is pressed, and the ratio of this difference to the baseline descent distance, the difference in brick weight (moisture content) is quantified. The calculation expression for the distance change coefficient is as follows:

[0044]

[0045] K: Distance variation coefficient, which is dimensionless. The larger the value, the heavier the brick blank and the higher the moisture content.

[0046] D0: The initial distance of the roller detected by the distance sensor when there are no brick blanks;

[0047] D i The actual distance of the roller detected by the distance sensor during brick pressing;

[0048] D ref The reference descent distance of the roller during the pressing of brick blanks with standard moisture content is determined by experiment.

[0049] Reference Figures 1-7 Furthermore, the control module also includes a crack detection module, used to detect crack state data within the brick. This module detects internal cracks in the brick blank, reflecting the crack data within the brick blank during the drying process. Cracks within the brick blank also reflect internal stress, directly affecting the brick's brittleness. More cracks release more stress, making the brick more resistant to impact. The crack detection module uses an ultrasonic sensor 502 to detect the cracks and generates a crack variation coefficient F. This coefficient F is then transmitted to the processor. The calculation expression for the crack variation coefficient F is as follows:

[0050]

[0051] F: Crack variation coefficient, which is dimensionless. The larger the value, the more cracks there are and the more fully the stress is released.

[0052] ΔP i : Actual attenuation of ultrasonic waves during brick blank testing;

[0053] ΔP ref The ultrasonic attenuation of a crack-free reference brick blank is determined experimentally.

[0054] ΔT i The actual time difference of ultrasonic wave propagation during brick blank inspection;

[0055] ΔT ref The ultrasonic propagation time difference of the reference brick blank without cracks is determined by experiment.

[0056] Furthermore, the control module also includes a data processing module, which collects distance change data transmitted by the distance detection module and crack state data transmitted by the crack detection module, analyzes and processes multiple sets of data, obtains the final logical decision, and generates an adjustment coefficient. The adjustment factor for this logical decision The processor controls the next stepper motor 305 to control the opening and closing degree of the gas distribution valve 303 of the drying component at the position where the bricks are about to be conveyed. This controls the amount of gas entering the drying flame to adjust the drying effect of the bricks. The adjustment coefficient... The calculation expression is:

[0057] ;

[0058] Wherein:

[0059] : The distance change coefficient generated by the distance detection module;

[0060] : The crack change coefficient generated by the crack detection module;

[0061] : The weight of the distance change coefficient;

[0062] : The weight of the crack change coefficient.

[0063] Furthermore, after the data processing module analyzes and obtains an adjustment coefficient S, the processor controls the stepper motor 305. When the adjustment coefficient: S > 1, increase the gas volume; 0 < S ≤ 1, decrease the gas volume; S ≤ 0, shut off the gas.

[0064] When the present invention is in use: below the feeding rod 201, the array - distributed drying components are started synchronously. The drying fire pans 302 of each drying component are connected to the gas through the air inlet pipe heads 304. In the initial state, the gas distribution valves 303 controlled by the stepper motor 305 on each gas pipe are opened at the reference opening degree. The drying fire pans 302 release flames to heat and dry the green bricks conveyed above. The array layout enables the green bricks to pass through the heating areas of multiple groups of drying components in sequence during the conveying process, realizing gradual and uniform drying, and avoiding over - drying or under - drying in local areas;

[0065] After the brick blanks pass through the drying areas of each drying assembly, they immediately enter the detection area set in the middle of the feeding rod 201 to complete the synchronous detection of weight and internal cracks. The detection data is transmitted to the processor in real time. Weight detection: When the brick blanks move above the rotating roller 406 structure of the detection mechanism, their own weight exerts downward pressure on the roller, causing the rotating roller 406 structure to descend. The distance sensor 408 detects the actual distance of the roller 406 after its descent in real time and compares it with the initial distance when there are no brick blanks. The weight of the brick blanks is quantified by the distance change, a distance change coefficient K is generated, and it is transmitted to the processor. Crack detection: The ultrasonic sensor 502 at the top of the conveyor box 101 emits ultrasonic signals to the brick blanks passing below. When the ultrasonic waves propagate inside the brick blanks, if there are cracks, they will be reflected and attenuated. Sensor 502 receives the echo signal and quantifies the number and distribution density of cracks inside the brick blank by analyzing the signal attenuation and propagation time difference, generating a crack variation coefficient F and transmitting it to the processor. The data processing module in the processor performs a collaborative analysis of the received distance variation coefficient K and crack variation coefficient F, generating an adjustment coefficient S, which then controls the stepper motor 305 of the next set of drying components to operate. If the brick blank distance variation coefficient K is detected to be too large, it indicates that the brick blank is heavy and has a high moisture content, and the crack variation coefficient F is too small, which means that there are few cracks and the stress has not been fully released, indicating that the drying is incomplete. The processor generates an adjustment coefficient S greater than 1, controlling the stepper motor 305 of the next set of drying components to increase the gas intake, improve the combustion degree of the drying fire plate 302, and achieve strong drying.

[0066] If the brick blank distance variation coefficient K is detected to be small, it indicates that the brick blank is light and has low moisture content. If the crack variation coefficient F is large, it indicates that the brick blank has many cracks and the stress is fully released, indicating that the drying has reached the standard. The processor generates an adjustment coefficient S between 0 and 1, reduces the gas supply or sets the adjustment coefficient S to less than or equal to 0, shuts off the gas supply, and controls the stepper motor 305 of the next drying component to reduce or shut off the gas supply to avoid over-drying. If the detection data is close to the experimentally calibrated reference threshold, the adjustment coefficient S is maintained at 1, and the next drying component continues to work according to the reference gas supply.

[0067] After passing through multiple sets of "drying-inspection-adjustment" units, the brick blanks gradually reach a qualified drying state and are finally discharged from the discharge end of the conveyor box 101. The whole process forms a continuous and adaptive closed-loop drying process to ensure that the drying quality of each brick blank reaches the optimal level.

[0068] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A production process for electrofused rebonded magnesia-chrome bricks with excellent thermal shock resistance, comprising a conveying assembly (100), characterized in that, The conveying assembly (100) includes a conveyor box (101) and a top box (102). The top of the conveyor box (101) is also provided with an array of feeding assemblies (200). The inside of the conveyor box (101) is also provided with a drying assembly. The side wall of the conveyor box (101) is also provided with a control module, which includes a processor. Drying assembly: includes a main air pipe (301) fixed to the inner wall of the conveyor box (101), an array of drying fire plates (302) are installed on the top of the main air pipe (301), and a flame nozzle (306) is provided on the circumference of the drying fire plate (302). Feeding assembly: including a feeding rod (201) installed on the inner wall of the conveyor housing (101); The conveying assembly (100) is also provided with a weight detection assembly (400) and a crack detection assembly (500). Weight detection assembly (400): includes a support plate (401) fixed to the inner walls of both sides of the conveyor box (101). The top of the support plate (401) is fixed with four sets of detection structures. The detection structures include two fixed columns (402) fixed to the top of the support plate (401). The top of each of the two fixed columns (402) is fitted with a movable sleeve (403). The top of the two movable sleeves (403) is fixed with a top frame (405). A rotating roller (406) is installed on the top of the top frame (405). A distance sensor (408) is fixed at the top position inside the movable sleeve (403). A limit spring (404) is installed between the bottom of the movable sleeve (403) and the top of the support plate (401). The crack detection assembly (500) includes a mounting top box (501) that is snapped onto the top of the top housing (102), and multiple mounting top boxes (501) are installed in an array. Four ultrasonic sensors (502) are fixed at the bottom of the mounting top box (501). The control module includes a distance detection module for detecting distance changes caused by the brick pressing against the rotating roller (406) and transmitting the detected data to the processor. The control module also includes a crack detection module for detecting crack state data within the brick and transmitting the detected data to the processor. The control module also includes a data processing module for collecting distance change data transmitted by the distance detection module and crack state data transmitted by the crack detection module, and analyzing and processing multiple sets of data to obtain a final logical decision. This logical decision controls the next stepper motor (305) through the processor to control the opening and closing degree of the air distribution valve (303) of the drying component at the position where the brick is about to be conveyed, and controls the size of the drying flame to adjust the drying effect of the brick.

2. The production process for electrofused reconstituted magnesia-chrome bricks with excellent thermal shock stability according to claim 1, characterized in that, The drying assembly also includes a gas distribution valve (303) fixed to the outer wall of the conveyor box (101). The gas distribution valve (303) is sleeved with the main air pipe (301) inside. An air inlet head (304) is provided at the bottom of the gas distribution valve (303). A stepper motor (305) is installed on the side wall of the gas distribution valve (303) to control the opening and closing of the gas distribution valve (303).

3. The production process for electrofused reconstituted magnesia-chrome bricks with excellent thermal shock stability according to claim 1, characterized in that, The outer circumference of the feeding rod (201) is provided with five equally spaced brick isolation rings (202), and the feeding rod (201) is divided into four conveying areas (203) by the five brick isolation rings (202).

4. The production process for electrofused reconstituted magnesia-chrome bricks with excellent thermal shock stability according to claim 3, characterized in that, Both ends of the feeding rod (201) are provided with feeding rod end shafts (204), and the feeding rod end shafts (204) are installed and fixed to the inner wall of the conveyor box (101) through bearings.

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