Modularized, efficient and rapid assembly method for oven door bricks of coke oven

Abstract

The invention discloses a modular efficient and rapid assembly method for oven door bricks of a coke oven. The method comprises the steps that firstly, a brick lining is divided into a plurality of independent modular units according to the size of an inner cavity of a furnace door, and a special modular tooling table and all parts are prefabricated; then, the modular frame is accurately positioned on a tool table, oven door bricks are embedded and corrected till the working face is flush, brick joints are uniform, and then a coke oven oven door brick high-temperature-resistant composite binder is smeared; and then a stainless steel connecting rod is used for conducting transverse and longitudinal penetrating fastening on the brick body, brick joints are filled, a fire-resistant fiber board covers the brick body, and finally the end of the connecting rod is sealed. The assembled modular units are numbered and stored after being subjected to size and sealing detection; during on-site installation, the units are sequentially hoisted to the position of a furnace door through hoisting equipment, and the guide rods are used for assisting in positioning and completing splicing and overall acceptance inspection. According to the method, the furnace door brick lining is transformed from field manual masonry to factory prefabrication and field rapid assembly, and the assembly precision, efficiency and overall reliability are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of coke oven construction and maintenance technology, specifically to a modular, efficient, and rapid assembly method for coke oven door bricks. Background Technology

[0002] As a key piece of equipment for isolating the furnace and ensuring the sealing and thermal efficiency of the coking process, the refractory brick lining inside the coke oven door is subjected to high temperatures, airflow erosion, and the impact of opening and closing the door over a long period of time, making it a vulnerable component. Traditionally, the construction of the coke oven door lining involves on-site, brick-by-brick construction. This process involves transporting refractory bricks to the site, where construction workers measure, cut, lay, and grout the bricks within the door body based on their experience. This method not only has a long construction cycle, consuming valuable time during coke oven maintenance, but also heavily relies on the skill level of the construction workers, making it difficult to guarantee uniform brick joints, a smooth surface, and overall dimensional accuracy. This can easily lead to problems such as poor door sealing and increased heat loss.

[0003] Furthermore, the on-site masonry method has significant shortcomings in quality control. Due to the lack of unified assembly standards and effective fixing methods, the integrity of the completed brick lining is poor. Under the thermal stress and mechanical vibration of the coke oven during operation, local bricks are prone to loosening, displacement, or even falling off. This not only affects the lifespan of the furnace door but may also lead to safety accidents. In addition, there are limited means to inspect the masonry accuracy afterward, and problems often only become apparent after high-temperature operation, increasing maintenance costs and risks.

[0004] Furthermore, when some furnace door bricks are damaged and need to be replaced, traditional methods often require removing a large area of ​​brick lining for partial repair or complete reconstruction. This process is cumbersome, and it is difficult to achieve the original precision in the fit between the old and new bricks, resulting in low maintenance efficiency and failing to meet the high-efficiency, fast-paced maintenance requirements of modern coke ovens. Therefore, there is an urgent need for a modular, efficient, and rapid assembly method for coke oven door bricks. Summary of the Invention

[0005] To address the problems mentioned in the background section, this invention provides a modular, efficient, and rapid assembly method for coke oven door bricks.

[0006] This invention provides a modular, efficient, and rapid assembly method for coke oven door bricks, comprising the following steps: Step S1: Modular unit design and prefabrication preparation. Based on the net inner cavity dimensions of the coke oven door and the design dimensions of the door bricks, the door brick lining is divided into structurally independent modular units. A special modular tooling table matching the modular units is prefabricated, as well as door bricks, modular frames, sealing components, stainless steel connecting rods and anti-loosening nuts that are prefabricated in the factory and have passed dimensional inspection. Step S2: Modular unit pre-assembly. Position and fasten the modular frame to the special modular tooling table using positioning pins. Embed the furnace door bricks one by one into the brick installation groove of the modular frame. After aligning the bricks until the refractory working surface is flush and the gaps between the bricks are uniform, apply coke oven door brick high-temperature resistant composite adhesive evenly to the mating surface of the furnace door bricks and the modular frame. Step S3: Modular unit connection and sealing reinforcement. The bricks are tightened horizontally and vertically by stainless steel connecting rods. The gaps between the bricks are filled with high-temperature resistant composite adhesive for coke oven door bricks and compacted. After covering with refractory fiberboard, it is fixed to the modular frame by metal pressure strips. The ends of the connecting rods and the anti-loosening nuts are sealed. Step S4: Modular unit inspection and labeling. The dimensional accuracy and sealing performance of the modular units are inspected. After passing the inspection, the units are numbered and marked according to their installation location and placed on a special storage rack. Step S5: Modular unit hoisting and overall installation. Select hoisting equipment with a rated lifting capacity, equipped with a balance beam and slings, and hoist the modular unit to the installation position. After positioning with the aid of guide rods, connect it to the furnace door body. Hoist and splice adjacent modular units in sequence. After all units are installed, conduct overall acceptance.

[0007] Furthermore, the inner cavity of the coke oven door has a length of 2.0m-3.0m and a width of 1.0m-1.5m; the thickness of the door brick is 200mm-300mm and the width is 400mm-600mm; a single modular unit contains 4 or 6 door bricks; and the splicing surfaces of adjacent modular units are provided with splicing flange structures. Furthermore, the splicing flange structure includes a sealing groove and bolt connection holes; Furthermore, the width of the sealing groove is 8mm-12mm and the depth is 4mm-6mm; a high-temperature resistant sealing gasket with a thickness of 4.5mm-5.5mm is pre-installed inside the sealing groove; Furthermore, in step S1, the sealing assembly includes a high-temperature resistant sealing cap, ceramic fiber filler, metal pressure strip, and a high-temperature resistant sealing gasket.

[0008] Furthermore, in step S1, the dedicated modular tooling table is welded from Q235B steel, and the table surface is covered with 304 stainless steel panels with a thickness of 8mm-12mm and milled for precision machining. The flatness error of the table surface is ≤0.5mm / m. Positioning pins and limit blocks adapted to the modular frame are fixedly installed on the table surface. The positioning accuracy of the positioning pins is ≤±0.3mm, the diameter of the positioning pins is 12mm-16mm, and the height is 30mm-50mm.

[0009] Furthermore, the preparation method of the high-temperature resistant composite adhesive for coke oven door bricks includes the following steps: A1: Accurately weigh the raw materials according to the following parts by weight: 45-55 parts of high-alumina refractory slurry, 20-25 parts of silica powder, 5-8 parts of borax, 3-5 parts of sodium carboxymethyl cellulose, 8-12 parts of zirconium oxide powder, and 15-20 parts of deionized water. A2: Place high-alumina refractory slurry, silica powder, borax, and zirconium oxide powder into a planetary high-speed mixer and dry mix for 15-20 minutes at a speed of 800-1000 r / min to obtain a uniformly mixed dry powder. A3: Slowly add sodium carboxymethyl cellulose to deionized water and stir at 200r / min-300r / min for 10min-15min at room temperature until completely dissolved and no visible particles are found, to obtain a viscous aqueous solution; A4: Slowly add the viscous aqueous solution along the inner wall of the mixer to the dry powder, and stir at a speed of 600r / min-800r / min for 30min-40min to form a paste with the consistency required for application; A5: Transfer the paste-like material into a sealed container and age it for 24-36 hours in a constant temperature and humidity environment of 25℃-30℃ and 50%-60% relative humidity to obtain a high-temperature resistant composite adhesive for coke oven door bricks.

[0010] Furthermore, in step S2, the flatness error of the refractory working surface of the brick facing the furnace after correction is ≤1.0mm, and the gap between the bricks is 2.0mm-3.0mm; the coating thickness of the high-temperature resistant composite adhesive for the coke oven door brick is 1.0mm-2.0mm.

[0011] Furthermore, in step S3, the tightening torque of the stainless steel connecting rod is controlled between 35.0 N·m and 45.0 N·m; the covering thickness of the fire-resistant fiberboard is 10 mm to 20 mm.

[0012] Further, in step S3, the sealing process specifically involves: installing high-temperature resistant sealing caps on all anti-loosening nuts and the ends of the connecting rods; the high-temperature resistant sealing caps have ceramic fiber fillers inside, the compaction density of the ceramic fiber fillers is 1.2 g / cm³-1.5 g / cm³, and the interference fit between the high-temperature resistant sealing caps and the ends of the connecting rods is 0.05 mm-0.10 mm.

[0013] Furthermore, in step S4, dimensional accuracy is tested using a laser rangefinder and a level. The overall length, width, and height deviation of the modular unit is controlled within ±1.0mm, and the maximum deviation of the brick gap is ≤0.50mm. The sealing performance is tested by introducing dry compressed air at 0.1MPa-0.15MPa into the modular unit and maintaining it for 20min-30min. Soap solution is applied to all connection parts, splicing gaps, and sealing areas. No bubbles are generated, indicating that it is qualified.

[0014] Furthermore, in step S5, the hoisting equipment selected is a truck crane or crawler crane with a rated lifting capacity of ≥10.0t, equipped with a special balance beam and high-strength polyester flexible slings adapted to the weight of the modular unit. The modular unit is hoisted by connecting the four corners of the frame with symmetrical hoisting points, and the installation positioning deviation is controlled within ±2.0mm.

[0015] The beneficial effects of this invention are: This invention achieves factory prefabrication and full-process quality control of furnace door linings, completely revolutionizing the traditional construction method. By introducing modular unit design and dedicated modular tooling, this invention transfers the core assembly and calibration processes to a controlled factory environment. On the tooling, high-precision positioning elements rigidly fix the modular frame, and then prefabricated refractory bricks are embedded one by one and finely calibrated, ensuring that each modular unit becomes a standard component with uniform size and regular structure before leaving the factory. This factory production mode effectively eliminates the quality uncertainty caused by differences in personnel skills and fluctuations in the construction environment during on-site operations. Furthermore, advanced testing methods can be used after assembly to conduct comprehensive factory inspections of the dimensional accuracy and sealing performance of the finished product, thus ensuring the reliability and consistency of the furnace door lining quality from the source and solving the inherent problems of large quality fluctuations and difficult post-construction verification in traditional on-site masonry methods.

[0016] This invention significantly improves the efficiency of on-site installation and maintenance, and substantially reduces downtime of the coke oven system. It transforms complex on-site masonry work into standardized modular hoisting and assembly operations. Prefabricated modular units have all brickwork fixed, gap filled, and sealed in the factory, and are clearly marked with installation numbers and orientations. During on-site construction, only appropriate hoisting equipment is needed, along with pre-set hoisting points and positioning aids, to achieve rapid and precise placement and connection. This modular assembly method greatly reduces the previously time-consuming and lengthy on-site masonry work. Most importantly, when a local lining is damaged, extensive dismantling and repair are unnecessary; only the corresponding individual module needs to be replaced, achieving precise and rapid maintenance and significantly improving the operational efficiency and maintenance economy of the coke oven equipment.

[0017] This invention comprehensively enhances the structural integrity and long-term operational reliability of the furnace door brick lining by constructing a systematic reinforcement and sealing system. This invention is not simply a combination of bricks, but rather a multi-layered, synergistic reinforcement and protection system. At the structural level, stainless steel connecting rods are used to mechanically fasten the bricks throughout, integrating them with the modular frame into a robust whole, greatly improving the lining's resistance to thermal stress and mechanical impact. At the sealing level, it innovatively integrates high-temperature resistant composite adhesive filling for coke oven door bricks, refractory insulation layer coverage, and end sealing technology with built-in elastic filler. The specialized high-temperature resistant composite adhesive for coke oven door bricks ensures the strength of the joints under high-temperature conditions; the elastic sealing material provides continuous and effective stress compensation and sealing protection for the connection points. Practice has proven that the various elements in this integrated design complement each other, jointly forming the key support for ensuring the furnace door maintains structural integrity and tight sealing under harsh operating conditions over the long term. Detailed Implementation

[0018] To make the embodiments of the present invention easier to understand, the present invention will be described in detail below with reference to specific embodiments. These embodiments are for illustrative purposes only and are not limited to the application scope of the present invention.

[0019] The specific parameters of the raw materials used in this invention are as follows: The high-alumina refractory slurry used in this invention was purchased from Zhengzhou Kerui Refractory Materials Co., Ltd.

[0020] The silicon micro powder used in this invention is 1250 mesh and was purchased from Guangdong Yufeng Powder Materials Co., Ltd.

[0021] The borax used in this invention has CAS number 1303-96-4 and was purchased from Jinan Jinyu Chemical Co., Ltd.

[0022] The zirconium oxide powder used in this invention has a particle size of 10 μm and was purchased from Jiangsu Tianhong Hastelloy Co., Ltd.

[0023] The ceramic fiber filler used in this invention is type 1260 ceramic fiber cotton, which was purchased from Baotou Runqing Thermal Insulation and Waterproof Materials Co., Ltd.

[0024] Example 1 A modular, efficient, and rapid assembly method for coke oven door bricks includes the following preparation steps: The preparation method of high-temperature resistant composite adhesive for coke oven door bricks includes the following steps: A1: Accurately weigh the raw materials according to the following parts by weight: 45 parts high-alumina refractory slurry, 20 parts silica powder, 5 parts borax, 3 parts sodium carboxymethyl cellulose, 8 parts zirconium oxide powder, and 15 parts deionized water. A2: Place high-alumina refractory slurry, silica powder, borax, and zirconium oxide powder into a planetary high-speed mixer and dry mix for 15 minutes at a speed of 800 r / min to obtain a uniformly mixed dry powder. A3: Slowly add sodium carboxymethyl cellulose to deionized water and stir at 200 r / min for 10 min at room temperature until completely dissolved and no visible particles are found, to obtain a viscous aqueous solution; A4: Slowly add the viscous aqueous solution along the inner wall of the mixer to the dry powder, and stir at 600 r / min for 30 min to form a paste with the consistency required for application. A5: Transfer the paste-like material into a sealed container and age it for 24 hours in a constant temperature and humidity environment of 25℃ and 50% relative humidity to obtain a high-temperature resistant composite adhesive for coke oven door bricks. Step S1: Modular Unit Design and Prefabrication Preparation Based on the net internal dimensions of the target coke oven door, which is 2.0m long and 1.0m wide, and considering the thickness of the door brick (200mm) and the width (400mm), the entire door brick lining is divided into several structurally independent modular units. Each modular unit is designed to contain 4 or 6 door bricks. The maximum external dimensions of the modular unit are limited to a length not exceeding 2.5m, a width not exceeding 1.2m, and a total weight not exceeding 3 tons. The splicing surfaces of adjacent modular units are designed with splicing flange structures. These flange structures have sealing grooves with a width of 8mm and a depth of 4mm, and evenly distributed bolt connection holes. High-temperature resistant gaskets with a thickness of 4.5mm are pre-installed in the sealing grooves. Prefabricated modular tooling table matching the dimensions of the modular units: The tooling table is welded from Q235B steel, and the table surface is covered with 304 stainless steel panel with a thickness of 8mm. It is milled and precision machined to ensure that its flatness error is ≤0.5mm / m. On the table surface, positioning pins and limit blocks that are adapted to the shape of the modular frame are fixedly installed. The positioning pins have a diameter of 12mm and a height of 30mm, and their positioning accuracy is ≤±0.3mm. Prepare the following components that are prefabricated in the factory and have passed strict dimensional inspection: furnace door bricks (dimensional deviation ≤ ±0.5mm), modular frame, sealing components (including high temperature resistant sealing caps, 1260 type ceramic fiber cotton, metal pressure strips and the aforementioned high temperature resistant sealing gaskets), stainless steel connecting rods and anti-loosening nuts; Step S2: Modular unit pre-assembly Precisely position and fasten the modular framework on the dedicated modular tooling table through the positioning pins. According to the horizontal and vertical arrangement methods specified in the design drawings, embed the furnace door bricks one by one and tightly into the brick installation grooves preset in the modular framework. Use calibration tools for adjustment until the flatness error of the refractory working surfaces of all bricks facing the furnace is ≤ 1.0 mm, and the reserved gaps between the bricks are evenly 2.0 mm; After calibration, evenly apply a layer of high-temperature resistant composite binder for coke oven furnace door bricks on the entire bonding surface between the furnace door bricks and the modular framework. The applied thickness is controlled at 1.0 mm to ensure complete coverage without omission; Step S3: Mechanically reinforce the bricks in place using stainless steel connecting rods. Horizontally penetrate and fasten along the bricks in the same row and vertically penetrate and fasten along the bricks in the same column respectively. The tightening torque of the connecting rods is uniformly controlled at 35.0 N·m to ensure firm connection without damaging the bricks; In the splicing gaps between the bricks, fill the same high-temperature resistant composite binder for coke oven furnace door bricks used in Step S2, and use tools to compact and fill it completely. Subsequently, cover a layer of refractory fiber board on the surface of the modular framework with a covering thickness of 10 mm, and use metal pressing strips to fix it to the modular framework through bolts to press the fiber board tightly; Finally, seal the ends of all stainless steel connecting rods and locknuts exposed outside. The specific method is: sleeve a high-temperature resistant sealing cap outside it. The sealing cap is filled with compacted 1260-type ceramic fiber cotton with a density of 1.2 g / cm³, and the sealing cap and the end of the connecting rod are in interference fit with an interference amount of 0.05 mm; Step S4: Modular unit inspection and identification Strictly inspect the assembled modular unit. For dimensional accuracy inspection, use a laser rangefinder and a level. It is required that the dimensional deviations of the overall length, width, and height of the unit are controlled within ±1.0 mm, and the maximum deviation of all brick gaps is ≤ 0.50 mm. For sealing performance inspection, use the air pressure method: introduce dry compressed air with a pressure of 0.1 MPa into the internal cavity of the modular unit components, keep the pressure for 20 min, and at the same time apply soap solution at all connection parts, brick splicing gaps, and sealing treatment places. It is qualified only when no bubbles are observed; For the modular units passing the inspection, assign a unique number according to their final installation positions on the furnace door and clearly mark the installation orientation. Subsequently, place them horizontally on the dedicated storage rack and store them properly for installation;<0​​​ The modular unit is smoothly lifted to the coke oven door installation position by connecting the lifting device through the symmetrical lifting points at the four corners of the frame. The pre-installed guide rod is used for initial positioning, and then it is fastened to the oven door body. The positioning deviation during installation is required to be controlled within ±2.0mm. Following a predetermined sequence from bottom to top and from the middle to both sides, adjacent modular units are hoisted and spliced ​​in turn to ensure that the splicing flanges are tightly joined. After all modular units are installed, a comprehensive overall acceptance is carried out, including final dimension verification, sealing surface inspection and connection tightness confirmation. Once qualified, the modular assembly of the entire furnace door brick lining is completed.

[0025] Example 2 A modular, efficient, and rapid assembly method for coke oven door bricks includes the following preparation steps: The preparation method of high-temperature resistant composite adhesive for coke oven door bricks includes the following steps: A1: Accurately weigh the raw materials according to the following parts by weight: 50 parts of high-alumina refractory slurry, 22 parts of silica powder, 6.5 parts of borax, 4 parts of sodium carboxymethyl cellulose, 10 parts of zirconium oxide powder, and 18 parts of deionized water. A2: Place high-alumina refractory slurry, silica powder, borax, and zirconium oxide powder into a planetary high-speed mixer and dry mix for 18 minutes at a speed of 900 r / min to obtain a uniformly mixed dry powder. A3: Slowly add sodium carboxymethyl cellulose to deionized water and stir at 250 r / min for 12 min at room temperature until completely dissolved and no visible particles are found, to obtain a viscous aqueous solution; A4: Slowly add the viscous aqueous solution along the inner wall of the mixer to the dry powder, and stir at 700 r / min for 35 min to form a paste with the consistency required for application. A5: Transfer the paste-like material into a sealed container and age it for 30 hours in a constant temperature and humidity environment of 27℃ and 55% relative humidity to obtain a high-temperature resistant composite adhesive for coke oven door bricks. Step S1: Modular Unit Design and Prefabrication Preparation Based on the net internal dimensions of the target coke oven door, which is 2.5m long and 1.2m wide, and considering the thickness of the door brick (250mm) and the width (500mm), the entire door brick lining is divided into several structurally independent modular units. Each modular unit is designed to contain 4 or 6 door bricks. The maximum external dimensions of the modular unit are limited to a length not exceeding 2.5m, a width not exceeding 1.2m, and a total weight not exceeding 3 tons. The splicing surfaces of adjacent modular units are designed with splicing flange structures. A sealing groove with a width of 10mm and a depth of 5mm is opened on the flange structure, and bolt connection holes are evenly arranged. A high-temperature resistant sealing gasket with a thickness of 5mm is pre-installed in the sealing groove. Prefabricated modular tooling table matching the dimensions of the modular units: The tooling table is welded from Q235B steel, and the table surface is covered with a 10mm thick 304 stainless steel panel, which is milled and precision machined to ensure that its flatness error is ≤0.5mm / m. On the table surface, positioning pins and limit blocks that are adapted to the shape of the modular frame are fixedly installed. The positioning pins have a diameter of 14mm and a height of 40mm, and their positioning accuracy is ≤±0.3mm. Prepare the following components that are prefabricated in the factory and have passed strict dimensional inspection: furnace door bricks (dimensional deviation ≤ ±0.5mm), modular frame, sealing components (including high temperature resistant sealing caps, 1260 type ceramic fiber cotton, metal pressure strips and the aforementioned high temperature resistant sealing gaskets), stainless steel connecting rods and anti-loosening nuts; Step S2: Modular unit pre-assembly The modular frame is precisely positioned and fastened on a dedicated modular tooling table using the positioning pins. According to the horizontal and vertical arrangement specified in the design drawings, the furnace door bricks are embedded one by one and tightly into the brick installation slots of the modular frame. Adjustments are made using a calibration tool until the flatness error of the refractory working surface of all bricks facing the furnace is ≤1.0mm, and the reserved gap between bricks is uniformly 2.5mm. After the alignment is completed, apply a layer of high-temperature resistant composite adhesive for coke oven door bricks evenly to the entire mating surface of the furnace door bricks and the modular frame. The thickness of the adhesive should be controlled at 1.5mm to ensure complete coverage without any omissions. Step S3: Stainless steel connecting rods are used to mechanically reinforce the bricks that have been placed. They are tightened laterally along the same row of bricks and longitudinally along the same column of bricks. The tightening torque of the connecting rods is uniformly controlled at 40 N·m to ensure that the connection is firm and does not damage the bricks. In the gap between the bricks, fill the gap with the same high-temperature resistant composite adhesive used in step S2 for the coke oven door bricks, and compact it with a tool. Then, cover the surface of the modular frame with a layer of refractory fiberboard with a thickness of 15mm, and fix it to the modular frame with bolts using metal strips to press the fiberboard tightly. Finally, all exposed stainless steel connecting rod ends and anti-loosening nuts are sealed. The specific method is as follows: a high-temperature resistant sealing cap is installed on the outside. The sealing cap is filled with 1260 type ceramic fiber cotton with a compaction density of 1.4g / cm³. The sealing cap and the connecting rod end are interference fit with an interference amount of 0.08mm. Step S4: Modular Unit Detection and Identification Strictly inspect the assembled modular units. For dimensional accuracy inspection, use a laser rangefinder and a level. It is required that the dimensional deviations of the overall length, width, and height of the unit be controlled within ±1.0 mm, and the maximum deviation of all brick gaps ≤ 0.50 mm. For the airtightness inspection, use the air pressure method: introduce dry compressed air with a pressure of 0.12 MPa into the internal cavity of the modular unit components, maintain the pressure for 25 minutes, and at the same time apply soap solution to all connection parts, brick splicing gaps, and sealing treatment areas. It is qualified only when no bubbles are observed. For the qualified modular units, assign unique numbers according to their final installation positions on the oven door and clearly mark the installation orientations. Subsequently, place them horizontally on a special storage rack and store them properly for installation. Step S5: Hoisting and overall installation of modular units In the on-site installation stage, select a truck crane or crawler crane with a rated lifting capacity of not less than 10.0 tons as the hoisting equipment, and equip it with a special balance beam and high-strength polyester flexible sling that match the weight of the modular unit. Connect the lifting tool through the symmetric lifting points preset at the four corners of the frame, smoothly lift and transport the modular unit to the installation position of the coke oven door, use the pre-installed guide rod for auxiliary initial positioning, and then tightly connect it to the oven door body. The positioning deviation during installation is required to be controlled within ±2.0 mm. [[ID=​​​​​​​​​​​​​​​A4: Slowly add the viscous aqueous solution along the inner wall of the mixer to the dry powder, and stir at 800 r / min for 40 min to form a paste with the consistency required for application. A5: Transfer the paste-like material into a sealed container and age it for 36 hours in a constant temperature and humidity environment of 30℃ and 60% relative humidity to obtain a high-temperature resistant composite adhesive for coke oven door bricks. Step S1: Modular Unit Design and Prefabrication Preparation Based on the net internal dimensions of the target coke oven door, which is 3.0m long and 1.5m wide, and considering the thickness of the door brick (300mm) and width (600mm), the entire door brick lining is divided into several structurally independent modular units. Each modular unit is designed to contain 4 or 6 door bricks. The maximum external dimensions of the modular unit are limited to a length not exceeding 2.5m, a width not exceeding 1.2m, and a total weight not exceeding 3 tons. The splicing surfaces of adjacent modular units are designed with splicing flange structures. A sealing groove with a width of 12mm and a depth of 6mm is opened on the flange structure, and bolt connection holes are evenly arranged. A high-temperature resistant sealing gasket with a thickness of 5.5mm is pre-installed in the sealing groove. Prefabricated modular tooling table matching the size of the modular unit: The tooling table is welded from Q235B steel, and the table surface is covered with a 12mm thick 304 stainless steel panel, which is milled and precision machined to ensure that its flatness error is ≤0.5mm / m. On the table surface, positioning pins and limit blocks that are adapted to the shape of the modular frame are fixedly installed. The positioning pins have a diameter of 16mm and a height of 50mm, and their positioning accuracy is ≤±0.3mm. Prepare the following components that are prefabricated in the factory and have passed strict dimensional inspection: furnace door bricks (dimensional deviation ≤ ±0.5mm), modular frame, sealing components (including high temperature resistant sealing caps, 1260 type ceramic fiber cotton, metal pressure strips and the aforementioned high temperature resistant sealing gaskets), stainless steel connecting rods and anti-loosening nuts; Step S2: Modular unit pre-assembly The modular frame is precisely positioned and fastened on a dedicated modular tooling table using the positioning pins. According to the horizontal and vertical arrangement specified in the design drawings, the furnace door bricks are embedded one by one and tightly into the brick installation slots of the modular frame. Adjustments are made using a calibration tool until the flatness error of the refractory working surface of all bricks facing the furnace is ≤1.0mm, and the reserved gap between bricks is uniformly 3.0mm. After the correction is completed, apply a layer of high-temperature resistant composite adhesive for coke oven door bricks evenly to the entire mating surface of the furnace door bricks and the modular frame. The thickness of the adhesive should be controlled at 2.0 mm to ensure complete coverage without any omissions. Step S3: Mechanically reinforce the installed brick bodies using stainless steel connecting rods, with transverse through-fastening along the same row of brick bodies and longitudinal through-fastening along the same column of brick bodies. The tightening torque of the connecting rods is uniformly controlled at 45.0 N·m to ensure firm connection and no damage to the brick bodies; In the splicing gap between brick bodies, fill with the same high-temperature resistant composite binder for coke oven door bricks used in step S2, and use tools to compact and fill it. Subsequently, cover a layer of refractory fiber board on the surface of the modular frame, with a covering thickness of 20 mm, and use metal straps to fix it to the modular frame through bolts to press the fiber board tightly; Finally, seal all the exposed ends of the stainless steel connecting rods and locknuts. The specific method is: sleeve a high-temperature resistant sealing cap outside them. The sealing cap has been filled with 1260-type ceramic fiber cotton with a compacted density of 1.5 g / cm³, and the sealing cap and the end of the connecting rod are in interference fit, with an interference amount of 0.10 mm; Step S4: Modular unit inspection and identification Strictly inspect the assembled modular unit. For dimensional accuracy inspection, use a laser rangefinder and a level. It is required that the dimensional deviation of the overall length, width, and height of the unit is controlled within ±1.0 mm, and the maximum deviation of all brick body gaps ≤ 0.50 mm. For seal performance inspection, use the air pressure method: introduce dry compressed air with a pressure of 0.15 MPa into the internal cavity of the modular unit components, keep the pressure for 30 min, and at the same time apply soap solution at all connection parts, brick body splicing gaps, and seal treatment places. It is qualified only when no bubbles are observed; For the modular unit that passes the inspection, assign a unique number according to its final installation position on the oven door, and clearly mark the installation orientation. Subsequently, place it horizontally on a special storage rack and store it properly for installation; Step S5: Hoisting and overall installation of the modular unit, In the on-site installation stage, select a truck crane or crawler crane with a rated lifting capacity not less than 10.0 tons as the hoisting equipment, and equip it with a special balance beam and high-strength polyester flexible sling that match the weight of the modular unit; Connect the lifting tool through the symmetric lifting points preset at the four corners of the frame, smoothly lift and transport the modular unit to the installation position of the coke oven door, use the pre-installed guide rod for auxiliary initial positioning, and then tightly connect it to the oven door body. The positioning deviation during installation is required to be controlled within ±2.0 mm; In accordance with the established order from bottom to top and from the middle to both sides, hoist and splice adjacent modular units in sequence to ensure that the splicing flanges are closely combined. After all modular units are installed, conduct a comprehensive overall acceptance, including final dimension recheck, sealing surface inspection, and connection tightness confirmation. After passing the inspection, the modular assembly of the entire oven door brick lining is completed.

[0027] Comparative Example 1 Compared with Example 1, this comparative example replaces the "high-temperature resistant composite adhesive for coke oven door bricks" with an equal mass of "high-alumina refractory slurry". All other steps and parameters are the same, and will not be repeated in this comparative example.

[0028] Comparative Example 2 Compared with Example 1, this comparative example omits the transverse and longitudinal fastening process of the stainless steel connecting rod in step S3, attempting to fix the brick body solely by relying on the high-temperature resistant composite adhesive for the coke oven door brick and the constraint force of the modular frame. The remaining steps and parameters are the same, and will not be repeated in this comparative example.

[0029] Comparative Example 3 Compared with Example 1, in the sealing process of step S3, no ceramic fiber filler was added to the sealing cap. The remaining steps and parameters are the same, and will not be repeated in this comparative example.

[0030] Performance testing: The modular units prepared in Examples 1-3 and Comparative Examples 1-3 were tested, and the results are recorded in Table 1.

[0031] 1. Dimensional accuracy inspection methods: The inspection was conducted using a laser rangefinder and a level. Before inspection, the level was used to calibrate the dedicated inspection reference surface to ensure a flat inspection environment. Then, the laser rangefinder was used to measure the overall length, width, and height of the modular unit at multiple points. At the same time, the flatness of the refractory working surface of the brick facing the furnace and the gap between the bricks were measured. The overall length, width, and height deviation of the modular unit was required to be controlled within ±1.0mm, the flatness error of the refractory working surface of the brick was ≤1.0mm, the gap between the bricks was 3.0mm with a maximum deviation of ≤0.50mm, and the positioning deviation during the installation and positioning of the modular unit was controlled within ±2.0mm.

[0032] 2. Sealing performance testing methods: The air pressure test was conducted by introducing dry compressed air at a pressure of 0.15 MPa into the cavity inside the modular unit and maintaining the pressure stable for 30 minutes using a pressure maintaining device. During this process, a layer of soap solution was evenly applied to all the connection points between the stainless steel connecting rods and the brick body, the gaps between the brick body joints, the joints between the high-temperature resistant sealing caps and the ends of the connecting rods, and the sealing grooves of the splicing flanges. The area where the soap solution was applied was continuously observed for 30 minutes to see if any bubbles were generated. If no bubbles were generated, the sealing performance was deemed to be qualified.

[0033] 3. Connection tightness testing method: Using a torque wrench, the tightening torque of all stainless steel connecting rods penetrating the brickwork in both the transverse and longitudinal directions was tested. The torque value was measured and recorded for each rod to ensure that the tightening torque of each connecting rod was controlled within the range of 45.0 N·m. At the same time, the bolt connection status between the metal pressure strip and the modular frame was visually inspected. The metal pressure strip and the fire-resistant fiberboard were gently shaken by hand to confirm that the bolts were not loose, the fire-resistant fiberboard was compacted and fixed without any warping or falling off, and the high-temperature resistant sealing cap was tightly fitted to the end of the connecting rod without any loose gaps. This indicates that the connection is qualified for tightness.

[0034] Table 1: Performance test data of modular units As shown in Table 1, the modular units of coke oven door bricks prepared in Examples 1-3 exhibit stable and excellent performance in terms of dimensional accuracy, sealing performance, and connection tightness. The overall dimensional deviation of the unit, the flatness of the brick surface, the control of the gap between bricks, and the installation positioning accuracy all meet the design requirements. The sealing performance is qualified, and the connection torque meets the requirements. This demonstrates the systematic superiority of this modular assembly method in terms of process integrity, quality control, and structural reliability.

[0035] The comparison between Comparative Example 1 and Example 1 shows that after replacing the high-temperature resistant composite adhesive for coke oven door bricks with high-alumina refractory mortar, the overall dimensional deviation of the modular unit exceeds the allowable range. This indicates that the high-temperature resistant composite adhesive for coke oven door bricks not only has an adhesive function, but also plays a key role in the positioning and dimensional stability of the bricks during the curing process. Its composition design and preparation process are indispensable to ensuring assembly accuracy.

[0036] The comparison between Comparative Example 2 and Example 1 shows that after omitting the transverse and longitudinal through-fastening process of the stainless steel connecting rod, the connection tightness of the modular unit is rated as "poor". Although the dimensional accuracy can still be maintained, the overall structural integrity and resistance to deformation are significantly reduced. This proves the important role of the mechanical connecting rod in strengthening the overall integrity of the module and resisting thermal stress and installation load. It is not possible to rely solely on the high-temperature resistant composite adhesive for the coke oven door brick and the frame constraint.

[0037] The comparison between Comparative Example 3 and Example 1 shows that when ceramic fiber filler is omitted in the sealing process and only the sealing cap is used for interference fit, the modular unit fails the air pressure sealing test. This indicates that the filler not only fills the gap, but also maintains the sealing elasticity and compensates for thermal deformation in high temperature environment, and is a key component for achieving long-term sealing.

[0038] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention.

Claims

1. A modular, efficient, and rapid assembly method for coke oven door bricks, characterized in that, Includes the following steps: Step S1: Modular unit design and prefabrication preparation. Based on the net inner cavity dimensions of the coke oven door and the design dimensions of the door bricks, the door brick lining is divided into structurally independent modular units. A special modular tooling table matching the modular units is prefabricated, as well as door bricks, modular frames, sealing components, stainless steel connecting rods and anti-loosening nuts that are prefabricated in the factory and have passed dimensional inspection. Step S2: Modular unit pre-assembly. Position and fasten the modular frame to the special modular tooling table using positioning pins. Embed the furnace door bricks one by one into the brick installation groove of the modular frame. After aligning the bricks until the refractory working surface is flush and the gaps between the bricks are uniform, apply coke oven door brick high-temperature resistant composite adhesive evenly to the mating surface of the furnace door bricks and the modular frame. Step S3: Modular unit connection and sealing reinforcement. The bricks are tightened horizontally and vertically by stainless steel connecting rods. The gaps between the bricks are filled with high-temperature resistant composite adhesive for coke oven door bricks and compacted. After covering with refractory fiberboard, it is fixed to the modular frame by metal pressure strips. The ends of the connecting rods and the anti-loosening nuts are sealed. Step S4: Modular unit inspection and labeling. The dimensional accuracy and sealing performance of the modular units are inspected. After passing the inspection, the units are numbered and marked according to their installation location and placed on a special storage rack. Step S5: Modular unit hoisting and overall installation. Select hoisting equipment with a rated lifting capacity, equipped with a balance beam and slings, and hoist the modular unit to the installation position. After positioning with the aid of guide rods, connect it to the furnace door body. Hoist and splice adjacent modular units in sequence. After all units are installed, conduct overall acceptance.

2. The modular, efficient, and rapid assembly method for coke oven door bricks according to claim 1, characterized in that, In step S1, the inner cavity of the coke oven door has a length of 2.0m-3.0m and a width of 1.0m-1.5m; the thickness of the door brick is 200mm-300mm and the width is 400mm-600mm; a single modular unit contains 4 or 6 door bricks; and a splicing flange structure is provided at the splicing surface of adjacent modular units. The splicing flange structure includes a sealing groove and bolt connection holes; The sealing groove has a width of 8mm-12mm and a depth of 4mm-6mm; a high-temperature resistant sealing gasket with a thickness of 4.5mm-5.5mm is pre-installed inside the sealing groove.

3. The modular, efficient, and rapid assembly method for coke oven door bricks according to claim 1, characterized in that, In step S1, the sealing assembly includes a high-temperature resistant sealing cap, ceramic fiber filler, metal pressure strip, and a high-temperature resistant sealing gasket.

4. The modular, efficient, and rapid assembly method for coke oven door bricks according to claim 1, characterized in that, In step S1, the dedicated modular tooling table is welded from Q235B steel. The table surface is covered with a 304 stainless steel panel with a thickness of 8mm-12mm and is milled and precision machined. The flatness error of the table surface is ≤0.5mm / m. Positioning pins and limit blocks adapted to the modular frame are fixedly installed on the table surface. The positioning accuracy of the positioning pins is ≤±0.3mm, the diameter of the positioning pins is 12mm-16mm, and the height is 30mm-50mm.

5. The modular, efficient, and rapid assembly method for coke oven door bricks according to claim 1, characterized in that, The preparation method of the high-temperature resistant composite adhesive for coke oven door bricks includes the following steps: A1: Accurately weigh the raw materials according to the following parts by weight: 45-55 parts of high-alumina refractory slurry, 20-25 parts of silica powder, 5-8 parts of borax, 3-5 parts of sodium carboxymethyl cellulose, 8-12 parts of zirconium oxide powder, and 15-20 parts of deionized water. A2: Place high-alumina refractory slurry, silica powder, borax, and zirconium oxide powder into a planetary high-speed mixer and dry mix for 15-20 minutes at a speed of 800-1000 r / min to obtain a uniformly mixed dry powder. A3: Slowly add sodium carboxymethyl cellulose to deionized water and stir at 200r / min-300r / min for 10min-15min at room temperature until completely dissolved and no visible particles are found, to obtain a viscous aqueous solution; A4: Slowly add the viscous aqueous solution along the inner wall of the mixer to the dry powder, and stir at a speed of 600r / min-800r / min for 30min-40min to form a paste with the consistency required for application; A5: Transfer the paste-like material into a sealed container and age it for 24-36 hours in a constant temperature and humidity environment of 25℃-30℃ and 50%-60% relative humidity to obtain a high-temperature resistant composite adhesive for coke oven door bricks.

6. The modular, efficient, and rapid assembly method for coke oven door bricks according to claim 1, characterized in that, In step S2, the flatness error of the refractory working surface of the brick facing the furnace after correction is ≤1.0mm, and the gap between the bricks is 2.0mm-3.0mm; the coating thickness of the high temperature resistant composite adhesive for the coke oven door brick is 1.0mm-2.0mm.

7. The modular, efficient, and rapid assembly method for coke oven door bricks according to claim 1, characterized in that, In step S3, the tightening torque of the stainless steel connecting rod is controlled between 35.0 N·m and 45.0 N·m; the covering thickness of the fire-resistant fiberboard is 10 mm to 20 mm.

8. The modular, efficient, and rapid assembly method for coke oven door bricks according to claim 1, characterized in that, In step S3, the sealing process specifically involves: installing high-temperature resistant sealing caps on all anti-loosening nuts and the ends of the connecting rods; the high-temperature resistant sealing caps have ceramic fiber fillers inside, the compaction density of the ceramic fiber fillers is 1.2 g / cm³-1.5 g / cm³, and the interference fit between the high-temperature resistant sealing caps and the ends of the connecting rods is 0.05 mm-0.10 mm.

9. The modular, efficient, and rapid assembly method for coke oven door bricks according to claim 1, characterized in that, In step S4, dimensional accuracy is tested using a laser rangefinder and a level. The overall length, width, and height deviation of the modular unit is controlled within ±1.0mm, and the maximum deviation of the brick gap is ≤0.50mm. The sealing performance is tested by introducing dry compressed air at 0.1MPa-0.15MPa into the modular unit and maintaining it for 20min-30min. Soap solution is applied to all connection parts, splicing gaps, and sealing areas. No bubbles are generated, indicating that it is qualified.

10. The modular, efficient, and rapid assembly method for coke oven door bricks according to claim 1, characterized in that, In step S5, the hoisting equipment selected is a truck crane or crawler crane with a rated lifting capacity of ≥10.0t, equipped with a special balance beam and high-strength polyester flexible slings adapted to the weight of the modular unit. The modular unit is hoisted by connecting the four corners of the frame with symmetrical hoisting points, and the installation positioning deviation is controlled within ±2.0mm.

Images