Furnace pressure control method suitable for hot-state electrode replacement of glass kiln

Abstract

The invention belongs to the field of furnace pressure control methods in the electrode replacement process of kilns, and discloses a furnace pressure control method suitable for hot-state electrode replacement of a glass kiln. The process control method is characterized by being an implementation method for controlling the furnace pressure process of tank furnace hot-end equipment in the process of replacing electrode bricks under the condition that a furnace is not stopped. That is to say, the implementation method of the tank furnace pressure process control mainly refers to that the control furnace pressure of the tank furnace equipment is transited from the normal production furnace pressure of the tank furnace to the furnace pressure required for discharging of the tank furnace, then to the furnace pressure required for dismounting the electrode bricks of the tank furnace, and to the furnace pressure required for mounting and propelling the new electrode bricks. And finally, the furnace pressure required by normal production after tank furnace feeding is finished is recovered. The whole control process forms a closed loop, the furnace pressure adjustment logic in each stage is coherent, the target is clear, and the core problem that in the prior art, the furnace pressure control lacks pertinence, operability and systematicness is comprehensively solved.

Description

Technical Field

[0001] This invention belongs to the field of furnace pressure control process in the process of replacing electrodes in a kiln. Specifically, it relates to a furnace pressure control method applicable to hot electrode replacement in a glass kiln, and particularly to an implementation method for furnace pressure control of the hot end equipment of the pool furnace during the replacement of electrode bricks in an ultra-thin glass electric melting kiln without shutting down the furnace. Background Technology

[0002] Glass kilns are the core equipment of glass manufacturing enterprises. Their structural rationality and process control level directly affect the lifespan of the kiln and the output and quality of glass products. During the operation of the kiln, it is necessary to carry out the replacement of equipment and refractory materials such as electrode bricks without stopping the furnace.

[0003] Replacement operations without shutting down the furnace require extremely high levels of process control, necessitating a comprehensive plan to ensure smooth construction and avoid impacting production and equipment operation. Currently, to minimize the impact of construction operations, the industry generally adopts the method of replacing equipment and refractory materials such as electrode bricks without shutting down the furnace. However, a specific process control plan for this type of operation has not yet been developed, and the relevant operations are carried out solely based on general control logic from conventional production.

[0004] The existing general control logic lacks specificity and detail, and cannot provide clear basis for furnace pressure adjustment, operation procedures, and personnel guidance in the process of changing furnaces without stopping the furnace. This can easily lead to non-standard construction process and unstable furnace pressure control, which in turn affects the safety of furnace operation, equipment service life and glass product quality, and makes it difficult to meet the precise control requirements of the operation. Summary of the Invention

[0005] The purpose of this invention is to solve the problem of the lack of a complete, quantitative and systematic furnace pressure process control scheme when replacing electrodes in a glass furnace during hot operation in the prior art, and to provide a furnace pressure control method suitable for replacing electrodes in a glass furnace during hot operation.

[0006] To achieve the above objectives, the present invention employs the following technical solution: The present invention proposes a furnace pressure control method suitable for hot electrode replacement in glass furnaces, comprising the following steps: When the kiln is replaced without shutting down, the furnace pressure of the pool furnace is reduced from the normal production furnace pressure to the discharge furnace pressure by reducing the exhaust capacity. After all the molten glass in the furnace has been drained, the furnace reaches the stage of electrode removal by increasing the capacity of the exhaust equipment. Remove the furnace electrodes and reduce the exhaust capacity to advance the furnace pressure state for installing new electrodes in the furnace. Electrodes are installed in the furnace until they reach the designated positions. The furnace pressure is reduced by adjusting the exhaust equipment capacity until the furnace reaches the normal production furnace pressure state.

[0007] Preferably, the electrode is installed in a hole in the pool wall, with one end connected to a current-carrying device and the other end in contact with the molten glass in the furnace, for use in a refractory material device that generates high-temperature molten glass raw materials by passing electricity.

[0008] Preferably, the electrode is assembled from several blocks of refractory bricks.

[0009] Preferably, several blocks of refractory material of the same size are assembled into two to three horizontal blocks and three to five vertical blocks of refractory material.

[0010] Preferably, the kiln in the "non-stop" state refers to a state in which the combustion equipment inside the kiln does not shut off and continuously provides a large amount of heat to the kiln under conditions exceeding 1000°C.

[0011] Preferably, the furnace pressure of the pool furnace is adjusted from the normal production furnace pressure to the discharge furnace pressure by reducing the exhaust capacity, specifically as follows: The normal operating pressure range of the pool furnace is 18 Pa to 22 Pa. By reducing the exhaust capacity, the furnace pressure increases at a rate of 1 Pa / h until the furnace pressure reaches the discharge state of the pool furnace. The furnace pressure range during the discharge stage of the pool furnace is 30 Pa to 35 Pa.

[0012] Preferably, after all the molten glass in the furnace has been drained, the furnace reaches the stage of electrode removal by increasing the capacity of the exhaust equipment. Specifically: After all the molten glass in the furnace has been drained, the furnace pressure is reduced by increasing the exhaust capacity at a rate of 2 Pa / h, thus reaching the stage of removing the electrodes from the furnace. The furnace pressure range for the electrode removal stage of the pool furnace is 2 Pa to 5 Pa.

[0013] Preferably, the removal of the furnace electrodes is achieved by reducing the exhaust capacity to bring the furnace pressure suitable for installing new electrodes, specifically as follows: During the removal of electrodes from the pool furnace, the furnace pressure is stabilized within the required range by adjusting the exhaust equipment and temporary exhaust holes. After the removal of electrodes is completed, the furnace pressure is increased at a rate of 2 Pa / h by reducing the exhaust equipment capacity until the furnace pressure is reached for the installation of new electrodes. The range of furnace pressure values ​​for the new electrode furnace pressure state during the installation of the pool furnace is 25 Pa to 28 Pa.

[0014] Preferably, the process of installing electrodes into the furnace until they reach the designated positions, and then adjusting the furnace pressure by adjusting the exhaust capacity to achieve the normal operating furnace pressure, specifically involves: The electrode installation begins in the furnace. After installation, the electrode is pushed forward until it reaches the designated position. The furnace then adjusts the exhaust capacity to reduce the furnace pressure at a rate of 0.5 Pa / h, so that the furnace reaches the normal operating pressure.

[0015] Preferably, once the furnace pressure is reached, the furnace begins to feed material. By continuously adjusting the exhaust equipment, the furnace pressure is stabilized within the required range until the molten glass level reaches the required height.

[0016] Compared with the prior art, the present invention has the following beneficial effects: This invention proposes a furnace pressure control method suitable for hot electrode replacement in glass kilns. Based on the premise of continuous furnace operation, it strictly follows the operational sequence of normal production furnace pressure, discharge furnace pressure, electrode removal furnace pressure, new electrode installation furnace pressure, and restoration of normal production furnace pressure. It deeply integrates furnace pressure control with the key processes of electrode replacement (discharge, removal, installation, and resetting), filling the gap in existing technologies that lack specific control solutions. Addressing the problem in existing technologies where personnel are unaware of how to adjust exhaust equipment and where there are no standards for the timing and magnitude of adjustments, this claim clarifies the core means of furnace pressure adjustment at each stage. By reducing or increasing the capacity of the exhaust equipment, furnace pressure switching is achieved, providing specific and actionable operational guidelines for on-site operators, managers, and supervisors, and avoiding furnace pressure loss due to blind adjustments. During the discharge phase, the furnace pressure is reduced to achieve the discharge state by decreasing the venting capacity, ensuring complete discharge of molten glass and solving the problem of incomplete discharge caused by improper furnace pressure in existing technologies. During electrode removal, the venting capacity is increased to create a safe and stable working environment and reduce the risk of equipment damage during disassembly and assembly. When installing new electrodes, the venting capacity is adjusted again to ensure precise electrode advancement to the designated position, improving installation accuracy. Finally, the normal production furnace pressure is restored by adjusting the venting capacity, achieving a smooth transition between operations and production. The entire control process forms a closed loop, with coherent furnace pressure adjustment logic and clear objectives at each stage. This not only ensures smooth construction but also makes the furnace pressure control data systematic and consistent, facilitating later analysis and optimization. It also provides a reference control basis for similar operations on other production lines or kilns, comprehensively solving the core problems of insufficient specificity, operability, and systematic approach in existing furnace pressure control technologies. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1This is a process flow diagram of furnace pressure control during electrode replacement according to the present invention.

[0019] Figure 2 This is a detailed flow chart of the furnace pressure control process during electrode replacement according to the present invention.

[0020] Among them, 1 represents the furnace pressure state during normal production of the pool furnace, 2 represents the furnace pressure state during material discharge of the pool furnace, 3 represents the furnace pressure state during electrode removal of the pool furnace, 4 represents the furnace pressure state during installation and promotion of new electrodes in the pool furnace, and 5 represents the furnace pressure increase and decrease adjustment rate. Detailed Implementation

[0021] The technical solution of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] This invention provides a furnace pressure control method suitable for hot electrode replacement in glass furnaces, such as... Figure 1 and Figure 2 It includes the following steps: Step 1: Replace the electrodes while the kiln is running. The furnace pressure of the pool furnace is reduced from the normal production furnace pressure to the discharge furnace pressure by reducing the exhaust capacity. The electrode is installed in a hole in the pool wall, with one end connected to a current-carrying device and the other end in contact with the molten glass inside the furnace. It is used to generate high-temperature refractory material for melting glass raw materials by applying electricity. The electrode is assembled from several blocks of refractory bricks. These blocks of refractory material are of the same size and are assembled into two to three horizontal blocks and three to five vertical blocks.

[0023] The kiln being in a non-stop state refers to a state in which the combustion equipment inside the kiln does not shut off and continues to provide a large amount of heat to the kiln under conditions exceeding 1000°C.

[0024] The furnace pressure of the pool furnace is adjusted from the normal production furnace pressure to the discharge furnace pressure by reducing the exhaust capacity. Specifically: The normal operating pressure range of the pool furnace is 18 Pa to 22 Pa. By reducing the exhaust capacity, the furnace pressure increases at a rate of 1 Pa / h until the furnace pressure reaches the discharge state of the pool furnace. The furnace pressure range during the discharge stage of the pool furnace is 30 Pa to 35 Pa.

[0025] Step 2: After all the molten glass in the furnace has been drained, the furnace electrode removal stage is reached by increasing the capacity of the exhaust equipment. After all the molten glass in the furnace has been drained, the furnace reaches the electrode removal stage by increasing the capacity of the exhaust equipment. Specifically: After all the molten glass in the furnace has been drained, the furnace pressure is reduced by increasing the exhaust capacity at a rate of 2 Pa / h, thus reaching the stage of removing the electrodes from the furnace. The furnace pressure range for the electrode removal stage of the pool furnace is 2 Pa to 5 Pa.

[0026] Step 3: Remove the furnace electrodes and reduce the exhaust capacity to allow the new electrodes to be installed in the furnace under the appropriate pressure. The removal of the furnace electrodes is achieved by reducing the exhaust capacity to bring the furnace pressure suitable for installing new electrodes. Specifically: During the removal of electrodes from the pool furnace, the furnace pressure is stabilized within the required range by adjusting the exhaust equipment and temporary exhaust holes. After the removal of electrodes is completed, the furnace pressure is increased at a rate of 2 Pa / h by reducing the exhaust equipment capacity until the furnace pressure is reached for the installation of new electrodes. The range of furnace pressure values ​​for the new electrode furnace pressure state during the installation of the pool furnace is 25 Pa to 28 Pa.

[0027] Step 4: Install electrodes on the furnace until the electrodes reach the designated position. The furnace pressure is reduced by adjusting the exhaust equipment capacity, and the furnace reaches the normal production furnace pressure state.

[0028] The process involves installing electrodes into the furnace until they reach the designated positions, then adjusting the exhaust system to reduce the furnace pressure, ultimately achieving the normal operating pressure for the furnace. The electrode installation begins in the furnace. After installation, the electrode is pushed forward until it reaches the designated position. The furnace then adjusts the exhaust capacity to reduce the furnace pressure at a rate of 0.5 Pa / h, so that the furnace reaches the normal operating pressure.

[0029] Once the furnace pressure is reached, the bath furnace begins feeding. By continuously adjusting the exhaust equipment, the furnace pressure is stabilized within the required range until the molten glass level reaches the required height.

[0030] The method is described in detail below: A furnace pressure control method applicable to hot electrode replacement in glass furnaces is disclosed. This method is characterized by its implementation of furnace pressure process control for the hot-end equipment of the furnace during electrode brick replacement while the furnace is running continuously. Specifically, the furnace pressure process control method mainly refers to the transition of the furnace pressure control from the normal production furnace pressure to the furnace pressure required for material discharge, then to the furnace pressure required for electrode brick removal, then to the furnace pressure required for installing and pushing in new electrode bricks, and finally back to the furnace pressure required for normal production after the furnace has finished feeding. The above furnace pressure control steps require at least four processes.

[0031] The definitions are as follows: A furnace is a type of kiln used to produce ultra-thin sheet glass for electronic display devices. It employs a furnace structure where the upper structure uses hydrogen-oxygen combustion, and the lower structure uses electrodes to apply current. The reaction of raw materials to produce glass primarily relies on hydrogen-oxygen combustion, supplemented by current application to provide heat. The electrode replacement process involves removing the old electrode used for current application from the furnace at its high temperature and installing a new one.

[0032] The electrode is assembled from multiple blocks of refractory bricks of the same size. It is a type of refractory material assembled in groups of two to three horizontally and three to five vertically. Installed within holes in the pool wall, one end is connected to a current-carrying device, and the other end contacts the molten glass inside the furnace. It is used to generate high-temperature melting of the glass raw material by passing electricity through the refractory material.

[0033] The kiln in a non-stop state refers to a state in which the combustion equipment inside the kiln does not shut off under conditions exceeding 1000℃, continuously providing a large amount of heat to the kiln and maintaining a certain temperature.

[0034] Furnace pressure refers to the value measured using pressure sensing instruments and equipment within the kiln's internal space.

[0035] Furnace pressure process control refers to a control process that adjusts the furnace pressure by changing the amount of gas inside the kiln through adjusting the capacity of the kiln exhaust equipment.

[0036] The normal operating pressure of a tank furnace refers to the pressure range required for a tank furnace to produce glass products during normal operation. Specifically, it's the pressure range measured by pressure sensors in the upper gas space of the furnace (excluding the space occupied by the molten glass at the bottom). This pressure range is from 18 Pa to 22 Pa, and the variation within this range should be within ±3 Pa.

[0037] The furnace pressure required for discharging molten glass refers to the range of pressure needed when a furnace is discharging hot, molten glass. In other words, as the amount of molten glass decreases during the discharging process, the space occupied by the molten glass inside the furnace increases. This increased space is measured by pressure sensing equipment, and the resulting pressure range is defined as 30 Pa to 35 Pa. Furthermore, the variation within this range should be within ±2 Pa.

[0038] The furnace pressure required for electrode removal in a pool furnace refers to the range of furnace pressure needed during electrode removal. In other words, it's the range of furnace pressure values ​​measured by pressure sensors within the furnace during the electrode removal process. This range is from 2 Pa to 5 Pa, and the variation within this range should be within ±1 Pa.

[0039] The furnace pressure required for installing the advancing electrode in a pool furnace refers to the range of furnace pressure needed after the previous electrode has been removed, during the installation of the new electrode, and its advancement into the furnace wall openings. In other words, it is a range of furnace pressure values ​​measured by testing instruments on the surface of the internal space of the pool furnace during the installation and advancement of the new electrode. This range of furnace pressure is 25 Pa to 28 Pa, and the variation within this range should be within ±2 Pa.

[0040] Compared with the prior art, the present invention has the following beneficial technical effects: This invention is the first of its kind to provide a furnace pressure control method for replacing electrodes in a glass electric melting furnace without shutting down the furnace, filling a gap in the lack of a dedicated process plan for this type of operation. 1) Firstly, the operation of replacing electrode bricks in a glass electric melting furnace without shutting down the furnace is entirely new. This operation had never been performed before. Therefore, the corresponding furnace pressure control method developed for this first attempt is also entirely new. 2) During the electrode replacement operation, a complete and detailed operation plan is essential, or at least a complete and detailed process execution plan document must be provided. 3) A complete and detailed step plan is developed for the operation of the hot-end equipment in the furnace, with targeted protective measures to safeguard critical equipment during abnormal production line operation. This avoids problems caused by equipment operation under different conditions; therefore, this invention addresses this issue. 4) A comprehensive and detailed set of guidelines for on-site furnace pressure operation, management, and supervision personnel, instructing them on how to operate and adjust kiln exhaust equipment, control furnace pressure changes, when to adjust the exhaust gas volume, the adjustment amount, and the control range of furnace pressure error. This represents an optimization process from no relevant content to qualitative and then quantitative content. 5) For the entire lifecycle of a kiln, from design and installation to trial production, normal operation, and finally cooling and shutdown, this invention fills a gap in process control for specific stages during operation. It also provides a reference for process control in other production lines or other kilns. 6) Compared to previous methods, the process control scheme provided by this invention offers advantages such as more systematic, coherent, unified, and summative data. It also facilitates later summarization and discussion of the entire process scheme.

[0041] The flowchart in the attached diagram illustrates the process when the furnace begins electrode replacement. First, the furnace pressure is controlled from normal production pressure state 1 (pressure range 18 Pa to 22 Pa). Then, by reducing the exhaust capacity, the pressure increases at a rate of 1 Pa / h, reaching furnace pressure state 2 (pressure range 30 Pa to 35 Pa). During furnace pressure state 2 (pressure range 30 Pa to 35 Pa), after all molten glass has drained, the pressure is slowly reduced by increasing the exhaust capacity at a rate of 2 Pa / h, reaching furnace pressure state 3 (pressure range 2 Pa to 5 Pa) for electrode removal. During electrode removal, the furnace pressure is stabilized within the required range by adjusting the exhaust equipment and temporary exhaust vents. Once electrode removal is complete, the pressure is increased again by reducing the exhaust capacity at a rate of 2 Pa / h, reaching furnace pressure state 4 (pressure range 25 Pa to 28 Pa) for installing and pushing in the new electrode. The installation of electrodes begins in the furnace. After installation, new electrodes are slowly advanced until they reach the designated position, completing the process. The furnace then gradually reduces the furnace pressure by slowly adjusting the exhaust system at a rate of 0.5 Pa / h, bringing the furnace to normal production pressure state 1 (pressure range of 18 Pa to 22 Pa). Once the pressure is reached, the furnace begins feeding material. The exhaust system is continuously adjusted to stabilize the furnace pressure within the required range until the molten glass level reaches the desired height. Finally, the furnace returns to normal production pressure state 1 (pressure range of 18 Pa to 22 Pa).

[0042] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A furnace pressure control method suitable for hot electrode replacement in glass furnaces, characterized in that, Includes the following steps: When the kiln is replaced without shutting down, the furnace pressure of the pool furnace is reduced from the normal production furnace pressure to the discharge furnace pressure by reducing the exhaust capacity. After all the molten glass in the furnace has been drained, the furnace reaches the stage of electrode removal by increasing the capacity of the exhaust equipment. Remove the furnace electrodes and reduce the exhaust capacity to advance the furnace pressure state for installing new electrodes in the furnace. Electrodes are installed in the furnace until they reach the designated positions. The furnace pressure is reduced by adjusting the exhaust equipment capacity until the furnace reaches the normal production furnace pressure state.

2. The furnace pressure control method for hot electrode replacement in a glass furnace according to claim 1, characterized in that, The electrode is installed in a hole in the pool wall, with one end connected to a current-carrying device and the other end in contact with the molten glass inside the furnace. It is used to generate high-temperature refractory material equipment for melting glass raw materials by passing electricity.

3. The furnace pressure control method for hot electrode replacement in a glass furnace according to claim 1, characterized in that, The electrode is assembled from several blocks of refractory bricks.

4. The furnace pressure control method for hot electrode replacement in a glass furnace according to claim 3, characterized in that, Several blocks of refractory material of the same size are assembled into two to three horizontal blocks and three to five vertical blocks.

5. The furnace pressure control method for hot electrode replacement in a glass furnace according to claim 1, characterized in that, The kiln being in a non-stop state refers to a state in which the combustion equipment inside the kiln does not shut off and continues to provide a large amount of heat to the kiln under conditions exceeding 1000°C.

6. The furnace pressure control method for hot electrode replacement in a glass furnace according to claim 1, characterized in that, The furnace pressure of the pool furnace is adjusted from the normal production furnace pressure to the discharge furnace pressure by reducing the exhaust capacity. Specifically: The normal operating pressure range of the pool furnace is 18 Pa to 22 Pa. By reducing the exhaust capacity, the furnace pressure increases at a rate of 1 Pa / h until the furnace pressure reaches the discharge state of the pool furnace. The furnace pressure range during the discharge stage of the pool furnace is 30 Pa to 35 Pa.

7. The furnace pressure control method for hot electrode replacement in a glass furnace according to claim 1, characterized in that, After all the molten glass in the furnace has been drained, the furnace reaches the electrode removal stage by increasing the capacity of the exhaust equipment. Specifically: After all the molten glass in the furnace has been drained, the furnace pressure is reduced by increasing the exhaust capacity at a rate of 2 Pa / h, thus reaching the stage of removing the electrodes from the furnace. The furnace pressure range for the electrode removal stage of the pool furnace is 2 Pa to 5 Pa.

8. The furnace pressure control method for hot electrode replacement in a glass furnace according to claim 1, characterized in that, The removal of the furnace electrodes is achieved by reducing the exhaust capacity to bring the furnace pressure suitable for installing new electrodes. Specifically: During the removal of electrodes from the pool furnace, the furnace pressure is stabilized within the required range by adjusting the exhaust equipment and temporary exhaust holes. After the removal of electrodes is completed, the furnace pressure is increased at a rate of 2 Pa / h by reducing the exhaust equipment capacity until the furnace pressure is reached for the installation of new electrodes. The range of furnace pressure values ​​for the new electrode furnace pressure state during the installation of the pool furnace is 25 Pa to 28 Pa.

9. The furnace pressure control method for hot electrode replacement in a glass furnace according to claim 1, characterized in that, The process involves installing electrodes into the furnace until they reach the designated positions, then adjusting the exhaust system to reduce the furnace pressure, ultimately achieving the normal operating furnace pressure. Specifically: The electrode installation begins in the furnace. After installation, the electrode is pushed forward until it reaches the designated position. The furnace then adjusts the exhaust capacity to reduce the furnace pressure at a rate of 0.5 Pa / h, bringing the furnace to the normal operating pressure.

10. The furnace pressure control method for hot electrode replacement in a glass furnace according to claim 1, characterized in that, Once the furnace pressure is reached, the bath furnace begins feeding. By continuously adjusting the exhaust equipment, the furnace pressure is stabilized within the required range until the molten glass level reaches the required height.

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