An on-line replacement method for a burner ignition electrode of a roller hearth non-oxidizing heat treatment furnace

Abstract

The application discloses an online replacement method for an ignition electrode of a burner of a roller hearth non-oxidizing heat treatment furnace, and relates to the technical field of heat treatment equipment in the metallurgical industry. The method comprises the following steps: performing safety isolation on a target burner, and cutting off fuel supply of the target burner; separating a main body assembly comprising at least an ignition electrode from a base assembly fixed to a furnace wall, and moving the main body assembly out of the furnace, wherein the base assembly keeps the furnace sealed in the separated state; processing the ignition electrode on the moved main body assembly; returning the processed main body assembly to the base assembly; and resuming fuel supply, conducting leakage detection and ignition debugging, and achieving safe and rapid replacement of the ignition electrode of the burner without stopping the furnace, so that the influence on production is minimized.

Description

Technical Field

[0001] This invention relates to the field of heat treatment equipment technology in the metallurgical industry, and in particular to an online replacement method for the ignition electrode of the burner in a roller hearth type non-oxidizing heat treatment furnace. Background Technology

[0002] Roller hearth non-oxidizing heat treatment furnaces play a crucial role in the production of high-end specialty steels, silicon steel, and non-ferrous metal strips. This equipment achieves non-oxidizing bright heat treatment of strips by precisely controlling the protective atmosphere (such as a high-purity nitrogen-hydrogen mixture) and the combustion process. However, the ignition electrode, a key component for burner startup, is highly susceptible to erosion, carbon buildup, or breakage due to prolonged exposure to the harsh environment of high temperature, high frequency, and high voltage electric sparks. This can lead to ignition failure and severely impact production.

[0003] Currently, there are two main methods for replacing failed ignition electrodes:

[0004] Furnace shutdown for replacement: The entire production line is stopped, and after the furnace temperature cools to room temperature, operators enter the furnace or remove the burner from the outside to replace the ignition electrode. While this method is safe and reliable, it results in production line shutdowns of up to tens of hours, leading to significant energy waste and production losses. For example, in large steel companies, furnace shutdowns for ignition electrode replacement can cause thousands of tons of product to be lost daily, while also significantly increasing energy costs.

[0005] Online blind replacement: While the furnace is running continuously, the ignition electrode is quickly removed and attempted to be replaced. However, this method has many drawbacks, such as limited operating space and obstructed vision, resulting in extremely low replacement efficiency. Moreover, it is difficult to guarantee the accuracy of the new electrode installation position, leading to a low ignition success rate.

[0006] Therefore, there is an urgent need in this field for a method that can safely and efficiently replace ignition electrodes online to solve the problems existing in the prior art. Summary of the Invention

[0007] The purpose of this invention is to provide an online replacement method for the ignition electrode of the burner in a roller hearth type non-oxidizing heat treatment furnace, so as to solve the problems existing in the prior art and realize the safe and rapid replacement of the burner ignition electrode without shutting down the furnace, thereby minimizing the impact on production.

[0008] To achieve the above objectives, the present invention provides the following solution:

[0009] This invention provides an online replacement method for the ignition electrode of a burner in a roller hearth type non-oxidizing heat treatment furnace, wherein the heat treatment furnace is kept in operation, comprising the following steps:

[0010] Implement safety isolation measures on the target burner, cutting off its fuel supply;

[0011] The main component of the burner, which includes at least an ignition electrode, is separated from and removed from the base assembly fixed to the furnace wall, while the base assembly maintains the furnace seal in the separated state.

[0012] Process the ignition electrodes removed from the main assembly;

[0013] The processed main component is reinstalled into the base component;

[0014] Restore fuel supply and conduct leak detection and ignition testing.

[0015] Preferably, the main body component and the base component, as well as the main body component and the fuel line and ignition line, are operably connected by a quick-release connection structure.

[0016] Preferably, the quick-release connection structure includes: flange bolts connecting the main body assembly and the base assembly, and quick-connect couplings connecting the fuel line and the ignition line.

[0017] Preferably, the safety isolation further includes: extinguishing the target burner in the central control room, switching the control authority to the off state on-site, and closing the fuel pipeline shut-off valve of the burner.

[0018] Preferably, the safety isolation further includes: setting up or having operators equipped with portable combustible gas and oxygen content alarms in the operating area for real-time monitoring.

[0019] Preferably, the processing of the ignition electrode is completed offline, including electrode replacement or repair, and pre-calibration of the electrode insertion depth and working position before reinstallation.

[0020] Preferably, the restoration of fuel supply and leak detection includes: slowly opening the fuel pipeline shut-off valve and performing leak detection on all disassembled interfaces.

[0021] Preferably, on-site ignition is performed, and after successful ignition, the burner control is switched back to centralized control, and the combustion parameters are adjusted to the preset operating conditions.

[0022] The present invention achieves the following technical effects compared to the prior art:

[0023] This invention provides an online replacement method for the ignition electrode of a roller hearth non-oxidizing heat treatment furnace burner. While the heat treatment furnace is running, the target burner is safely isolated and the fuel supply is cut off. The main assembly containing the ignition electrode is then separated from the base assembly fixed to the furnace wall and removed. Utilizing the base assembly's ability to maintain furnace sealing while separated, the ignition electrode can be processed offline in an online environment, including replacement or repair. Before reinstallation, the electrode's insertion depth and working position are pre-calibrated. After reinstallation, the fuel supply is restored, and leak detection and ignition testing are performed to ensure the burner's safe and stable operation. This method significantly improves replacement efficiency through quick-detachable connection structures between the main assembly and base assembly, fuel lines, and ignition circuits, such as flange bolts and quick-connect couplings. Simultaneously, measures such as extinguishing the burner in the central control room, switching control permissions on-site, closing the fuel shut-off valve, and setting up combustible gas and oxygen content alarms during the safety isolation process effectively ensure operational safety. Compared with traditional furnace shutdown and replacement methods, this invention avoids the huge energy consumption and output loss caused by long-term shutdowns. Compared with online blind replacement, it ensures the accuracy of electrode installation position through offline processing and pre-calibration, improves the ignition success rate, and thus minimizes the impact on production, providing a strong guarantee for the continuous and stable operation of the roller hearth non-oxidizing heat treatment furnace. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 A flowchart of the online replacement method for the ignition electrode of the burner in the roller hearth type non-oxidizing heat treatment furnace provided by the present invention; Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and 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.

[0027] The purpose of this invention is to provide an online replacement method for the ignition electrode of the burner in a roller hearth type non-oxidizing heat treatment furnace, so as to solve the problems existing in the prior art and realize the safe and rapid replacement of the burner ignition electrode without shutting down the furnace, thereby minimizing the impact on production.

[0028] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0029] This invention provides an online replacement method for the ignition electrode of a burner in a roller hearth type non-oxidizing heat treatment furnace, wherein the heat treatment furnace is kept in operation, comprising:

[0030] The target burner is safely isolated and its fuel supply is cut off. Without shutting down the heat treatment furnace, the fuel supply to the target burner is cut off, eliminating the safety hazard caused by fuel leakage at the source. This ensures that no dangerous situations such as combustion or explosion will occur during the subsequent replacement of the ignition electrode, creating a safe operating environment for online replacement of the ignition electrode.

[0031] The main component of the burner, including at least the ignition electrode, is separated from and removed from the base assembly fixed to the furnace wall. The base assembly maintains a sealed furnace state during this separation. This separation method allows for individual operation of the main component containing the ignition electrode without affecting the overall furnace seal. Maintaining a sealed furnace ensures that the high-temperature, high-pressure environment within the furnace remains undisturbed, allowing other burners to continue operating normally and maintaining stable operation of the heat treatment furnace. This avoids production disruptions due to fluctuations in furnace pressure, temperature, and other parameters, achieving the crucial step of replacing the ignition electrode without shutting down the furnace.

[0032] The ignition electrode is removed from the main assembly and then processed. The operation space is relatively open, which makes it easier for maintenance personnel to replace or repair the ignition electrode. This improves the efficiency and accuracy of ignition electrode processing, while also reducing the difficulty and risk of operation.

[0033] Reinstalling the processed main body component back into the base assembly allows for rapid restoration of the burner's overall structure, enabling it to resume normal operation. The reinstallation operation is relatively simple, and because the components were previously separated, the process can be more precise, reducing adjustment time and facilitating a quick return to normal burner operation.

[0034] Restoring fuel supply and performing leak detection and ignition testing are essential steps for the normal operation of the burner. Leak detection ensures the fuel supply system is properly sealed, preventing fuel leaks that could lead to safety accidents. Ignition testing enables the burner to reach optimal combustion conditions, ensuring the heating effect of the heat treatment furnace and the stability of the production process, guaranteeing the normal and efficient operation of the entire system and restoring production.

[0035] In a preferred embodiment, the main body assembly and the base assembly, as well as the main body assembly and the fuel lines and ignition circuits, are operably connected via quick-release connection structures. These quick-release connection structures significantly improve the speed of separation and connection between the main body assembly and the base assembly, as well as with the fuel lines and ignition circuits, reducing the operation time for online ignition electrode replacement and improving replacement efficiency. This design makes the entire replacement process more convenient and efficient, minimizing the impact on production.

[0036] In a preferred embodiment, the quick-release connection structure includes: flange bolts connecting the main body assembly and the base assembly, and quick-connect couplings connecting the fuel line and the ignition circuit. The flange bolts connect the main body assembly and the base assembly, providing a strong connection and good sealing. Furthermore, they allow for quick disassembly and assembly using appropriate tools, ensuring stable and reliable connections between components during separation and reassembly. The quick-connect couplings connect the fuel line and the ignition circuit, enabling rapid insertion and removal, simplifying operation, and further improving the overall system's disassembly and assembly efficiency, ensuring the high efficiency and convenience of online ignition electrode replacement.

[0037] In a preferred embodiment, the safety isolation further includes: extinguishing the target burner in the central control room, switching control authority to the off state on-site, and closing the fuel pipeline shut-off valve of the burner. The central control room extinguishes the target burner, enabling remote control and allowing operators to monitor the burner's overall status. Switching control authority to the off state on-site adds an extra layer of safety, preventing accidental burner startup due to abnormal remote control signals. Closing the fuel pipeline shut-off valve physically cuts off the fuel supply. These multiple safety measures ensure that the target burner remains in a safe, non-operating state during ignition electrode replacement, comprehensively guaranteeing operational safety.

[0038] In a preferred embodiment, the safety isolation further includes: installing a portable combustible gas and oxygen content alarm in the operating area, or having the operator equip themselves with one, for real-time monitoring. This alarm, installed in the operating area or equipped by the operator, can monitor the concentration of combustible gas and oxygen content in the operating area in real time. In the event of a combustible gas leak or abnormal oxygen content, the alarm can promptly issue an alert, reminding the operator to take appropriate measures, further ensuring the personal safety of the operator and the safety of the operating environment, and preventing safety accidents such as poisoning and explosions caused by gas leaks.

[0039] In a preferred embodiment, the processing of the ignition electrode is completed offline, including electrode replacement or repair, and pre-calibration of the electrode's insertion depth and working position before reinstallation. Processing the ignition electrode offline allows maintenance personnel to operate in a relatively stable environment, unaffected by the operation of the heat treatment furnace, thus improving processing quality. Pre-calibrating the electrode's insertion depth and working position ensures that the reinstalled ignition electrode is in optimal working condition, reducing post-reinstallation debugging time, increasing ignition success rate, and ensuring the burner can quickly and stably resume normal operation.

[0040] In a preferred embodiment, the fuel supply restoration and leak detection includes: slowly opening the fuel pipeline shut-off valve and performing leak detection on all disassembled interfaces. Slowly opening the fuel pipeline shut-off valve facilitates the timely detection of potential abnormalities in the fuel supply system, such as pipeline vibration or abnormal pressure. Performing leak detection on all disassembled interfaces ensures that the entire system maintains good sealing after fuel supply is restored, preventing fuel leaks from causing safety accidents and providing reliable assurance for the normal operation of the burner.

[0041] In a preferred embodiment, on-site ignition is performed. After successful ignition, control of the burner is switched back to centralized control, and combustion parameters are adjusted to preset operating conditions. On-site ignition directly verifies the working effect after the ignition electrode replacement, ensuring the burner can ignite normally. Switching control back to centralized control after successful ignition allows operators to manage and monitor the burner uniformly from the central control room, improving operational convenience and systemicity. Adjusting combustion parameters to preset operating conditions ensures the burner achieves optimal combustion efficiency, guaranteeing the heating effect of the heat treatment furnace and the stability of the production process, meeting production requirements.

[0042] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A method for online replacement of the ignition electrode of a burner in a roller hearth type non-oxidizing heat treatment furnace, wherein the heat treatment furnace is kept in operation, characterized in that... Includes the following steps: Implement safety isolation measures on the target burner, cutting off its fuel supply; The main component of the burner, which includes at least an ignition electrode, is separated from and removed from the base assembly fixed to the furnace wall, while the base assembly maintains the furnace seal in the separated state. Process the ignition electrodes removed from the main assembly; The processed main component is reinstalled into the base component; Restore fuel supply and conduct leak detection and ignition testing.

2. The method according to claim 1, characterized in that, The main body assembly and the base assembly, as well as the main body assembly and the fuel pipeline and ignition circuit, are operably connected by a quick-release connection structure.

3. The method according to claim 2, characterized in that, The quick-release connection structure includes: flange bolts connecting the main body assembly and the base assembly, and quick-connect couplings connecting the fuel line and the ignition line.

4. The method according to claim 1, characterized in that, The safety isolation further includes: extinguishing the target burner in the central control room, switching the control authority to the off state on-site, and closing the fuel pipeline shut-off valve of the burner.

5. The method according to claim 4, characterized in that, The safety isolation also includes: setting up or having operators equipped with portable combustible gas and oxygen content alarms in the operating area for real-time monitoring.

6. The method according to claim 1, characterized in that, The processing of the ignition electrode is completed offline, including electrode replacement or repair, and pre-calibration of the electrode insertion depth and working position before reinstallation.

7. The method according to claim 1, characterized in that, The restoration of fuel supply and leak detection includes: slowly opening the fuel pipeline shut-off valve and performing leak detection on all disassembled interfaces.

8. The method according to claim 7, characterized in that, The process after leak detection also includes: performing on-site ignition, and after confirming successful ignition, switching the burner control back to centralized control and adjusting the combustion parameters to the preset operating conditions.

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