High tensile strength prefabricated part for fluidized calcining furnaces and method for manufacturing same

Abstract

The application discloses a high-tensile super-strong prefabricated part for a boiling calcining furnace and a manufacturing method thereof, and relates to the technical field of calcining furnaces. The prefabricated part comprises a plurality of prefabricated part bodies, at least one anchor is embedded in the interior of each prefabricated part body, and one end of the anchor extends out of the back of the prefabricated part body to form a connecting part for connecting with a furnace shell. By embedding the anchor in the interior of each prefabricated part body, the traditional connecting mode of externally welding the anchor is replaced, meanwhile, the anchor and the prefabricated part body are combined into an integrated whole in the prefabricating stage in the factory, and the interface gap between the traditional welded anchor and the refractory lining is effectively eliminated. Meanwhile, the plurality of prefabricated part bodies are detachably connected to form a modular structure, which not only facilitates the quick installation of the prefabricated part, but also enables the single replacement of the damaged prefabricated part body without large-area furnace shutdown and maintenance, thereby avoiding the shutdown loss caused by the overall replacement of the traditional lining when the lining is totally invalid.

Description

Technical Field

[0001] This invention relates to the field of calcining furnace technology, and in particular to a high tensile strength and ultra-high strength preform for fluidized bed calcining furnaces and its manufacturing method. Background Technology

[0002] Fluidized bed calcining furnaces are key thermal equipment used in processes such as mineral roasting and decomposition in industries such as chemical engineering and metallurgy. Their internal refractory linings are subjected to extreme environments of high temperature, high-speed particle erosion, frequent thermal shock, and chemical corrosion for extended periods. Currently, the industry commonly uses cast-in-place refractory materials or conventional precast refractory components as furnace linings. While cast-in-place materials possess a certain degree of integrity, their construction quality is significantly affected by human and environmental factors, making them prone to cracking and spalling at construction joints under vibration and thermal stress. Traditional precast components, although factory-prefabricated and relatively stable in quality, are designed primarily for pressure resistance and erosion resistance, exhibiting significant shortcomings in structural strength, particularly tensile strength and resistance to mechanical vibration.

[0003] Currently, existing precast components typically rely on externally welded anchors to connect to the furnace body. Under the continuous vibration and thermal cycling of the fluidized bed furnace, the anchoring interface is prone to cracking and detachment due to stress concentration, leading to overall lining failure and severely restricting the long-term safe operation of the equipment. Moreover, the fiber reinforcement effect in conventional precast components is limited, and the flexural strength and toughness of the material itself are insufficient, making it prone to brittle fracture under the combined effects of thermal shock and mechanical vibration. In addition, the shape and internal structure of the precast components lack optimization for fluid erosion and stress distribution, resulting in accelerated local wear, and making repair difficult and maintenance costs high after damage. Summary of the Invention

[0004] This invention provides a high tensile strength and ultra-high strength prefabricated component for fluidized bed calcining furnaces, which can solve the problem in the prior art where externally welded anchors are usually used to connect the furnace body. Under the continuous vibration and thermal cycling of the fluidized bed furnace, the anchor interface is prone to cracking and falling off due to stress concentration, resulting in the overall failure of the lining and seriously restricting the long-term safe operation of the equipment.

[0005] A high tensile strength precast component for a fluidized bed calcining furnace includes multiple precast components. Each precast component has at least one anchor embedded inside it, and one end of the anchor extends out of the back of the precast component to form a connection portion for connection with the furnace shell. The connection portion is detachably connected to the furnace shell by bolts, and adjacent precast components are detachably connected to each other.

[0006] The present invention provides a high tensile strength and ultra-high strength preform for fluidized bed calcining furnaces, which, compared with the prior art, has the following beneficial effects, but is not limited to:

[0007] This fluidized bed calcining furnace uses high-tensile-strength precast components. Each precast component has an anchor embedded within it, replacing the traditional external welded anchor connection method. This avoids damage to the anchor material caused by on-site welding. Simultaneously, the anchor and the precast component form a tightly integrated whole during the factory prefabrication stage, effectively eliminating the interface gap between the traditional welded anchor and the refractory lining, solving the problem of stress concentration at the anchoring interface, and preventing cracking and detachment between the anchor and the precast component. The anchor extends from the back of the precast component and is detachably connected to the furnace shell via bolts, ensuring a stable connection and facilitating installation and disassembly, further improving the reliability of the anchoring structure. Furthermore, the detachable connection between multiple precast components forms a modular structure, which not only facilitates rapid installation of the precast components but also allows for individual replacement of damaged components without large-scale furnace shutdowns for maintenance, avoiding the downtime losses caused by the need for complete replacement of the entire lining in the traditional method.

[0008] Furthermore, the precast body is made of refractory castable after casting, curing and baking, and the interior of the precast body is provided with heat-resistant steel fibers and organic fibers.

[0009] Furthermore, nanoscale reinforcing materials are dispersed in the matrix of the refractory castable.

[0010] Furthermore, the precast component body is also pre-embedded with built-in reinforcing ribs, which are heat-resistant alloy metal mesh or irregularly shaped anchoring ribs, and the built-in reinforcing ribs and anchors are spatially intersected or connected.

[0011] Furthermore, the preform body includes a high wear-resistant layer and an impact-resistant backing layer from the working surface to the back surface, wherein the bulk density of the high wear-resistant layer is higher than that of the impact-resistant backing layer.

[0012] Furthermore, the working surface profile of the high wear-resistant layer is a curved or irregular surface optimized based on the fluid dynamics simulation results in the fluidized bed furnace, in order to reduce local eddies and turbulence.

[0013] Furthermore, a protrusion is provided on one side of the high wear-resistant layer, and a groove adapted to the protrusion is provided on one side of the impact-resistant backing layer.

[0014] Furthermore, the heat-resistant steel fiber has a length of 10-30 mm and a diameter of 0.1-0.5 mm, and the organic fiber is polypropylene fiber with a length of 3-12 mm.

[0015] A method for manufacturing a high tensile strength and ultra-high strength preform for a fluidized bed calcining furnace, based on the aforementioned high tensile strength and ultra-high strength preform for a fluidized bed calcining furnace, includes the following steps: S1, weighing refractory aggregate, powder, binder and additives according to the proportion, and adding heat-resistant steel fiber, organic fiber and nano-level reinforcing material, mixing evenly to prepare refractory castable; S2, fixing the treated anchors and built-in reinforcing ribs to the designated positions in the preform mold; S3, injecting the refractory castable into the mold for casting; S4, curing and demolding the cast blank, and then drying and baking it to obtain the preform body.

[0016] Furthermore, in step S3, when casting a preform containing a high wear-resistant layer and an impact-resistant backing layer, a layered casting process is adopted: first, the casting material constituting the high wear-resistant layer is cast, and then the casting material constituting the impact-resistant backing layer is cast on top of it. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the installation of a high tensile strength ultra-strong prefabricated component for a fluidized bed calcining furnace according to an embodiment of the present invention;

[0018] Figure 2 This is a schematic diagram of the structure of a high tensile strength ultra-high strength preform for a fluidized bed calcining furnace according to an embodiment of the present invention;

[0019] Figure 3 This is a cross-sectional view of a high tensile strength ultra-high strength preform for a fluidized bed calcining furnace according to an embodiment of the present invention. Figure 1 ;

[0020] Figure 4 This is a cross-sectional view of a high tensile strength ultra-high strength preform for a fluidized bed calcining furnace according to an embodiment of the present invention. Figure 2 ;

[0021] Figure 5 This is a flowchart illustrating a method for manufacturing high-tensile-strength, ultra-strong preforms for a fluidized bed calcining furnace according to an embodiment of the present invention.

[0022] Explanation of reference numerals in the attached figures:

[0023] 1. Precast component body; 2. Anchor; 3. Furnace shell; 4. Heat-resistant steel fiber; 5. Organic fiber; 6. Nanoscale reinforcing material; 7. Built-in reinforcing rib; 8. Protrusion; 9. Groove; 11. High wear-resistant layer; 12. Impact-resistant backing layer; 21. Connecting part. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings showing multiple embodiments according to this application. It should be understood that the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments described in this application without creative effort will fall within the scope of protection of this application.

[0025] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used in the description of this application is for the purpose of describing specific embodiments only and is not intended to limit this application; the terms "comprising," "including," "having," "containing," etc., in the description, claims, and accompanying drawings of this application are open-ended terms. Therefore, "comprising," "including," or "having" refers to, for example, a method or apparatus having one or more steps or elements, but is not limited to having only these one or more elements. The terms "first," "second," etc., in the description, claims, or accompanying drawings of this application are used to distinguish different objects, not to describe a specific order or hierarchy. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0026] In the description of this invention, it should be understood that the terms "upper", "lower", "left", "right", "front", "rear", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0027] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "attachment" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0028] It should be emphasized that when the term "comprising / including" is used in this specification, it is used to explicitly indicate the presence of the stated feature, integer, step, or component, but does not exclude the presence or addition of one or more other features, integers, steps, parts, or groups of features, integers, steps, or parts.

[0029] In this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, in this application, the character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0030] like Figure 1-3 As shown in the figure, an embodiment of the present invention provides a high tensile strength and ultra-high strength preform for a fluidized bed calcining furnace, comprising a plurality of preform bodies 1, each preform body 1 having at least one anchor 2 embedded inside, and one end of the anchor 2 extending out of the back of the preform body 1 to form a connection portion 21 for connection with the furnace shell 3. The connection portion 21 is detachably connected to the furnace shell 3 by bolts, and adjacent preform bodies 1 are detachably connected.

[0031] In this embodiment, anchors 2 are pre-embedded inside each precast component body 1, replacing the traditional external welding anchor connection method. This avoids damage to the material of the anchors 2 caused by on-site welding operations. At the same time, the anchors 2 and the precast component body 1 form a tightly integrated whole during the factory prefabrication stage, effectively eliminating the interface gap between the traditional welded anchors and the refractory lining, solving the problem of stress concentration at the anchor interface, and preventing cracking and detachment between the anchors 2 and the precast component body 1. The connecting part 21 of the anchors 2 extending from the back of the precast component body 1 is detachably connected to the furnace shell 3 by bolts. The connection is stable and easy to install and disassemble, further improving the reliability of the anchor structure. At the same time, the multiple precast component bodies 1 are detachably connected to form a modular structure, which not only facilitates the rapid installation of precast components, but also allows for individual replacement of a single precast component body 1 when it is damaged, without the need for large-scale furnace shutdown for maintenance, avoiding the downtime losses caused by the need for complete replacement after the overall failure of the traditional lining.

[0032] Specifically, functionally graded materials are designed for different parts, and multiple prefabricated body 1 adopts a non-uniform density design. The prefabricated body 1 adopts functionally graded materials and non-uniform density design for different parts. That is, according to the differences in working conditions such as material scouring, thermal stress, and mechanical vibration in the fluidized bed calcining furnace, the density of the prefabricated body 1 is differentially controlled. For example, the material scouring surface and other parts with severe material scouring adopt a high-density design to improve wear resistance and scouring resistance, while the backing surface and other parts with relatively low stress adopt a low-density design to reduce thermal stress transmission and structural self-weight. Through the functionally graded non-uniform density distribution, the performance of the prefabricated body 1 is precisely matched with the working conditions, avoiding the problem of "insufficient strength in wear-resistant parts and redundant energy consumption in non-wear-resistant parts" caused by the overall uniform density of traditional prefabricated parts.

[0033] This non-uniform density design enables the precast body 1 to have a more reasonable stress distribution when subjected to mechanical stress and thermal cycling, effectively buffering stress concentration in local areas, reducing the risk of cracking and spalling caused by stress concentration, further enhancing the thermal shock resistance and vibration resistance of the precast body 1, extending its service life in key parts such as the bed and cyclone cone, reducing the frequency of unplanned shutdowns, and ensuring the long-term safe and efficient operation of the fluidized bed calciner.

[0034] like Figure 1 and Figure 3 As shown, the precast body 1 is made of refractory castable after casting, curing and baking, and the interior of the precast body 1 is provided with heat-resistant steel fibers 4 and organic fibers 5.

[0035] In this embodiment, the precast component body 1 is made of refractory castable through integrated casting, curing, and baking. Compared with traditional on-site castables, which are greatly affected by the environment and personnel and are prone to construction joints and weak points, its molding quality is more stable and its integrity is stronger. It can effectively avoid structural hazards formed during construction and reduce the risk of cracking and peeling from weak points under vibration conditions. At the same time, the heat-resistant steel fibers 4 and organic fibers 5 set inside the precast component body 1 form a synergistic reinforcement effect. The heat-resistant steel fibers 4 can form a three-dimensional support skeleton inside the precast component body 1, significantly improving the precast component body. The flexural strength and overall rigidity of the preform body 1 enhance its ability to resist material erosion and mechanical vibration, preventing brittle fracture of the body. The organic fiber 5 can melt and volatilize during the baking stage of the preform body 1, leaving uniformly distributed micropores. These micropores can effectively buffer the thermal stress caused by the rapid temperature changes brought about by the start-up and shutdown of the fluidized bed furnace and the fluctuation of operation, improve the thermal shock resistance of the preform body 1, prevent it from peeling and being damaged due to thermal shock, and thus solve the pain point of insufficient flexural and thermal shock resistance of traditional preforms, extend the service life of the preform body 1, and ensure the long-term stable operation of the fluidized bed calcining furnace.

[0036] like Figure 1 and Figure 3 As shown, nanoscale reinforcing materials 6 are also dispersed in the matrix of the refractory castable.

[0037] In this embodiment, nano-scale reinforcing material 6 is dispersed in the refractory castable matrix of the precast body 1. It has extremely high activity and specific surface area, and can uniformly fill the tiny pores inside the refractory matrix, as well as the interfacial gaps between the refractory matrix and the heat-resistant steel fiber 4, organic fiber 5, and refractory aggregate. It effectively fills the micro-defects that are difficult to avoid in the traditional precast matrix, so that the refractory castable matrix forms a denser and more uniform overall structure.

[0038] Specifically, the nano-reinforcing material 6 can promote the sintering reaction of the refractory matrix during curing and baking, significantly strengthen the interfacial bonding force between the matrix and the heat-resistant steel fiber 4 and organic fiber 5, avoid the problem of reinforcement failure caused by fiber separation from the matrix, further improve the flexural strength, tensile strength and toughness of the precast body 1, and enhance its ability to resist material erosion and mechanical vibration in the fluidized bed furnace; in addition, the densified matrix structure can also effectively block the penetration of corrosive media such as alkaline vapor and sulfides in the furnace, reduce the damage of chemical erosion to the precast body 1, make up for the lack of corrosion resistance and damage resistance of traditional precast parts, extend the service life of the precast body 1, and ensure the long-term stable operation of the fluidized bed calcining furnace.

[0039] The matrix of the precast body 1 also incorporates a nano-modifier, which is SiO2 or Al2O3 sol. This nano-modifier, with its extremely high chemical activity, effectively promotes the sintering reaction of the refractory matrix during the curing, baking, and service of the precast body 1. It accelerates the bonding between matrix particles, reduces microscopic pores and cracks caused by insufficient sintering within the matrix, and enables the refractory matrix to form a dense and uniform overall structure, fundamentally improving the matrix's strength and density. Simultaneously, this nano-modifier fully fills the interfacial gaps between the refractory matrix and aggregates, and between the matrix and heat-resistant steel fibers 4 and organic fibers 5, filling the interfacial defects that are difficult to avoid in traditional precast components. This greatly strengthens the bonding force between the matrix and aggregates, and between the matrix and fibers, preventing aggregate detachment and fiber separation from the matrix. It fully utilizes the wear resistance of the aggregates and the reinforcing and toughening effects of the fibers, effectively solving the pain points of fiber reinforcement failure and loose interfacial bonding in traditional precast components.

[0040] like Figure 1 and Figure 4 As shown, the precast body 1 also has an embedded reinforcing rib 7 inside. The embedded reinforcing rib 7 is a heat-resistant alloy metal mesh or a special-shaped anchoring rib, and the embedded reinforcing rib 7 and the anchor 2 are intersected or connected in space.

[0041] In this embodiment, the built-in reinforcing ribs 7 embedded inside the precast body 1 are made of heat-resistant alloy metal mesh or irregularly shaped anchoring ribs, and the built-in reinforcing ribs 7 and the anchors 2 are spatially interwoven or connected to form a synergistic reinforcement structure. The built-in reinforcing ribs 7 provide rigid support, and the anchors 2 transmit mechanical stress and vibration load. The spatial interwoven or connected design can effectively transfer the mechanical stress and vibration stress borne by the precast body 1 from the brittle refractory matrix to the tough metal reinforcement, avoiding stress concentration inside the precast body 1 and causing brittle fracture.

[0042] Specifically, the synergistic effect of the built-in reinforcing rib 7 and the anchor 2 can further enhance the overall structural integrity and vibration resistance of the precast body 1, and improve the tensile strength of the combination of the anchor 2 and the precast body 1.

[0043] like Figure 1 and Figure 3 As shown, the preform body 1 includes a high wear-resistant layer 11 and an impact-resistant backing layer 12 from the working surface to the back surface. The bulk density of the high wear-resistant layer 11 is higher than that of the impact-resistant backing layer 12.

[0044] In this embodiment, the preform body 1 is provided with a high wear-resistant layer 11 and an impact-resistant backing layer 12 sequentially from the working surface to the back surface. The high wear-resistant layer 11 has a higher bulk density than the impact-resistant backing layer 12. Through the layered structure design, the preform body 1 can be precisely adapted to the complex working conditions inside the fluidized bed calcining furnace. The high wear-resistant layer 11 directly faces the high-speed material scouring and airflow impact inside the furnace. Its high density characteristics provide excellent wear resistance and scouring ability, effectively resisting physical wear. The impact-resistant backing layer 12 adopts a low-density design, which can effectively buffer thermal stress and mechanical vibration, and prevent the high wear-resistant layer 11 from cracking or peeling due to thermal expansion and contraction or vibration impact. At the same time, it reduces the overall weight of the preform body 1 and reduces the load on the furnace body.

[0045] like Figure 1 and Figure 2 As shown, the working surface profile of the high wear-resistant layer 11 is a curved or irregular surface optimized based on the fluid dynamics simulation results in the fluidized bed furnace, which is used to reduce local eddies and turbulence.

[0046] In this embodiment, the working surface contour of the high wear-resistant layer 11 is optimized into a curved or irregular surface based on the fluid dynamics simulation results in the fluidized bed furnace. By precisely conforming to the flow trajectory of the airflow and material in the furnace, it can effectively break the local eddies and turbulence that are easily generated by traditional planar structures, reduce the directional scouring and impact intensity of airflow and material on the surface of the preform, and reduce the local wear rate of the material on the high wear-resistant layer 11 from the source. At the same time, the curved or irregular surface design can make the material more evenly dispersed in the flow process, avoid the wear aggravation caused by local stress concentration, further enhance the wear resistance and scouring resistance of the high wear-resistant layer 11, and extend its service life in key parts such as the material receiving surface.

[0047] like Figure 1 and Figure 4 As shown, a protrusion 8 is provided on one side of the high wear-resistant layer 11, and a groove 9 that matches the protrusion 8 is provided on one side of the impact-resistant backing layer 12.

[0048] In this embodiment, a protrusion 8 is provided on one side of the high wear-resistant layer 11, and a groove 9 adapted to the protrusion 8 is provided on one side of the impact-resistant backing layer 12. This interlocking splicing structure allows adjacent precast body 1 to be quickly assembled and disassembled through the precise engagement of the protrusion 8 and the groove 9, without the need for complex connecting tools or on-site welding operations, greatly improving installation efficiency. At the same time, this splicing structure can form a tight-fitting integrated connection inside the precast body 1, effectively eliminating interlayer interface gaps and avoiding interlayer peeling and loosening caused by fluidized bed furnace vibration and thermal circulation, thus enhancing the overall structural stability of the precast component. In addition, when a precast body 1 is partially worn or damaged, the corresponding component can be disassembled and replaced individually without large-scale furnace shutdown for maintenance, reducing maintenance costs and downtime losses, and ensuring the long-term safe and efficient operation of the fluidized bed calcining furnace.

[0049] like Figure 1 As shown, the heat-resistant steel fiber 4 has a length of 10-30 mm and a diameter of 0.1-0.5 mm. The organic fiber 5 is a polypropylene fiber with a length of 3-12 mm.

[0050] In this embodiment, the heat-resistant steel fibers 4 inside the preform body 1 have a length of 10-30 mm and a diameter of 0.1-0.5 mm, and the organic fibers 5 are made of polypropylene fibers with a length of 3-12 mm. This allows the heat-resistant steel fibers 4 to form a three-dimensional mesh support skeleton inside the preform body 1, effectively improving the flexural strength and overall toughness of the preform body 1, enhancing its ability to resist material erosion and mechanical vibration, and avoiding reinforcement failure or local stress concentration caused by improper fiber length and diameter. At the same time, the short length design of the organic fibers 5 can quickly melt and volatilize during the baking stage to form uniform micropores, effectively buffering thermal stress, improving thermal shock resistance, and not affecting the fluidity and thixotropy of the refractory castable due to excessive fiber length.

[0051] like Figure 4 As shown, a method for manufacturing a high tensile strength and ultra-high strength precast component for a fluidized bed calcining furnace includes the following steps: S1, weighing refractory aggregate, powder, binder and additives according to the proportion, and adding heat-resistant steel fiber 4, organic fiber 5 and nano-level reinforcing material 6, mixing evenly to prepare refractory castable; S2, fixing the treated anchor 2 and built-in reinforcing rib 7 to the set position in the precast component mold; S3, injecting the refractory castable into the mold for casting; S4, curing and demolding the cast blank, and then drying and baking it to obtain the precast component body 1.

[0052] In this embodiment, a standardized and integrated prefabrication process is used to achieve high-quality molding and stable performance of the precast component body 1. By accurately weighing refractory aggregates, powders, binders, and additives according to the specified ratio, and adding heat-resistant steel fibers 4, organic fibers 5, and nano-level reinforcing materials 6, uniform mixing of all components is ensured, resulting in a dense and uniform composite reinforced structure in the refractory castable. This avoids microscopic defects caused by uneven material proportions and insufficient mixing in traditional on-site castables. The treated anchors 2 and built-in reinforcing ribs 7 are fixed at predetermined positions in the precast component mold, achieving precise pre-embedding of the anchors 2 and built-in reinforcing ribs 7 within the precast component body 1. This ensures the bonding strength between the anchors 2 and the precast component body 1, avoiding material damage and stress concentration during traditional welding of anchors. By using refractory aggregates, powders, binders, and additives according to the specified ratio, and adding heat-resistant steel fibers 4, organic fibers 5, and nano-level reinforcing materials 6, the refractory castable body 1 achieves a dense and uniform composite reinforced structure, avoiding microscopic defects caused by uneven material proportions and insufficient mixing in traditional on-site castables. The castable refractory is injected into the mold for casting. The standardized constraints of the mold allow for precise control of the structural dimensions of the precast body 1, effectively avoiding shape deviations caused by manual operation in traditional construction. Through curing, demolding, drying, and baking of the billet, a scientific heat treatment process promotes the sintering reaction of the refractory matrix, strengthens the bonding force between the components, and ensures that the micropores formed by the melting of organic fibers 5 are evenly distributed, improving the thermal shock resistance of the precast body 1. The resulting precast body 1 has ultra-high tensile strength, excellent wear resistance, and thermal shock resistance, and the overall molding quality is stable and the integrity is strong. This solves the problems of long curing time and low maintenance efficiency of traditional precast parts, significantly shortens the production cycle of precast parts, reduces maintenance costs, and ensures the long-term safe operation of the fluidized bed calcining furnace.

[0053] In step S3, when casting the preform containing the high wear-resistant layer 11 and the impact-resistant backing layer 12, a layered casting process is adopted: first, the casting material constituting the high wear-resistant layer 11 is cast, and then the casting material constituting the impact-resistant backing layer 12 is cast on top of it.

[0054] In this embodiment, a layered casting process is adopted for the preform containing a high wear-resistant layer 11 and an impact-resistant backing layer 12. First, the casting material constituting the high wear-resistant layer 11 is cast, and then the casting material constituting the impact-resistant backing layer 12 is cast on top of it. This ensures that the high wear-resistant layer 11 and the impact-resistant backing layer 12 form a tightly fitted gradient structure inside the preform body 1, effectively avoiding mutual interference in performance caused by the mixed casting of the two functional layers. This solves the problem of weak interfacial bonding and easy interlayer delamination in traditional layered structures.

[0055] Specifically, layered casting can precisely control the density and compactness of the high wear-resistant layer 11, allowing it to fully exert its wear-resistant effect against direct material erosion. Meanwhile, the impact-resistant backing layer 12 can form an effective buffer on the back of the high wear-resistant layer 11, further improving the thermal shock resistance and impact resistance of the preform body 1. In addition, this process can strengthen the interfacial bonding strength between the high wear-resistant layer 11 and the impact-resistant backing layer 12, reduce the risk of interlayer cracking under thermal cycling and mechanical vibration, improve the overall structural stability of the preform body 1, extend its service life in key parts of the fluidized bed calcining furnace, and reduce maintenance costs.

[0056] The above-disclosed embodiments are merely a few specific examples of the present invention. However, the embodiments of the present invention are not limited thereto, and any variations that can be conceived by those skilled in the art should fall within the protection scope of the present invention.

Claims

1. A high tensile strength, ultra-high strength precast component for a fluidized bed calcining furnace, characterized in that, It includes multiple prefabricated body bodies (1), each of the prefabricated body bodies (1) has at least one pre-embedded anchor (2) inside, and one end of the anchor (2) extends out of the back of the prefabricated body body (1) to form a connection part (21) for connection with the furnace shell (3). The connection part (21) is detachably connected to the furnace shell (3) by bolts, and adjacent prefabricated body bodies (1) are detachably connected.

2. The high tensile strength ultra-high strength precast component for fluidized bed calcining furnace as described in claim 1, characterized in that, The precast body (1) is made of refractory castable after casting, curing and baking. The precast body (1) is provided with heat-resistant steel fiber (4) and organic fiber (5).

3. The high tensile strength ultra-high strength precast component for fluidized bed calcining furnace as described in claim 2, characterized in that, The matrix of the refractory castable also contains nanoscale reinforcing materials (6).

4. The high tensile strength ultra-high strength precast component for fluidized bed calcining furnace as described in claim 1, characterized in that, The precast body (1) is also pre-embedded with built-in reinforcing ribs (7), which are heat-resistant alloy metal mesh or irregular anchoring ribs, and the built-in reinforcing ribs (7) and the anchors (2) are intersected or connected in space.

5. The high tensile strength ultra-high strength precast component for fluidized bed calcining furnace as described in claim 1, characterized in that, The preform body (1) includes a high wear-resistant layer (11) and an impact-resistant backing layer (12) from the working surface to the back surface. The high wear-resistant layer (11) has a higher bulk density than the impact-resistant backing layer (12).

6. The high tensile strength ultra-high strength precast component for fluidized bed calcining furnace as described in claim 5, characterized in that, The working surface profile of the high wear-resistant layer (11) is a curved or irregular surface optimized based on the fluid dynamics simulation results in the fluidized bed furnace, which is used to reduce local eddies and turbulence.

7. The high tensile strength ultra-high strength precast component for fluidized bed calcining furnace as described in claim 5, characterized in that, The high wear-resistant layer (11) has a protrusion (8) on one side, and the impact-resistant backing layer (12) has a groove (9) on one side that matches the protrusion (13).

8. The high tensile strength ultra-high strength precast component for fluidized bed calcining furnace as described in claim 2, characterized in that, The heat-resistant steel fiber (4) has a length of 10-30 mm and a diameter of 0.1-0.5 mm. The organic fiber (5) is a polypropylene fiber and has a length of 3-12 mm.

9. A method for manufacturing a high-tensile-strength, ultra-high-strength preform for a fluidized bed calcining furnace, characterized in that, The high tensile strength and ultra-high strength preform for fluidized bed calcining furnaces as described in any one of claims 1-8 comprises the following steps: S1. Weigh out refractory aggregates, powders, binders and additives according to the proportion, and add heat-resistant steel fibers (4), organic fibers (5) and nano-scale reinforcing materials (6), mix evenly, and prepare refractory castable; S2. Fix the processed anchor (2) and the built-in reinforcing rib (7) to the set position in the precast mold; S3. Inject the refractory castable into the mold and cast it into shape; S4. Curing and demolding the cast blank, and then drying and baking it to obtain the preform body (1).

10. The method for manufacturing high tensile strength ultra-high strength preforms for fluidized bed calcining furnaces as described in claim 9, characterized in that, In step S3, when casting a preform containing a high wear-resistant layer (11) and an impact-resistant backing layer (12), a layered casting process is adopted: first, the casting material constituting the high wear-resistant layer (11) is cast, and then the casting material constituting the impact-resistant backing layer (12) is cast on top of it.

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