A sectional combustion kiln structure and control power assembly

Abstract

This invention relates to a segmented combustion kiln structure and its control and power assembly. The segmented combustion kiln structure and control and power assembly include a kiln body, a segmented combustion structure, and a control and power assembly. The kiln body is sequentially divided into a preheating section, a firing section, a heat preservation section, and a cooling section along the material conveying direction. Each section is separated by an air curtain sealing partition and a flexible sealing structure to achieve physical isolation between temperature zones. The segmented combustion structure includes a dedicated burner group independently configured for each temperature zone. The control and power assembly includes a temperature PID closed-loop control module, an air-fuel ratio dynamic optimization module, a micro-pressure difference anti-interference module, and an oxygen content real-time feedback module to achieve intelligent closed-loop control throughout the entire kiln process. This segmented combustion kiln structure and control and power assembly can achieve high-precision temperature control, significant energy savings, ultra-low emissions, and flexible production, significantly improving product firing quality and production efficiency while reducing operating costs and environmental risks.

Description

Technical Field

[0001] This invention relates to the field of ceramic firing kiln technology, and in particular to a segmented combustion kiln structure and control power assembly. Background Technology

[0002] Ceramic firing is the core process in ceramic production, and the kiln, as its key carrier, directly determines the firing quality, energy consumption, and environmental emissions of ceramic products through its combustion and control performance. Traditional ceramic firing kilns often adopt a large, integrated, open-plan structure, dividing the material transport direction into preheating, firing, holding, and cooling zones only by process control. This lacks physical isolation structures and independent unit control, resulting in significant industry pain points: First, the integrated structure leads to easy lateral flow of heat and flue gas, blurring the boundaries between temperature zones, and causing temperature fluctuations of ±15-20℃. This results in uneven heating of ceramic materials, poor product firing consistency, and a high scrap rate, making it difficult to meet the firing requirements of high-end products. Second, to counteract temperature crosstalk, traditional kilns often use excessive combustion to maintain the core temperature zone while simultaneously introducing additional cold air for forced cooling, leading to low thermal efficiency, with waste heat recovery rates generally below 50%, resulting in significant fuel waste and increased operating costs. Third, centralized combustion and uniform air distribution easily generate large amounts of thermal NOx. x Emission concentrations often exceed 100 mg / Nm³, making it difficult to meet increasingly stringent environmental standards and posing significant environmental compliance risks to enterprises. Finally, the process parameters of traditional kilns require manual adjustment segment by segment, making it difficult to adapt the firing curves of different types of ceramics, resulting in long conversion times and an inability to meet the flexible production needs of multiple categories and small batches, thus restricting the market responsiveness of enterprises.

[0003] Currently, although a few improved solutions for segmented kilns have emerged in the industry, most only achieve simple physical segmentation and do not include independent combustion units and intelligent closed-loop control systems. This makes it difficult to fundamentally solve the problems of temperature crosstalk and insufficient temperature control accuracy, resulting in limited energy-saving and emission-reduction effects. Therefore, there is an urgent need to develop a segmented combustion kiln and its control assembly with optimized structure and control to achieve high-precision, low-energy-consumption, low-emission, and flexible ceramic firing production. Summary of the Invention

[0004] To overcome the shortcomings of the prior art, this invention provides a segmented combustion kiln structure and control power assembly, which can achieve high-precision temperature control, significant energy saving, ultra-low emissions and flexible production, significantly improve product firing quality and production efficiency, while reducing operating costs and environmental risks.

[0005] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: A segmented combustion kiln structure and control power assembly are characterized by comprising a kiln body, a segmented combustion structure, and a control power assembly. The kiln body is divided into four temperature zones along the material conveying direction: a preheating zone, a firing zone, a heat preservation zone, and a cooling zone. Each zone is separated by an air curtain sealing partition and a flexible sealing structure to achieve physical isolation between the temperature zones and structurally block the lateral flow of heat and flue gas. The segmented combustion structure includes a dedicated burner group independently configured for each temperature zone. The control power assembly includes a temperature PID closed-loop control module, an air-fuel ratio dynamic optimization module, a micro-pressure difference anti-interference module, and an oxygen content real-time feedback module to achieve intelligent closed-loop control of the entire kiln process.

[0006] Preferably, the air curtain sealing partition includes multiple high-pressure air curtain nozzles arranged along the width of the kiln. The high-pressure air curtain nozzles are connected to a high-pressure blower to form an air curtain barrier by outputting a high-pressure airflow of 3000-5000Pa. The flexible sealing structure uses high-temperature resistant ceramic fiber seals with a temperature resistance of not less than 1400℃ to fill the mechanical gaps between sections to improve the sealing effect.

[0007] Preferably, the dedicated burner group includes high-speed temperature-regulating burners, regenerative burners, and low-speed stable-burner burners, to match different types of burners according to the temperature requirements of the ceramic firing process in each temperature zone. Specifically, the preheating section is equipped with regenerative burners, which can use the high-temperature flue gas discharged from the kiln to preheat the combustion air to above 800°C, improving thermal efficiency and reducing fuel consumption; the firing section is equipped with high-speed temperature-regulating burners with a combustion speed of not less than 150m / s to achieve rapid heating and precise temperature control in the high-temperature zone; the heat preservation section is equipped with low-speed stable-burner burners to ensure temperature stability and avoid fluctuations affecting product quality; the cooling section is equipped with an independent forced air cooling system to achieve rapid and uniform cooling of the product and avoid cracking caused by uneven cooling.

[0008] Preferably, the temperature PID closed-loop control module arranges 3-5 K-type temperature sensors along the height and length directions in each temperature zone to collect kiln temperature data in real time, and automatically adjusts the combustion power of the burner in the corresponding temperature zone through the PID algorithm to control the temperature fluctuation of each temperature zone within ±1.5℃.

[0009] Preferably, the control powertrain further includes a waste heat recovery system, which recovers heat from each section of flue gas through a flue gas waste heat recovery device to preheat the combustion air, and the waste heat recovery rate is greater than 80%.

[0010] Preferably, the powertrain control system further includes a low-NOx combustion control module. This module employs segmented air distribution technology, dividing the combustion process into a main combustion zone and a burnout zone. The main combustion zone uses fuel-rich combustion (air coefficient of 0.8) to suppress NOx emissions. xThe combustion process involves supplementing the air supply in the burnout zone to achieve a total air coefficient of 1.1, ensuring complete combustion and thus achieving NO reduction. x Emissions are below 50 mg / Nm³.

[0011] Preferably, the control powertrain also includes a flexible production control module, which is used to store firing process parameter groups for multiple types of ceramics (including temperature curves of each temperature zone, combustion power, air-fuel ratio and other core parameters), and supports one-click switching of parameter groups without manual segmental adjustment, thereby shortening the kiln turnaround time by 70%.

[0012] Preferably, the micro-pressure difference anti-interference module controls the micro-positive pressure in each temperature zone to form a stable pressure difference gradient of 5-10 Pa between adjacent temperature zones, so as to further block the crossflow of heat and flue gas.

[0013] Preferably, the real-time oxygen content feedback module is equipped with a zirconia oxygen content sensor in each temperature zone to monitor the oxygen concentration in the kiln in real time and control the oxygen content within the range of 3%-5% in order to dynamically optimize the air distribution and achieve a balance between low-NOx combustion and high-efficiency combustion.

[0014] Preferably, the air-fuel ratio dynamic optimization module dynamically adjusts the air-fuel ratio based on real-time temperature data and oxygen content data of each temperature zone, with an air-fuel ratio control accuracy of ±2%, to ensure complete combustion and avoid over-combustion.

[0015] The control powertrain is the core of the kiln's intelligent control system. It integrates a temperature PID closed-loop control module, an air-fuel ratio dynamic optimization module, a micro-pressure difference anti-interference module, and an oxygen content real-time feedback module. It is also equipped with a waste heat recovery system, a low-NOx combustion control module, and a flexible production control subsystem, which enables intelligent closed-loop control of the entire kiln process.

[0016] The present invention employs the above-described structure and has the following advantages: 1. This invention achieves high-precision temperature control within ±1.5℃ for temperature fluctuations in each temperature zone through physical segmentation and quadruple intelligent closed-loop control, completely solving the crosstalk problem in temperature zones of traditional kilns, improving the firing consistency of ceramic products by more than 30%, significantly reducing the scrap rate, and meeting the firing requirements of high-end ceramic products.

[0017] 2. This invention avoids excessive combustion through precise temperature control and is equipped with a waste heat recovery system with a waste heat recovery rate of more than 80%, which reduces the overall energy consumption of the kiln by 20%-35%, significantly reducing fuel consumption costs and improving production economic efficiency.

[0018] 3. This invention suppresses NO at its source through the segmented air distribution technology of the low-NOx combustion control module. x Generate, make NO x Emissions below 50 mg / Nm3 It is far superior to current environmental standards, helping enterprises achieve green manufacturing and avoid environmental compliance risks.

[0019] 4. This invention reduces kiln turnaround time by 70% through the one-click switching function of the process parameter group in the flexible production control module. It can efficiently adapt to the flexible production needs of multiple categories and small batches, and improve the market responsiveness of enterprises.

[0020] 5. This invention deeply integrates the segmented physical isolation structure with the intelligent control powertrain, achieving synergistic optimization of structure and control. The technical solution is complete and rationally designed, requiring no large-scale modification of traditional kiln production lines, and is easy to promote and apply in industrialization. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the segmented combustion kiln provided in an embodiment of the present invention.

[0022] Figure 2 This is a schematic diagram of a single-temperature zone combustion structure provided in an embodiment of the present invention.

[0023] Figure 3 This is a logic block diagram of the powertrain control system provided in an embodiment of the present invention.

[0024] Figure 4 This is a schematic diagram of an air curtain sealing partition structure provided in an embodiment of the present invention.

[0025] In the diagram, 1-preheating section, 2-firing section, 3-insulation section, 4-cooling section, 5-air curtain sealing partition, 6-dedicated burner group, 7-K-type temperature sensor, 8-oxygen content sensor, 9-combustion air duct, 10-exhaust duct, 11-material conveying channel, 12-control power assembly cabinet. 20-Kiln cavity, 21-Sectional independent burner, 22-Fuel inlet, 24-Combustion air inlet, 26-Flue gas outlet, 27-Waste heat recovery interface; 31-Temperature sensor, 32-Oxygen content sensor, 33-Pressure sensor, 34-PLC / controller, 35-PID temperature closed-loop module, 36-Air-fuel ratio optimization module, 37-Micro differential pressure control module, 38-Low-NOx combustion control module, 39-Burner actuator, 40-Fan speed control unit, 41-Air curtain fan, 42-Smoke exhaust valve, 43-Human-machine interface unit; 51-Top air curtain main pipe, 52-Air curtain nozzle, 53-High-pressure air curtain fan, 54-Ceramic fiber flexible sealing plate, 55-Kiln lining refractory layer, 56-Material channel. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0027] Example 1

[0028] This embodiment provides a segmented combustion kiln structure and control power assembly, the specific composition and implementation method of which are as follows: (1) Construction of the main kiln body Along the direction of ceramic green body conveying, the kiln body is divided into four independent temperature zones: preheating zone 1, firing zone 2, heat preservation zone 3, and cooling zone 4. A double isolation structure consisting of an air curtain sealing partition 5 and a flexible ceramic fiber sealing plate is installed between the zones. The high-pressure air curtain fan of the air curtain sealing partition 5 outputs a pressure of 4000 Pa, and 12 high-pressure air curtain nozzles are evenly distributed along the width of the kiln to form a dense air curtain barrier. The flexible sealing plate is made of alumina ceramic fiber material resistant to 1450℃, filling the mechanical gaps between the zones to achieve physical isolation between each temperature zone.

[0029] Regarding the main body of the kiln, such as Figure 1 As shown, the main body of the kiln is also equipped with a combustion air duct 9, a flue gas duct 10, and a material conveying channel 11.

[0030] To better understand the structure of the air curtain sealing partition 5, a cross-sectional view of the air curtain sealing partition 5 is provided, as follows: Figure 4 As shown, 51 represents the top air curtain main pipe, 52 is the air curtain nozzle, 53 is the high-pressure air curtain fan, 54 is the ceramic fiber flexible sealing plate, 55 is the kiln lining refractory layer, and 56 is the material channel.

[0031] (2) Segmented combustion structure configuration

[0032] Each temperature zone is independently equipped with a dedicated burner group 6: the preheating section is equipped with 2 regenerative burners, which use the waste heat of flue gas to preheat the combustion air to 850℃; the firing section is equipped with 4 high-speed temperature-regulating burners with a combustion speed of 180m / s, which can meet the high-temperature firing requirements of ceramics at 1200-1350℃; the heat preservation section is equipped with 2 low-speed stable combustion burners to ensure that the temperature of the heat preservation section is stable at 1100℃±1℃; and the cooling section is equipped with 4 variable frequency forced air cooling fans to achieve uniform cooling of the ceramic body from 1100℃ to room temperature.

[0033] To better understand the segmented combustion structure, a single-zone combustion structure is provided, such as... Figure 2As shown, 20 is the kiln cavity, 21 is the segmented independent burner, 22 is the fuel inlet, 23 is the kiln temperature measuring point, 24 is the combustion air inlet, 26 is the flue gas outlet, and 27 is the waste heat recovery interface.

[0034] (3) Control powertrain deployment

[0035] like Figure 1 As shown in the figure, 12 is the control power assembly cabinet, used to realize intelligent control of the kiln. Figure 3 As shown, the PLC / controller 34 is the control center for the powertrain cabinet and is connected to the human-machine interface unit 43. The specific deployment of the various modules controlling the powertrain (PID temperature closed-loop module 35, air-fuel ratio dynamic optimization module 36, micro-pressure differential control module 37, and low-NOx combustion control module 38) is as follows: PID temperature closed-loop module: Four K-type temperature sensors 7 are arranged along the height and length directions in each temperature zone to collect temperature data in real time. The burner power is automatically adjusted by the PID algorithm of the PLC controller. The burner execution unit 39 controls the temperature fluctuations of the preheating section 1, firing section 2, heat preservation section 3, and cooling section 4 to ±1.2℃, ±1.5℃, ±1.0℃, and ±2.0℃, respectively.

[0036] Air-fuel ratio and oxygen content control: Zirconia oxygen content sensors 8 are arranged in each temperature zone to control the oxygen concentration in the kiln at 4%. The air-fuel ratio dynamic optimization module adjusts the air distribution according to the temperature and oxygen content data, and the air-fuel ratio control accuracy is ±1.5%.

[0037] Micro differential pressure control module: The PLC controller adjusts the exhaust valve 42 and air inlet valve of each temperature zone to make the differential pressure gradient between the preheating section and the firing section, the firing section and the heat preservation section, and the heat preservation section and the cooling section 8Pa, 10Pa and 6Pa respectively, so as to block the crossflow of heat and flue gas.

[0038] Low-NOx combustion control module: Employs segmented air distribution technology, specifically controlled by the fan speed regulation unit 40. The air coefficient in the main combustion zone is controlled at 0.8, and the supplementary air in the burnout zone brings the total air coefficient to 1.1, achieving NOx control. x Emissions are controlled at 45 mg / Nm³.

[0039] Waste heat recovery: A tubular flue gas waste heat recovery device is installed at the exhaust end to recover the heat of the flue gas to preheat the combustion air, with a waste heat recovery rate of 85%.

[0040] Flexible production control: The firing process parameter groups for three types of products, namely daily-use ceramics, building ceramics and art ceramics, are stored in the human-machine interaction unit 43, which supports one-click switching and reduces the production adjustment time from the traditional 8 hours to 2 hours.

[0041] (4) Implementation effect verification

[0042] The segmented combustion kiln structure and control power assembly provided in this embodiment were applied to a ceramic production line and compared with a traditional integrated kiln. The results are shown in Table 1.

[0043] Table 1. Performance comparison between the kiln of the present invention and a conventional kiln in Example 1.

[0044] The test results show that the present invention effectively solves the core pain points of traditional ceramic kilns, such as unclear temperature zones, excessive energy consumption, excessive emissions, and insufficient flexibility. It achieves high-precision, low-energy consumption, low-emission, and flexible production in the ceramic firing process, with significant application effects.

[0045] Example 2

[0046] This embodiment provides another specific application of a segmented combustion kiln structure and control power assembly, particularly suitable for firing large-scale, high-value-added industrial ceramics (such as alumina ceramic rollers and silicon carbide square beams), where more stringent requirements for temperature uniformity and product consistency are needed. The specific implementation steps are as follows: (1) Construction of the main kiln body The kiln body is divided into a preheating section 1, a firing section 2, a heat preservation section 3, and a cooling section 4 along the material conveying direction, with a total length of 42 meters, including a 9-meter preheating section, a 12-meter firing section, a 9-meter heat preservation section, and a 12-meter cooling section. The sections are also equipped with a double isolation system consisting of an air curtain sealing partition 5 and a flexible ceramic fiber sealing plate. The output pressure of the high-pressure blower for the air curtain sealing is increased to 5500Pa, and the number of air curtain nozzles 52 is increased to 16 per section to form a stronger high-pressure air curtain barrier, completely blocking the crossflow of high-temperature flue gas. The flexible sealing plate uses mullite ceramic fiber with a temperature resistance of 1500℃.

[0047] (2) Segmented combustion structure configuration

[0048] Each temperature zone is equipped with its own dedicated burner group, and the burner power and layout are optimized for larger products: Preheating section: Equipped with 4 regenerative burners (each with a power of 120kW), which utilize the waste heat of flue gas to preheat the combustion air to 900℃, effectively shortening the preheating time.

[0049] Firing section: Equipped with 8 high-speed temperature-regulating burners (combustion speed ≥200m / s), arranged in two staggered layers to achieve rapid heating and precise temperature control within ±1.0℃ in the high-temperature zone (firing temperature 1380℃-1450℃).

[0050] Insulation section: Equipped with 4 low-speed stable combustion burners and an additional infrared radiation plate, the temperature fluctuation of the insulation section is controlled within ±0.8℃, ensuring the full development of the product's crystal structure.

[0051] Cooling section: Equipped with 6 variable frequency forced air cooling fans and set up segmented slow cooling zones (first slow cooling to 800℃, then rapid cooling to room temperature), effectively avoiding cracking of large-sized products due to rapid cooling.

[0052] (3) Control powertrain deployment

[0053] Temperature PID closed-loop control: Five K-type temperature sensors are arranged along the height (upper, middle, and lower layers) in each temperature zone, and one K-type temperature sensor is arranged every 2 meters along the length, for a total of 36 temperature measurement points. The burner power is automatically adjusted by the PLC controller using a fuzzy PID algorithm to control the temperature fluctuations in the preheating section, firing section, heat preservation section, and cooling section within ±1.5℃, ±1.0℃, ±0.8℃, and ±2.0℃, respectively.

[0054] Air-fuel ratio and oxygen content control: Zirconia oxygen content sensors are installed in each temperature zone to precisely control the oxygen concentration in the kiln between 2.8% and 3.5% (slightly lower than usual to reduce the oxidizing atmosphere). The air-fuel ratio dynamic optimization module adjusts the air distribution based on real-time data, with a control accuracy of ±1.2%.

[0055] Micro-pressure differential control: The exhaust valves and air inlet valves of each temperature zone are finely adjusted by the PLC controller to make the pressure differential gradients between the preheating section and the firing section, the firing section and the heat preservation section, and the heat preservation section and the cooling section 12Pa, 15Pa, and 10Pa respectively, forming a stronger stepped pressure differential and completely blocking crossflow.

[0056] Low-NOx combustion control: Staged combustion + flue gas recirculation technology is adopted, the air coefficient in the main combustion zone is controlled at 0.75, and the make-up air in the burnout zone brings the total air coefficient to 1.05. In addition, 10% low-temperature flue gas is introduced into the combustion zone to further suppress thermal NOx. x Generate, achieve NO x Emissions are below 35 mg / Nm³.

[0057] Waste heat recovery: A high-efficiency finned tube flue gas waste heat recovery device is installed at the flue gas exhaust end to recover the heat of the flue gas for preheating the combustion air and materials in the drying section, with a waste heat recovery rate of 88%.

[0058] Flexible production control: The human-machine interaction unit stores the firing process parameter groups for five types of products, including alumina rollers, silicon carbide square beams, cordierite mullite saggers, etc., and supports one-click switching, reducing the production changeover adjustment time from the traditional 12 hours to 3 hours.

[0059] (4) Implementation effect verification

[0060] The segmented combustion kiln structure and control power assembly of this embodiment were applied to an industrial ceramics production enterprise and compared with a traditional integrated kiln of the same scale. After three months of continuous operation, the main results are shown in Table 2. Table 2. Performance comparison between the kiln of the present invention and a conventional kiln in Example 2.

[0061] Furthermore, the bending strength of the fired alumina ceramic rollers was tested, with an average value of 68 MPa, which is 30.8% higher than that of products fired in traditional kilns (52 MPa). The oxidation resistance test (1200℃×100h) of the silicon carbide square beams showed a weight loss rate of only 0.12%, far superior to the 0.35% of traditional products. The results indicate that this embodiment can significantly improve the firing quality and production efficiency of high value-added industrial ceramics.

[0062] In summary, Example 2 further demonstrates the wide adaptability and excellent performance of the segmented combustion kiln structure and control power assembly of the present invention under different process requirements and product types, and has extremely high industrial promotion value.

[0063] Comparative Example 1

[0064] This comparative example provides a traditional integrated kiln structure and a simplified control system for comparison with the embodiments of the present invention, in order to verify the technical effects of the present invention. This comparative example adopts a conventional industrial kiln design, as detailed below: (1) Main structure of the kiln The kiln body is a single-cavity structure (36 meters long, 2.5 meters wide, and 1.8 meters high). Along the material conveying direction, it is divided into preheating, firing, heat preservation, and cooling zones only by process control, but there are no physical barriers between the zones (no air curtain seals or flexible sealing structures). All zones share the same kiln space, and heat and flue gas can flow freely laterally.

[0065] (2) Combustion system configuration

[0066] The entire kiln is equipped with only 6 ordinary high-speed burners (150kW each), evenly distributed on both sides of the kiln, without dedicated burner groups for each temperature zone. All burners share the same combustion air duct and fuel duct, making independent power adjustment for each zone impossible. The cooling zone only has a natural air inlet, without a forced air cooling system.

[0067] (3) Control system

[0068] The system uses conventional temperature control instruments, with only three thermocouples located in the middle of the kiln. Temperature data is fed back to the PLC, which uniformly adjusts the fuel valve openings of all burners (single-loop control). It lacks a dynamic air-fuel ratio optimization module, a micro-pressure differential anti-interference module, a real-time oxygen content feedback module, a low-NOx combustion control module, and a flexible production control module. The combustion air volume is manually set and cannot be automatically adjusted according to kiln conditions. There is no waste heat recovery device.

[0069] (4) Operating parameters and effects

[0070] Using the same ceramic blank (daily-use ceramic) as in Example 1, the test was conducted continuously for 7 days at the same output. The results are shown in Table 3: Table 3 Performance comparison between Example 1 and Comparative Example 1

[0071] Specific problem manifestations: Severe crosstalk in temperature zones: High-temperature flue gas from the firing section directly enters the preheating and heat preservation sections, causing temperature fluctuations in the preheating section to reach ±35℃ and in the heat preservation section to reach ±28℃. This results in numerous defects in the ceramic blanks, such as cracking, deformation, and color difference, with a scrap rate as high as 27.7%.

[0072] Low combustion efficiency: In order to maintain the required temperature of the firing section (1250°C), it is necessary to increase the total fuel supply, which causes the preheating section and the heat preservation section to overheat. In addition, cold air needs to be introduced for forced cooling, resulting in extremely low thermal efficiency. The gas consumption per unit product is 42% higher than that of Example 1.

[0073] Environmental non-compliance: Due to the lack of low-NOx combustion control and the centralized arrangement of burners leading to localized high-temperature zones, thermal NOx emissions are high. x Large quantities were generated, with an emission concentration of 168 mg / Nm³, far exceeding the 100 mg / Nm³ limit stipulated in the National Standard for Pollutant Emission from Ceramic Industry (GB 25464-2010), posing a risk of environmental penalties.

[0074] Inability to produce flexibly: When switching products, process parameters need to be adjusted manually step by step, and repeated firing tests are required. The production switchover time is as long as 9 hours, and the pass rate is only about 65%, which seriously restricts the company's ability to accept orders for multiple varieties in small batches.

[0075] A comparison of Comparative Example 1 with Embodiments 1 and 2 of this invention reveals that traditional integrated kilns, lacking physical segmentation and isolation structures, independent temperature zone combustion units, and intelligent closed-loop control power systems, exhibit significant deficiencies in temperature control accuracy, energy consumption, emission standards, and production flexibility. Consequently, they fail to meet the modern ceramic industry's demands for high-quality, low-energy, green, and flexible production. This invention, through synergistic innovation in structure and control, fundamentally addresses these pain points, achieving unexpected technical benefits.

[0076] The specific embodiments described above should not be construed as limiting the scope of protection of this invention. Any alternative modifications or variations made to the embodiments of this invention by those skilled in the art will fall within the scope of protection of this invention. All aspects not detailed in this invention are well-known to those skilled in the art.

Claims

1. A segmented combustion kiln structure and control power assembly, characterized in that, The system includes a kiln body, a segmented combustion structure, and a control and power assembly. The kiln body is divided into four temperature zones along the material conveying direction: a preheating zone, a firing zone, a heat preservation zone, and a cooling zone. Each zone is separated by an air curtain sealing barrier and a flexible sealing structure to achieve physical isolation between the temperature zones. The segmented combustion structure includes a dedicated burner group configured independently for each temperature zone. The control and power assembly includes a temperature PID closed-loop control module, an air-fuel ratio dynamic optimization module, a micro-pressure differential anti-interference module, and an oxygen content real-time feedback module to achieve intelligent closed-loop control of the entire kiln process.

2. The segmented combustion kiln structure and control power assembly according to claim 1, characterized in that, The air curtain sealing partition includes multiple high-pressure air curtain nozzles arranged along the width of the kiln. The high-pressure air curtain nozzles are connected to a high-pressure blower to form an air curtain barrier by outputting high-pressure airflow. The flexible sealing structure uses high-temperature resistant ceramic fiber seals with a temperature resistance of not less than 1400℃ to fill the mechanical gaps between sections.

3. The segmented combustion kiln structure and control power assembly according to claim 1, characterized in that, The dedicated burner group includes a high-speed temperature-regulating burner, a regenerative burner, and a low-speed stable-burner; wherein, the preheating section is equipped with a regenerative burner, the firing section is equipped with a high-speed temperature-regulating burner, the heat preservation section is equipped with a low-speed stable-burner, and the cooling section is equipped with an independent forced air cooling system.

4. The segmented combustion kiln structure and control power assembly according to claim 1, characterized in that, The temperature PID closed-loop control module arranges 3-5 K-type temperature sensors along the height and length directions in each temperature zone to collect kiln temperature data in real time, and automatically adjusts the combustion power of the burner in the corresponding temperature zone through the PID algorithm to control the temperature fluctuation of each temperature zone within ±1.5℃.

5. The segmented combustion kiln structure and control power assembly according to claim 1, characterized in that, The control powertrain also includes a waste heat recovery system, which recovers heat from each section of flue gas through a flue gas waste heat recovery device to preheat the combustion air.

6. The segmented combustion kiln structure and control power assembly according to claim 1, characterized in that, The powertrain control system also includes a low-NOx combustion control module, which employs segmented air distribution technology to divide the combustion process into a main combustion zone and a burnout zone. The main combustion zone uses fuel-rich combustion to suppress NOx. x The combustion zone is filled with air to bring the total air coefficient to 1.

1.

7. The segmented combustion kiln structure and control power assembly according to claim 1, characterized in that, The control powertrain also includes a flexible production control module, which stores firing process parameter sets for multiple types of ceramics and supports one-click switching of firing process parameter sets.

8. The segmented combustion kiln structure and control power assembly according to claim 1, characterized in that, The micro-pressure differential anti-interference module controls the micro-positive pressure in each temperature zone to create a stable pressure differential gradient of 5-10 Pa between adjacent temperature zones, thereby further blocking the crossflow of heat and flue gas.

9. The segmented combustion kiln structure and control power assembly according to claim 1, characterized in that, The real-time oxygen content feedback module is equipped with a zirconia oxygen content sensor in each temperature zone to monitor the oxygen concentration in the kiln in real time and control the oxygen content within the range of 3%-5% in order to dynamically optimize the air distribution and achieve a balance between low-NOx combustion and high-efficiency combustion.

10. The segmented combustion kiln structure and control power assembly according to claim 1, characterized in that, The air-fuel ratio dynamic optimization module dynamically adjusts the air-fuel ratio based on real-time temperature and oxygen content data for each temperature zone, with an air-fuel ratio control accuracy of ±2%, to ensure complete combustion and avoid over-combustion.

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