A cleaning system and method for the main flue of a glass melting furnace.

Abstract

This invention discloses a cleaning system and method for the main flue of a glass melting furnace, belonging to the field of glass production equipment maintenance technology. The cleaning system includes: a traction rope, a rigid draggage, a first traction mechanism located outside the front end of the main flue, and a second traction mechanism located outside the end of the main flue. The two ends of the traction rope are connected to the front and rear ends of the rigid draggage, respectively, and are connected to the two traction mechanisms. The two traction mechanisms work together to drive the rigid draggage to reciprocate within the main flue. The cleaning method includes: opening a working hole at the end of the main flue; using a rigid connecting pipe to guide the traction rope through the flue; placing the rigid draggage into the flue and connecting it to the traction rope; and using the two traction mechanisms to drive the rigid draggage to reciprocate to push away accumulated ash. This invention does not require changes to the existing main flue structure and can clean the accumulated ash in the main flue during continuous furnace production without interruption, reducing the frequency of the induced draft fan and natural gas energy consumption, and ensuring stable kiln pressure.

Description

Technical Field

[0001] This invention relates to the field of glass production equipment maintenance technology, and more specifically, to a cleaning system for the main flue of a glass melting furnace and a cleaning method using the system. Background Technology

[0002] Glass melting furnaces are the core thermal equipment in flat glass production lines. During the continuous production of flat glass, the flue gas and fine dust generated by the furnace combustion are drawn by the induced draft fan and pass sequentially through the regenerator, branch flue, main flue, kiln pressure regulating gate, waste heat boiler, and desulfurization and denitrification device, and are finally discharged into the atmosphere through the chimney.

[0003] The production cycle of a glass melting furnace is typically 8 to 12 years. During this period, the furnace operates continuously for 24 hours, and the large amount of waste gas ash and dust generated by combustion accumulates at the bottom of the main flue. Over time, this ash gradually occupies the effective cross-sectional area of ​​the flue gas flow, reducing the effective flow section and increasing the resistance to gas flow. In the long run, flue blockage can lead to a series of process problems: firstly, blockage reduces the draft of the induced draft fan and increases the furnace pressure, affecting the combustion stability inside the furnace; secondly, blockage at the branch flue inlets prevents independent adjustment of the flue gas flow in individual furnaces, resulting in chaotic combustion atmospheres within each furnace and severely impacting glass melting quality and energy consumption.

[0004] The main flue of a glass melting furnace has unique structural features and a specific working environment: it is typically over 25 meters long, maintains an internal temperature of around 650°C, and has varying numbers of branch flues and furnace support columns on both sides. These structural characteristics prevent the installation of cleaning holes on the sides of the main flue, necessitating cleaning operations to be performed from either the end or the front of the flue.

[0005] Cleaning ash accumulation in the main flue without interrupting production has long been considered a technical challenge in this field. In the prior art, Chinese patent CN103073171A discloses a "non-stop ash cleaning device for flat glass melting furnace flues." This technical solution requires redesigning the flue structure during cold-state construction, pre-setting an ash accumulation trough at the bottom of the main flue, and installing a movable baffle at the ash accumulation trough. However, this solution has the following shortcomings:

[0006] First, the pre-set ash accumulation trough will increase the cross-sectional area of ​​the flue in the initial state. In the early stage of kiln operation, when the flue has not yet been blocked by ash accumulation, the increased cross-sectional area will lead to a decrease in the resistance of flue gas flow and a relative excess of the induced draft fan. This will require the induced draft fan to increase its frequency or power to maintain normal kiln pressure and flue gas flow, resulting in additional power consumption.

[0007] Secondly, the flue is a one-way, enclosed space. During normal production, the sealing and insulation of the flue are crucial for maintaining the stability of the thermal regime. Installing movable baffles at the bottom of the flue poses an extremely severe challenge to the flue's sealing and insulation performance. Air leakage and heat loss can easily occur at the movable baffles, affecting kiln pressure stability and thermal efficiency.

[0008] Third, this scheme must be pre-designed during the flue construction stage and cannot be applied to existing furnace flues that are already in operation, thus limiting its application scope.

[0009] Technological biases existing in the prior art: For a long time, the following technical biases have existed in this field: First, it is believed that flue cleaning must be carried out during cold repairs or shutdowns of the melting furnace, and that it is impossible to effectively clean the ash inside the main flue while the furnace is running. Second, it is believed that to achieve non-stop cleaning, ash accumulation troughs or cleaning ports must be pre-designed during the flue design phase, thus altering the original structure of the flue. Third, it is believed that drilling holes in the flue wall during high-temperature operation will damage the flue's sealing, leading to uncontrolled kiln pressure, cold air infiltration affecting combustion, and even causing safety accidents.

[0010] Therefore, how to safely and efficiently remove the long-term deposited ash in the main flue without changing the existing main structure of the flue or affecting the continuous production of the melting furnace has become a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0011] The purpose of this invention is to overcome the shortcomings of existing glass melting furnace main flue cleaning methods, which require cold repair or shutdown, require pre-setting ash accumulation troughs during flue construction to change the original structure, and cannot perform online cleaning of existing melting furnaces without shutting down production. This invention provides a cleaning system and method for the main flue of a glass melting furnace.

[0012] In a first aspect, the present invention provides a cleaning system for the main flue of a glass melting furnace, comprising: A traction rope, the length of which is set to be able to run through the entire main flue; A rigid draggage, having a predetermined weight, is used to be inserted into the main flue and to push away accumulated ash during movement; The first traction mechanism is located outside the front end of the main flue; The second traction mechanism is located outside the end of the main flue; The first end of the traction rope is connected to the front end of the rigid towing device and is connected to the first traction mechanism, and the second end of the traction rope is connected to the rear end of the rigid towing device and is connected to the second traction mechanism. The first traction mechanism and the second traction mechanism are configured to work together to drive the rigid drag to reciprocate within the main flue.

[0013] The aforementioned ash removal system establishes a mechanical ash removal system in the main flue of a glass melting furnace, which is characterized by high temperature, long distance, and inaccessibility from the side. This system involves rope threading, placement of a drag attachment, and reciprocating traction, achieving efficient ash removal without altering the original flue structure or interrupting production. The traction rope transmits the traction force, while the rigid drag attachment, relying on its own weight, pushes the accumulated ash against the bottom of the flue. The traction mechanisms at both ends work together to achieve reciprocating movement. The three components cooperate and work together to solve the technical problem of effectively cleaning the ash inside the main flue without interrupting production, a problem that cannot be effectively addressed in existing technologies.

[0014] Preferably, the rigid draggage is an I-beam, a rail, a square steel bar, or a cast iron block; the self-weight of the rigid draggage is capable of pushing or scraping away accumulated dust during movement, and the traction rope is a heat-resistant stainless steel wire rope.

[0015] The rigid towing device adopts the above selection, which not only ensures sufficient pushing force, but also facilitates insertion and removal from the working hole; the heat-resistant stainless steel wire rope ensures long-term reliability in high-temperature environments of 650℃.

[0016] Preferably, the system further includes a crossbeam for mounting outside the front end of the main flue, a fixed pulley mounted on the crossbeam, and the crossbeam is configured to move along the width direction of the main flue to adjust the horizontal position of the fixed pulley; the traction rope of the first traction mechanism is deflected by the fixed pulley and connected to the front end of the rigid drag.

[0017] In this invention, a crossbeam located at the front end of the main flue is configured to move along the width of the main flue, thereby driving a fixed pulley mounted on the crossbeam to move horizontally. This structure allows the operator to flexibly adjust the alignment of the traction rope according to the actual distribution of ash inside the main flue, ensuring that the rigid draggage accurately targets areas of concentrated ash (such as the middle of the main flue) during reciprocating movement, avoiding unnecessary travel and improving cleaning efficiency. Simultaneously, the movable crossbeam allows the same cleaning system to adapt to main flues of different widths, enhancing the system's versatility and applicability.

[0018] Preferably, it also includes multiple rigid connecting pipes and an adjustable gate; the rigid connecting pipes are detachably connected by threads to guide the traction rope through the main flue; the gate is installed at the working hole opened on the end wall of the main flue, and the opening and closing of the gate can control the kiln pressure stability during the ash removal process.

[0019] Multiple rigid connecting pipes are detachably connected via threaded joints, solving the problem of threading traction ropes through high-temperature flues exceeding 25 meters in length where side operation is not possible. Utilizing the straightness and connectability of the rigid pipes, the rope is pushed from the end to the front and then pulled back to guide it through the entire length. An adjustable gate valve is installed at the operating port, allowing for real-time adjustment of the opening based on kiln pressure changes. The gate valve is opened wider when inserting the drag tool or removing accumulated ash, and closed narrower when kiln pressure fluctuates, maintaining kiln pressure fluctuations within the allowable range. This is a crucial guarantee for achieving uninterrupted ash removal.

[0020] Preferably, the ratio of the width of the rigid drag to the width of the main flue is 1:3 to 1:1.5.

[0021] In a preferred embodiment, the width of the rigid draggage is smaller than the width of the main flue, but greater than or equal to the width of the ash accumulation area in the middle of the main flue. For example, when the width of the main flue is 4 meters, a 2-meter-wide I-beam is used as the rigid draggage. In this case, the width of the rigid draggage is approximately half the width of the flue, which can cover the main ash accumulation area in the middle of the main flue in one go, achieving effective ash removal without repeated movement along the width direction. At the same time, since the width of the rigid draggage is smaller than the width of the flue, gaps are left between its sides and the flue sidewalls, avoiding contact and friction between the draggage and the refractory material of the flue inner wall, thus protecting the flue inner wall and preventing the draggage from getting stuck.

[0022] In a second aspect, the present invention provides a method for cleaning the main flue of a glass melting furnace using the aforementioned cleaning system, comprising the following steps: Opening procedure: Open a working hole in the end wall of the main flue that connects to the inside of the flue; Traction establishment steps: Use the ash removal system to set up a traction rope that runs through the entire main flue, and make sure that both ends of the traction rope are located outside the main flue; Insertion step: Insert the rigid draggage into the main flue through the working hole, and connect the two ends of the traction rope to the front end and rear end of the rigid draggage respectively; Ash removal step: The first traction mechanism and the second traction mechanism work together to control the traction rope, so that the rigid draggage moves back and forth along its length inside the main flue, thereby pushing the ash accumulated at the bottom of the main flue to the preset ash removal outlet and removing it.

[0023] This invention utilizes the coordinated deployment and retraction of traction mechanisms at both ends to allow a rigid tow attachment to reciprocate forward or backward along the length of the main flue. During cleaning, accumulated ash is pushed to both ends of the main flue and removed through cleaning ports or working holes located at both ends. This bidirectional pushing cleaning method offers the following advantages compared to traditional unidirectional cleaning: First, it avoids excessive ash accumulation at one end of the flue, preventing proper discharge; second, it shortens the single pushing distance of the ash, reducing the traction load; and third, cleaning operations in both directions can be completed with a single rope threading, improving operational efficiency.

[0024] Preferably, the traction establishment step specifically includes: The multiple rigid connecting pipes are connected in sequence, inserted into the main flue through the working hole, and pushed forward to the front end area of ​​the main flue; The end of the rigid connecting pipe is led out from the side wall of the main flue, and the traction rope is fixedly connected to the end. Pull back the rigid connecting pipe to bring the traction rope in and through the entire main flue.

[0025] Through the above steps, this invention enables the rapid and reliable establishment of a traction system in long, high-temperature flues where it is impossible to thread ropes directly from the side. The straightness and connectability of the rigid connecting pipe make the rope threading operation unrestricted by the length of the flue and the high-temperature environment, making the operation simple and reliable.

[0026] Preferably, the working hole is located at the bottom of the end wall of the main flue, and the opening of the working hole is adjusted by the gate to control the kiln pressure in the main flue during the ash removal process.

[0027] The working hole is located at the bottom of the end wall, facilitating the insertion of the rigid draggage and the natural discharge of accumulated ash. The gate's opening adjustment function allows operators to adjust it in real time according to changes in kiln pressure, ensuring smooth ash removal operations while keeping kiln pressure fluctuations within the allowable range of the process.

[0028] Preferably, the reciprocating movement of the rigid drag is achieved by the coordinated winding and unwinding of two winches, and the moving speed of the rigid drag is 0.1-0.5 m / s.

[0029] Preferably, the preset cleaning outlet includes: the working hole itself, and / or an auxiliary cleaning hole opened at the front end or side of the main flue.

[0030] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention achieves safe and efficient cleaning of ash accumulation inside the main flue by opening a temporary working hole at the end of the main flue, guiding the rope through a rigid connecting pipe, and using a self-weight rigid dragger for double-end reciprocating movement. This is done without altering the existing flue structure or interrupting normal furnace production. Taking a glass melting furnace with a daily output of 600 tons as an example, existing shutdown cleaning methods require approximately 5 days of shutdown, resulting in a loss of about 3,000 tons of glass production. In contrast, the output of this invention remains unaffected during cleaning, resulting in a significant annualized output advantage. Furthermore, this invention overcomes the long-standing technical bias in the field that ash accumulation in the main flue cannot be effectively cleaned without interrupting production, and that ash accumulation troughs must be pre-designed during the flue design phase for uninterrupted cleaning. It has a wide range of applications, especially suitable for existing melting furnaces already in operation, requiring no structural modifications to the existing flue, only the opening of a temporary working hole, significantly reducing the implementation threshold and modification costs.

[0031] This invention effectively removes accumulated ash from the bottom of the main flue by using a rigid dragger to push it back and forth, restoring the effective flow cross-section of the flue. Example data shows that after cleaning, the branch flue temperatures became more uniform—the temperature of branch flue #1 decreased from 707℃ to 655℃ (a decrease of 52℃), and the temperature of branch flue #5 increased from 592℃ to 695℃ (an increase of 103℃). The temperatures of each branch flue tended to be more balanced, and the exhaust gas volume of individual small furnaces could be precisely adjusted through the branch flue dampers; the frequency of the waste heat induced draft fan decreased from 45Hz to 40.5Hz (a decrease of approximately 10%); and the natural gas consumption per ton of glass decreased from 190m³ / ton of glass to 186m³ / ton of glass (a decrease of approximately 2.1%). These data indicate that this invention not only solves the flue blockage problem but also optimizes the flue gas flow distribution and significantly reduces energy consumption. These effects are beyond what those skilled in the art could expect based on "removing accumulated ash and restoring the ventilation cross-section."

[0032] This invention eliminates the need for shutdown cycles (glass melting furnaces operate continuously for 24 hours a day for about 10 years, generally without interruption unless a major accident occurs; even then, only glass production stops, and the furnace temperature doesn't drop). Operators can schedule online cleaning whenever process parameters deteriorate, based on the actual ash accumulation in the flue. Cleaning every 6-12 months keeps the ash thickness consistently low, preventing the cumulative effect of flue blockage. In contrast, traditional cleaning methods are limited by shutdown cycles, typically requiring a 10-year shutdown. Furthermore, the crossbeams, pulleys, and winches in this invention can be retained on-site after initial installation, with marked work holes eliminating the need for re-threading traction ropes during subsequent cleaning. This achieves one-time investment and multiple reuses, resulting in extremely low amortization costs per cleaning cycle. The long-term overall economic benefits are significantly superior to shutdown-based cleaning methods. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the overall structure of the dust removal system of the present invention.

[0034] Figure 2 This is a partial schematic diagram of the side cross-sectional view of the dust removal system of the present invention.

[0035] Marked in the image: 1-Traction rope; 2-Rigid draggage; 3-First traction mechanism; 4-Second traction mechanism; 5-Crossbeam; 6-Fixed pulley; 7-Branch flue; 8-Ash removal hole; 9-Working hole; 100-Main flue. Detailed Implementation

[0036] The present invention will now be described in further detail with reference to specific embodiments. However, this should not be construed as limiting the scope of the present invention to the following embodiments; all technologies implemented based on the content of the present invention fall within the scope of the present invention.

[0037] Example 1 This embodiment provides a ash removal system for the main flue of a glass melting furnace, such as... Figure 1-2 As shown.

[0038] like Figure 1 As shown, the dust removal system mainly includes: traction rope 1, rigid drag 2, first traction mechanism 3, second traction mechanism 4, crossbeam 5, and fixed pulley 6.

[0039] The traction rope 1 is designed to be long enough to extend through the entire main flue 100. The traction rope 1 transmits traction force, transferring the power generated by the first traction mechanism 3 and the second traction mechanism 4 to the rigid draggage 2, thereby driving the rigid draggage 2 to move within the main flue 100. Preferably, the traction rope 1 is made of heat-resistant stainless steel wire rope with a diameter of approximately φ10mm, and its total length should be greater than twice the length of the main flue 100 to ensure it can extend through the flue and allow sufficient operational margin. The temperature resistance of the traction rope 1 should not be lower than the highest operating temperature within the main flue 100 to ensure it does not break or degrade during long-term use in high-temperature environments.

[0040] In one or more embodiments, the traction rope 1 may also be made of other high-temperature resistant materials, such as nickel-based alloy steel wire rope, ceramic fiber rope, etc., as long as its tensile strength and temperature resistance meet the working conditions within the main flue 100.

[0041] A rigid draggage 2, having a predetermined weight, is used to insert into the main flue 100 and push the accumulated ash 200 during movement. The rigid draggage 2 is the core actuator of this invention. It adheres to the bottom of the main flue 100 under its own weight and moves along the length of the main flue 100 under the influence of the traction rope 1, thereby pushing the accumulated ash 200 deposited at the bottom of the main flue 100 forward or backward. The rigid draggage 2 is configured not to form a sealed fit with the inner wall of the main flue 100 during movement; it only needs to contact the accumulated ash 200 at the bottom of the flue. The advantages of this design are: firstly, it avoids friction and damage between the rigid draggage 2 and the refractory material of the flue inner wall, extending the service life of both the flue inner wall and the draggage itself; secondly, the absence of a sealed fit means that the draggage's dimensions do not need to precisely match the flue cross-section, reducing the requirements for machining accuracy and avoiding safety accidents caused by draggage jamming.

[0042] Preferably, the rigid draggage 2 is an I-beam, a rail, a square steel bar, or a cast iron block. As a preferred embodiment, the rigid draggage 2 is an I-beam, with its width direction aligned with the width direction of the main flue 100, and the width of the I-beam being less than the width of the main flue 100. The specifications of the I-beam should be selected based on the actual width of the main flue and the ash accumulation distribution. For example, when the width of the main flue 100 is 3 meters and the ash accumulation is mainly concentrated in the central area, the rigid draggage 2 can use an I-beam with a width of 1.7 meters (such as a 1700×200×10mm specification, with a width of approximately 1.5-2.0 meters). In this case, the width of the rigid draggage 2 is approximately half the width of the flue, enabling it to cover the main ash accumulation area in the middle of the main flue 100 in a single pass, achieving effective ash removal without repeated movement along the width direction. Meanwhile, since the width of the rigid drag 2 (2 meters) is smaller than the width of the flue (3 meters), there is a gap of about 0.5 meters between its two sides and the side wall of the flue, which avoids contact and friction between the drag and the refractory material of the inner wall of the flue.

[0043] Preferably, the ratio of the width of the rigid draggaff 2 to the width of the main flue 100 is 1:3 to 1:1.5. More preferably, the ratio is 1:2. This ratio range is derived from the actual working condition that ash accumulation is mainly concentrated in the middle area of ​​the main flue: when the ratio is greater than 1:1.5 (i.e., the draggaff width exceeds 2 / 3 of the flue width), the gap between the two sides of the draggaff and the flue sidewall is too small, posing a risk of jamming; when the ratio is less than 1:3, a single push cannot effectively cover the central ash accumulation area, requiring multiple lateral adjustments, reducing cleaning efficiency. Therefore, configuring the width of the rigid draggaff 2 within the above-mentioned ratio range is an optimized balance between cleaning efficiency and anti-jamming safety.

[0044] The rigid draggage 2 should be heavy enough to push or scrape the ash accumulation 200 during movement without the need for additional pressing devices. The ash accumulation 200 is in a loosely packed or slightly sintered state under high temperatures, resulting in low shear strength. Under its own weight, the bottom edge of the rigid draggage 2 generates shear stress upon contact with the ash accumulation 200. When this shear stress exceeds the shear strength of the ash accumulation 200, it undergoes shear failure and is pushed forward or backward by the draggage. For an I-beam (2000×200×10mm specification) with a width of 2 meters and a height of approximately 0.2 meters, its weight is approximately 150-200 kg, sufficient to push a 0.3-0.8 meter thick ash layer inside the main flue 100.

[0045] A first traction mechanism 3 is located outside the front end of the main flue 100. A second traction mechanism 4 is located outside the end of the main flue 100. The first traction mechanism 3 and the second traction mechanism 4 provide power to drive the rigid towed device 2. The first end of the traction rope 1 is connected to the front end of the rigid towed device 2 and is connected to the first traction mechanism 3, and the second end of the traction rope 1 is connected to the rear end of the rigid towed device 2 and is connected to the second traction mechanism 4. The first traction mechanism 3 and the second traction mechanism 4 are configured to work together to drive the rigid towed device 2 to reciprocate within the main flue 100.

[0046] Preferably, both the first traction mechanism 3 and the second traction mechanism 4 are winches, such as electric winches or hydraulic winches. The two winches are respectively arranged at both ends of the main flue 100, and achieve the reciprocating movement of the rigid drag 2 by coordinating the winding and unwinding of the wire rope: when the front winch winds up the rope and the end winch unwinds the rope, the rigid drag 2 moves towards the front end; when the end winch winds up the rope and the front winch unwinds the rope, the rigid drag 2 moves towards the rear end. By controlling the winding and unwinding speed and force of the two winches, the moving speed and traction force of the rigid drag 2 can be precisely controlled.

[0047] A crossbeam 5 is used to be erected on the outer front end of the main flue 100. A fixed pulley 6 is installed on the crossbeam 5. The crossbeam 5 is configured to move along the width direction of the main flue 100 to adjust the horizontal position of the fixed pulley 6. The traction rope 1 of the first traction mechanism 3 is deflected by the fixed pulley 6 and connected to the front end of the rigid drag 2.

[0048] In this invention, the crossbeam 5 located at the front end of the main flue 100 is configured to move along the width of the main flue 100, thereby driving the fixed pulley 6 mounted on the crossbeam 5 to move horizontally. This structure allows the operator to flexibly adjust the alignment of the traction rope 1 according to the actual distribution of ash inside the main flue 100, ensuring that the rigid draggage 2 accurately targets the concentrated ash area during reciprocating movement, avoiding ineffective travel and improving cleaning efficiency. Simultaneously, the movable crossbeam 5 allows the same cleaning system to adapt to main flues of different widths, enhancing the system's versatility and applicability.

[0049] Preferably, the crossbeam 5 is made of 200mm channel steel or I-beam, and its length should be greater than the width of the main flue 100mm to allow it to be erected on the supporting structures on both sides of the flue. Sliding seats or rollers can be installed at both ends of the crossbeam 5 to facilitate movement along the width of the flue. Fixed pulleys 6 are welded or bolted to the center line of the crossbeam 5, or they can be installed on sliding seats on the crossbeam 5 to allow for fine-tuning of the position of the fixed pulleys 6 on the crossbeam 5.

[0050] In one or more embodiments, multiple fixed pulleys 6 may also be provided on the crossbeam 5, and the alignment position of the traction rope 1 can be adjusted by selecting fixed pulleys 6 at different positions.

[0051] The rigid connecting pipe is composed of multiple segments, which are detachably connected by threaded joints. The rigid connecting pipe guides the traction rope 1 through the main flue 100. In the main flue 100 of a glass melting furnace, the flue length typically exceeds 25 meters, the internal temperature reaches 650°C, and manholes cannot be opened on the sides due to limitations imposed by the branch flues 7 and columns, making direct insertion of the traction rope 1 extremely difficult. This invention solves this problem using rigid connecting pipes: multiple segments of rigid connecting pipe are connected sequentially and inserted through the end working hole 9, pushed forward along the bottom of the flue to the front end area, then the traction rope 1 is fixed to the end of the rigid connecting pipe, and the rigid connecting pipe is then pulled back, thus bringing the traction rope 1 in and through the entire main flue 100.

[0052] Preferably, the rigid connecting pipe is made of stainless steel, with each section approximately 6 meters long. Both ends of the pipe are threaded (internal or external), and adjacent sections are detachably connected via these threads. The stainless steel pipe possesses sufficient rigidity and straightness, maintaining shape stability even at high temperatures and resisting bending and deformation, thus ensuring accurate arrival at the front of the flue during long-distance pushing. The diameter of the rigid connecting pipe is approximately 20-50 mm, preferably 25 mm or 32 mm, to balance rigidity and ease of operation.

[0053] The gate is an adjustable structure. It is installed at the working hole 9 on the end wall of the main flue 100. The opening and closing of the gate controls the stability of the kiln pressure during the ash removal process. After the working hole 9 is opened on the end wall of the main flue 100, the negative pressure inside the flue is disrupted, and a large amount of external cold air may seep in, affecting kiln pressure stability and combustion efficiency. This invention solves this problem by setting a gate: the gate can adjust its opening in real time according to changes in kiln pressure. When it is necessary to insert or remove the rigid draggage 2 or remove accumulated ash, the gate is opened wider; when kiln pressure fluctuations are observed to exceed the allowable range, the gate is closed smaller, thereby maintaining kiln pressure fluctuations within the process-allowed range (e.g., within ±5 Pa of the set value).

[0054] Preferably, the gate is a steel plate gate, slightly wider than the working hole 9, and is installed at the working hole 9 via a sliding groove, allowing it to slide up and down to adjust the opening. The gate is made of heat-resistant steel plate with a thickness of approximately 10-20mm to withstand the heat radiation and convection of the high-temperature flue gas.

[0055] In one or more embodiments, the gate can also be a rotary gate or a slide gate, as long as the opening degree can be adjusted.

[0056] The collaborative working relationships between the above components are as follows: Before the dust removal operation begins, the operator selects a rigid drag bar 2 (I-beam) of appropriate width based on the width of the main flue 100 and the distribution of accumulated dust. The horizontal position of the fixed pulley 6 is adjusted by moving the crossbeam 5, aligning it with the central area of ​​the main flue 100 (the main area of ​​dust accumulation). An operating hole 9 is opened at the bottom of the wall at the end of the main flue 100, and a gate is installed at the operating hole 9.

[0057] At the start of the dust removal operation, the traction rope 1 is threaded through the end working hole 9 to the front end using a rigid connecting pipe, and after being turned by the fixed pulley 6, it is connected to the front end of the rigid drag 2 and connected to the first traction mechanism 3; the other end of the traction rope 1 is directly connected to the rear end of the rigid drag 2 and connected to the second traction mechanism 4. The rigid drag 2 is then inserted into the main flue 100 through the working hole 9.

[0058] During the ash removal operation, the first traction mechanism 3 and the second traction mechanism 4 work together: when the front rope is retracted and the rear rope is released, the rigid drag 2 moves forward, pushing the accumulated ash in the middle forward to the front ash removal port; when the rear rope is retracted and the front rope is released, the rigid drag 2 moves backward, pushing the accumulated ash in the middle backward to the end working hole 9. This process is repeated multiple times to complete the ash removal operation. During this period, the operator controls the kiln pressure stability in real time by adjusting the opening of the gate.

[0059] After the ash removal operation is completed, remove the rigid draggage 2 from the working hole 9, remove the traction rope 1 and the rigid connecting pipe, and seal the working hole 9 with refractory material. The crossbeam 5, fixed pulley 6, first traction mechanism 3 and second traction mechanism 4 can be left on site for reuse during the next ash removal operation.

[0060] The aforementioned ash removal system establishes a mechanical ash removal system in the main flue of a glass melting furnace, which is characterized by high temperature, long distance, and inability to be operated from the side. This system involves threading ropes, inserting draggear, and reciprocating traction, achieving efficient ash removal without altering the original structure of the flue or interrupting production.

[0061] This embodiment provides a method for cleaning the main flue of a glass melting furnace using the cleaning system described in Embodiment 1. The method includes the following steps: S1: Hole opening step.

[0062] An operating hole 9 is opened on the end wall of the main flue 100, which connects to the inside of the flue.

[0063] Preferably, the working hole 9 is located at the bottom of the wall at the end of the main flue 100 to facilitate the insertion of the rigid draggage 2 and the discharge of accumulated ash. The size of the working hole 9 should be larger than the maximum cross-sectional size of the rigid draggage 2 to ensure that the rigid draggage 2 can pass through smoothly. For example, when the rigid draggage 2 is an I-beam with a width of 2 meters and a height of 200 mm, the width of the working hole 9 should preferably be 2.2-2.5 meters and the height should preferably be 0.5-0.8 meters.

[0064] During the opening process, the furnace maintains normal production, and the flue is under negative pressure. The opening operation should be completed quickly while ensuring safety to minimize the infiltration of external cold air.

[0065] In one or more embodiments, the working hole 9 can also be located in the middle of the end wall of the flue or other suitable locations, as long as it is convenient for operation. For newly built or repaired furnaces, the location of the working hole 9 can be reserved in advance on the end wall of the main flue, constructed with refractory bricks and marked, so that it can be opened directly when ash removal is required.

[0066] S2: Traction establishment steps.

[0067] A traction rope 1 is installed through the entire main flue 100 using the dust removal system, with both ends of the traction rope 1 located outside the main flue 100.

[0068] Preferably, the traction establishment step S2 specifically includes the following sub-steps: S2.1: Connect multiple rigid connecting pipes in sequence (e.g., by threaded connection), insert them into the main flue 100 through the working hole 9, and push them forward along the bottom of the flue until the front end of the rigid connecting pipe reaches the front end area of ​​the main flue 100.

[0069] S2.2: Lead the end of the rigid connecting pipe out from the side wall of the main flue 100 (for example, lead it out from the pre-set process observation port or the temporarily opened small hole on the front side wall), and fix the traction rope 1 to the end.

[0070] S2.3: Pull the rigid connecting pipe back from one side of the end of the main flue 100. While pulling back, remove the rigid connecting pipe section by section, and bring the traction rope 1 in and through the entire main flue 100. At this time, the first end of the traction rope 1 is located outside the front end of the main flue 100, and the second end is located outside the end of the main flue 100.

[0071] Through the above sub-steps, the present invention enables the rapid and reliable establishment of a traction system in long-distance, high-temperature flues where it is impossible to thread the rope directly from the side.

[0072] S3: Positioning steps.

[0073] Move the crossbeam 5 along the width of the main flue 100 so that the fixed pulley 6 installed on the crossbeam 5 is aligned with the middle area of ​​the main flue 100.

[0074] Since the ash accumulation in the main flue 100 of the glass melting furnace is usually concentrated in the central area (the sides are relatively less affected by the flow of flue gas from the branch flues 7), by aligning the fixed pulley 6 with the central area, the rigid draggage 2 can directly act on the most concentrated ash area during reciprocating movement, avoiding ineffective strokes and improving the efficiency of single-cycle ash removal. At the same time, since the width of the rigid draggage 2 (approximately 2 meters) is sufficient to cover the main central ash accumulation area, there is no need to repeatedly adjust the position of the crossbeam 5 during the ash removal process.

[0075] In one or more embodiments, if the ash accumulation in the main flue 100 is uneven, for example, biased to the left or right, the fixed pulley 6 can be aligned with the area with the most severe ash accumulation by moving the crossbeam 5, thereby achieving targeted ash removal.

[0076] S4: Insertion and connection steps.

[0077] The rigid draggage 2 is inserted into the main flue 100 through the working hole 9, and the two ends of the traction rope 1 are connected to the front and rear ends of the rigid draggage 2, respectively. Specifically, the first end of the traction rope 1 is connected to the front end of the rigid draggage 2 after being turned by the fixed pulley 6, and is connected to the first traction mechanism 3; the second end of the traction rope 1 is directly connected to the rear end of the rigid draggage 2 and is connected to the second traction mechanism 4.

[0078] After the rigid drag 2 is inserted, it adheres tightly to the bottom of the main flue 100 by its own weight, and its bottom edge contacts the upper surface of the ash accumulation 200.

[0079] S5: Dust removal procedure.

[0080] By coordinating the first traction mechanism 3 and the second traction mechanism 4 to control the traction rope 1, the rigid drag 2 moves back and forth along its length inside the main flue 100, thereby pushing the accumulated ash at the bottom of the main flue 100 to the preset ash removal outlet and removing it.

[0081] Specifically, when it is necessary to push the accumulated ash forward, the first traction mechanism 3 retracts the rope, the second traction mechanism 4 releases the rope, and the rigid drag 2 moves forward, pushing the accumulated ash located in the middle area forward to the cleaning outlet at the front end of the main flue 100 (e.g., a pre-set auxiliary cleaning hole on the front side wall). When it is necessary to push the accumulated ash backward, the second traction mechanism 4 (end winch) retracts the rope, the first traction mechanism 3 (front winch) releases the rope, and the rigid drag 2 moves backward, pushing the accumulated ash located in the middle area backward to the working hole 9 at the end of the main flue 100. This process is repeated multiple times until the accumulated ash at the bottom of the main flue 100 is basically removed.

[0082] This invention utilizes the coordinated deployment and retraction of traction mechanisms at both ends to allow the rigid tow attachment 2 to reciprocate forward or backward along its length within the main flue 100. During cleaning, the accumulated ash is pushed to both ends of the main flue 100 and removed through cleaning ports or working holes 9 located at both ends. This bidirectional pushing cleaning method offers the following advantages compared to traditional unidirectional cleaning: First, it avoids excessive ash accumulation at one end of the flue, preventing it from being discharged; second, it shortens the single pushing distance of the ash, reducing the traction load; and third, cleaning operations in both directions can be completed with a single rope threading, improving operational efficiency.

[0083] Preferably, the reciprocating movement of the rigid draggage 2 is achieved by the coordinated operation of two winches, and the moving speed of the rigid draggage 2 is 0.1-0.5 m / s. More preferably, the moving speed is 0.2 m / s. This speed range was determined after comprehensively considering the cleaning efficiency and operational safety: too low a speed (less than 0.1 m / s) will result in excessively long cleaning time, increasing the potential impact on production; too high a speed (greater than 0.5 m / s) may cause the rigid draggage 2 to lose stability in the flue, colliding with or getting stuck against the inner wall of the flue.

[0084] In one or more embodiments, the preset dust removal outlet includes: the working hole 9 itself, for discharging the accumulated ash pushed to the end, and / or the auxiliary dust removal hole opened at the front end or side of the main flue 100, for discharging the accumulated ash pushed to the front end.

[0085] S6: Procedure for sealing the working hole.

[0086] After cleaning, remove the rigid draggage 2 from the working hole 9 and disconnect the traction rope 1 from the rigid draggage 2. Seal the working hole 9 with refractory material and restore the insulation layer. The gate can be removed or left in the working hole 9 for future use.

[0087] The crossbeam 5, fixed pulley 6, first traction mechanism 3 and second traction mechanism 4 can be retained on site for reuse during the next dust removal.

[0088] Preferably, it also includes S7: a dust removal effect verification step.

[0089] After the cleaning is completed, the cleaning effect can be verified by monitoring changes in process parameters such as flue temperature, induced draft fan frequency, and natural gas consumption. When a significant improvement in these parameters is detected, the cleaning operation is considered complete.

[0090] Example 3 This embodiment provides a specific application example of using the dust removal system and method of the present invention for online periodic dust removal, and further illustrates the technical effects of the present invention by comparing it with the prior art (dust removal during production stoppage).

[0091] I. Application Examples The main flue of a flat glass production line's melting furnace is approximately 28 meters long, 3.1 meters wide, and 2.7 meters high. The flue gas temperature inside the flue has been consistently maintained at around 650℃. This melting furnace has been operating continuously for four years, melting approximately 600 tons of molten glass per day. The ash accumulation at the bottom of the main flue has been measured at 0.4-0.6 meters, primarily concentrated in the central area (approximately 2 meters in the width direction), with relatively more ash accumulation near the branch flue openings on both sides. Before cleaning, the temperature of branch flue #1 was approximately 707℃, and branch flue #5 was approximately 592℃, showing significant temperature differences between the branch flues. This resulted in the inability to independently adjust the exhaust gas volume of each small furnace; the waste heat induced draft fan frequency was approximately 45Hz; and the natural gas consumption was approximately 190 m³ / ton of glass.

[0092] Online cleaning is performed using the cleaning system described in Embodiment 1 and the cleaning method described in Embodiment 2 of this invention. Specific parameters are as follows: Rigid draggage 2 uses a 2-meter-wide I-beam (2000×200×10mm specification, approximately 2 meters wide), which is more than half the width of the flue, enabling it to cover the main ash accumulation area in the middle in a single operation. The fixed pulley on the crossbeam is aligned with the middle area of ​​the flue. The traction rope is made of φ10mm heat-resistant stainless steel wire rope. Two winches are respectively located at the front and rear of the flue. The end working hole is 0.4 meters wide and 0.4 meters high, equipped with an adjustable gate.

[0093] During the ash removal process, the rigid draggage's moving speed was controlled at 0.2 meters per second, with approximately 50 reciprocating strokes. A single ash removal operation took approximately 8 hours in total. Throughout the entire ash removal process, the melting furnace maintained normal production without any shutdowns, production reductions, or process fluctuations.

[0094] After the dust removal is completed, the changes in each process parameter are as follows: The temperature of the No. 1 branch flue decreased from 707℃ to 655℃; the temperature of the No. 5 branch flue increased from 592℃ to 695℃; the temperature of each branch flue tended to be uniform, and the exhaust gas volume of a single small furnace could be precisely adjusted by the branch flue damper.

[0095] With the suction force remaining constant, the frequency of the waste heat induced draft fan decreased from 45Hz to 40.5Hz.

[0096] Natural gas consumption per ton of glass decreased from 190 m³ / ton to 186 m³ / ton of glass.

[0097] II. Comparative Experiment To more clearly illustrate the technical effects of the present invention, this embodiment compares the above application example (the present invention's solution, online periodic ash cleaning) with a typical solution of the prior art (shutdown ash cleaning). The comparison data comes from the actual operating data of the above-mentioned melting furnace before and after adopting the present invention's solution, as well as typical data of similar melting furnaces in the industry that adopt the shutdown ash cleaning solution.

[0098] Table 1 Comparison of Dust Removal Operation Methods

[0099] Table 2 Comparison of main process parameters before and after dust removal

[0100] Table 3 Comparison of Overall Economic Benefits and Maintainability

[0101] III. Comparative Conclusions The following conclusions can be drawn from the above comparison: First, the present invention achieves a dust removal effect comparable to or even better than shutdown dust removal without affecting normal production. Quantitative data such as the equalization of branch flue temperature after dust removal, a maximum temperature difference adjustment of 103℃, a decrease in induced draft fan frequency of approximately 10%, and a decrease in natural gas consumption of approximately 2.1% demonstrate that the present invention can effectively restore the flue gas flow capacity of the flue.

[0102] Secondly, the solution of this invention significantly reduces production losses caused by shutdowns. Taking a melting furnace with a daily output of 600 tons as an example, a single shutdown for ash removal would result in a loss of approximately 3,000 tons of glass production, while the solution of this invention does not affect production during the ash removal process, resulting in a significant annualized production advantage.

[0103] Third, the present invention avoids the costly modification of flue structure. Existing technologies require pre-designing ash accumulation troughs from the design stage, which is not applicable to existing melting furnaces; while the present invention does not require changes to the flue structure, only the opening of temporary working holes, which can be sealed and restored after ash removal, making it more widely applicable.

[0104] Fourth, the dust removal cycle of this invention is flexible and controllable. Since it does not require coordination with production shutdown cycles, operators can arrange online dust removal at any time based on the actual dust accumulation in the flue and when they observe deterioration of process parameters (such as increased temperature differences in the branch flues or increased induced draft fan frequency), keeping the dust accumulation thickness at a low level and avoiding the cumulative effect of flue blockage.

[0105] Fifth, the present invention features one-time investment and multiple reuse. Equipment such as the crossbeam, fixed pulley, and winch can be retained on-site after the initial investment, and the working hole positions are marked. Subsequent cleaning does not require re-threading of the traction rope, significantly reducing long-term maintenance costs.

[0106] In summary, the solution of this invention is significantly superior to the existing shutdown cleaning solution in multiple dimensions such as cleaning effect, production protection, investment cost, and maintenance flexibility, and has outstanding substantive features and significant progress.

[0107] Example 4 This embodiment provides an explanation of the applicability of the dust removal system of the present invention in main flues of different specifications.

[0108] It should be noted that the above embodiment uses a main flue with a width of 4 meters as an example for illustration, but the scope of protection of the present invention is not limited to this. For main flues of other widths, such as 3 meters, 3.5 meters, 4.5 meters, and 5 meters, it is only necessary to adjust the width of the rigid drag 2 according to the actual flue width: preferably 1 / 3 to 2 / 3 of the flue width, more preferably 1 / 2 of the flue width, and adjust the size of the working hole 9 accordingly to achieve the same dust removal function.

[0109] Specifically, for a main flue with a width of W, the width w of the rigid support 2 can be selected according to the following relationship: When W = 3 meters, w can be selected from 1.0 to 1.8 meters, with 1.8 meters being preferred; When W = 3.5 meters, w can be selected from 1.2 to 2.2 meters, with 1.8 meters being preferred; The inner width of a typical flue rarely exceeds 3.5 meters; for float glass, the inner width of a typical flue is between 2.7 and 3.1 meters. Similarly, for main flues of varying lengths, only the length of the traction rope 1 and the number of rigid connecting pipe segments need to be adjusted; no substantial modifications to the system structure are required. For example, for a 20-meter-long main flue, a total length of approximately 50 meters for the traction rope 1 is sufficient to meet the operational margin requirements at both ends; for a 35-meter-long main flue, a total length of approximately 80 meters for the traction rope 1 is sufficient. The number of rigid connecting pipe segments also increases or decreases accordingly based on the flue length, with each segment being 6 meters long and threaded.

[0110] Therefore, the dust removal system of the present invention has good versatility and scalability, and can be applied to the main flue of glass melting furnaces of different specifications.

[0111] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A ash removal system for the main flue (100) of a glass melting furnace, characterized in that, include: The length of the traction rope (1) is set to be able to pass through the entire main flue (100). A rigid draggage (2) having a predetermined weight is used to be inserted into the main flue (100) and to push away ash during movement; The first traction mechanism (3) is located outside the front end of the main flue (100); The second traction mechanism (4) is located outside the end of the main flue (100); The first end of the traction rope (1) is connected to the front end of the rigid drag (2) and connected to the first traction mechanism (3), and the second end of the traction rope (1) is connected to the rear end of the rigid drag (2) and connected to the second traction mechanism (4). The first traction mechanism (3) and the second traction mechanism (4) are configured to work together to drive the rigid drag (2) to reciprocate within the main flue (100).

2. The dust removal system according to claim 1, characterized in that, The rigid draggage (2) is an I-beam, rail, square steel or cast iron block; the self-weight of the rigid draggage (2) can push or scrape the accumulated dust when moving, and the traction rope (1) is a heat-resistant stainless steel wire rope.

3. The dust removal system according to claim 1, characterized in that, The system also includes a crossbeam (5) for mounting on the front end of the main flue (100), a fixed pulley (6) is mounted on the crossbeam (5), and the crossbeam (5) is configured to move along the width of the main flue (100) to adjust the horizontal position of the fixed pulley (6); the traction rope (1) of the first traction mechanism (3) is connected to the front end of the rigid drag (2) after being turned by the fixed pulley (6).

4. The dust removal system according to claim 1, characterized in that, It also includes multiple rigid connecting pipes, which are detachably connected by threaded joints to guide the traction rope (1) through the main flue (100); the system also includes an adjustable gate, which is installed at the working hole (9) opened on the end wall of the main flue (100), and the opening and closing of the gate can control the kiln pressure stability during the ash removal process.

5. The dust removal system according to claim 1, characterized in that, The ratio of the width of the rigid draggage (2) to the width of the main flue (100) is 1:3 to 1:1.

5.

6. A method for cleaning the main flue (100) of a glass melting furnace using the cleaning system described in any one of claims 1 to 5, characterized in that, Includes the following steps: Opening procedure: Open a working hole (9) on the end wall of the main flue (100) to connect to the inside of the flue. Traction establishment steps: Use the ash removal system to set up a traction rope (1) that runs through the entire main flue (100), and make both ends of the traction rope (1) located outside the main flue (100); Insertion step: Insert the rigid drag (2) into the main flue (100) through the working hole (9), and connect the two ends of the traction rope (1) to the front end and the rear end of the rigid drag (2) respectively; Ash removal step: The first traction mechanism (3) and the second traction mechanism (4) work together to control the traction rope (1), so that the rigid drag (2) moves back and forth along its length inside the main flue (100), thereby pushing the ash at the bottom of the main flue (100) to the preset ash removal outlet and removing it.

7. The method according to claim 6, characterized in that, The traction establishment steps specifically include: The multiple rigid connecting pipes are connected in sequence, inserted into the main flue (100) through the working hole (9) and pushed forward to the front end area of ​​the main flue (100); The end of the rigid connecting pipe is led out from the side wall of the main flue (100), and the traction rope (1) is fixedly connected to the end; Pull back the rigid connecting pipe to bring the traction rope (1) in and through the entire main flue (100).

8. The method according to claim 6, characterized in that, The working hole (9) is located at the bottom of the wall at the end of the main flue (100), and the opening of the working hole (9) is adjusted by the gate to control the kiln pressure in the main flue (100) during the ash removal process.

9. The method according to claim 6, characterized in that, The rigid drag (2) is reciprocated by the coordinated release and retraction of two winches, and the moving speed of the rigid drag (2) is 0.1-0.5 m / s.

10. The method according to claim 6, characterized in that, The preset cleaning outlets include: the working hole (9) itself, and / or auxiliary cleaning holes opened at the front end or side of the main flue (100).

Images