A method of controlling the cooling air for a glass furnace pool wall

Abstract

This invention belongs to the field of glass production technology, specifically relating to a method for controlling the cooling air of a glass melting furnace wall. The method includes the following steps: S1, determining the design remaining lifespan of the melting furnace wall at a certain operating time point, and formulating the annual erosion rate of the wall based on the design lifespan. When formulating the annual erosion rate, the erosion mechanism of the wall bricks and the cooling effect of different wall brick thicknesses should be considered; S2, determining the actual remaining lifespan of the melting furnace wall at a certain operating time point; firstly, determining the actual thickness of the melting furnace wall; secondly, determining the actual remaining lifespan of the melting furnace wall. This invention, by introducing a feedback mechanism based on a dynamic comparison between the actual remaining lifespan and the design remaining lifespan, achieves precise control of cooling air parameters (airflow, direction, and blowing distance), avoiding the problems of over-cooling or under-cooling caused by traditional experience-based operations, maximizing the remaining value of the melting furnace wall, and improving the yield and quality of glass products.

Description

Technical Field

[0001] This invention belongs to the field of glass production technology, specifically relating to a method for controlling the cooling air of the glass melting furnace pool wall. Background Technology

[0002] A glass melting furnace is a thermal equipment used in glass manufacturing to melt glass batches. It typically refers to a furnace primarily heated by flame radiation and constructed of refractory materials and steel. The service life of a melting furnace depends mainly on the degree of erosion and burn-off of the furnace wall, arch, and regenerator, with the degree of wall erosion being the most critical factor affecting its lifespan. To mitigate wall erosion, existing glass melting furnaces employ air cooling to protect the furnace wall. This involves blowing air onto the outer side of the wall, approximately 50mm below the liquid surface, to lower the temperature of the wall bricks and thus slow down the erosion of the wall bricks by the molten glass and the raw material.

[0003] However, traditional air-cooling control methods often employ fixed airflow or simple zone control, making it difficult to dynamically respond to changes in furnace operating conditions, molten glass surface fluctuations, and pool wall temperature field. This results in insufficient cooling efficiency or localized overcooling, which in turn exacerbates thermal stress damage. In current production practices, operators often rely on experience to increase the cooling airflow in high-temperature summer conditions and decrease it in low-temperature winter conditions. Some even go so far as to set the cooling airflow to maximum for pool wall safety, with the air outlet directly facing the molten glass surface. Once production is stable, they either don't adjust the cooling airflow or only make minor adjustments. While this may slow down pool wall erosion, excessive cooling airflow increases heat dissipation from the pool wall, thereby increasing natural gas and electricity consumption, resulting in significant energy waste. With the increasing demands for intelligent manufacturing and energy conservation, there is an urgent need for a refined cooling air control method that can respond in real time to the temperature distribution of the furnace wall and take into account both protection and energy efficiency to address the shortcomings of existing technologies in order to reasonably control and optimize the cooling air volume of the furnace wall during operation. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the present invention aims to provide a method for controlling the cooling air of the glass melting furnace tank wall.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A method for controlling the cooling air of a glass melting furnace wall includes the following steps: S1. Determine the design remaining life of the melting furnace wall at a certain operating time point, and formulate the annual erosion amount of the wall based on the design life of the melting furnace wall. When formulating the annual erosion amount, the erosion mechanism of the wall bricks (glass liquid composition, drawing amount, melting process temperature and thermal properties of the wall bricks) and the cooling effect of different wall brick thicknesses should be taken into account. S2. Determine the actual remaining lifespan of the furnace wall at a certain operating time point; firstly, determine the actual thickness of the furnace wall; secondly, determine the actual remaining lifespan of the furnace wall. S3. Compare the design remaining life value of the furnace wall bricks with the actual remaining life value of the furnace wall bricks under the same operating time, and adjust the cooling air parameters (air volume, air direction and blowing distance). S4. If the actual remaining lifespan is less than the designed remaining lifespan, increase the cooling air velocity (optimize the cooling air direction and distance) to enhance the cooling effect on the pool wall and slow down the erosion rate; if the actual remaining lifespan is greater than or equal to the designed remaining lifespan, maintain or appropriately reduce the cooling air parameters to avoid excessive cooling leading to increased energy consumption or abnormal stress on the pool wall.

[0006] S5. When the difference between the designed remaining lifespan of the furnace wall bricks and the actual remaining lifespan of the furnace wall bricks is greater than 5 days under the same operating time, the cooling air parameters of the furnace wall should be adjusted. If the difference is less than or equal to 5 days, they are considered equal and no adjustment is required.

[0007] In step S1, the annual erosion amount varies. The erosion of the furnace wall bricks is faster in the early stages of operation and slower in the later stages. The annual erosion amount of the furnace wall bricks is determined based on the furnace's drawing capacity, furnace structural dimensions, thermophysical properties of the furnace wall bricks, glass melt composition, glass melt melting process temperature, cooling effect of different wall brick thicknesses, erosion mechanism of the wall bricks, and the total design life of the furnace wall. The erosion amount in the first year is 50mm-150mm, in the second year it is 40mm-100mm, and in the third year it is 30mm. The erosion rate is 80mm in the first year, 20mm-60mm in the fourth year, and 10mm-40mm in the fifth year and beyond. The average daily erosion rate for each year is calculated. Based on the actual operating time of the furnace wall and the average daily erosion rate at that operating time, the design remaining life of the wall bricks is estimated. Finally, the design remaining life of the furnace wall is compared with the actual life. If they are equal, operation continues. If they are not equal, the cooling air parameters of the wall are adjusted to regulate the process, ultimately ensuring that the actual remaining life of the wall equals the design expected life.

[0008] In step S2, the actual thickness of the furnace wall is determined, and the outer temperature T of the tested furnace wall bricks is collected using an infrared thermometer. 实 The temperature T of the molten glass corresponding to the wall bricks of the tested area. 玻 The cooling wind speed V of the pool wall was collected using an anemometer. 冷 Use a protractor to measure the angle α between the cooling airflow direction and the pool wall bricks, and use a ruler to measure the distance L between the cooling air vent and the pool wall. 风 The ambient temperature T on the outside of the test pool wall was collected using a mercury thermometer. 环Using CFD thermal heat transfer simulation technology, the simulated temperature T on the outer side of the tested furnace wall was obtained. 模 Then, the actual outer wall temperature T of the corresponding part of the melting furnace pool was measured with an infrared meter. 实 Perform a size comparison, if T 模 ≠T 实 The pool wall thickness value in the 3D model was further corrected, and the simulation temperature T on the outer side of the pool wall was continuously adjusted. 模 When T 模 =T 实 At this time, the thickness value of the furnace pool wall in the three-dimensional model is equal to the actual thickness value of the furnace pool wall.

[0009] In step S2, the actual remaining lifespan of the furnace wall is determined by the cooling wind speed V. 冷 The angle α between the cooling airflow direction and the pool wall bricks, and the distance L between the cooling air vent and the pool wall. 风 The ambient temperature T outside the pool wall 环 The convective heat transfer coefficient on the outer side of the tested pool wall was obtained by CFD numerical simulation, and then combined with the glass melt temperature T corresponding to the tested pool wall bricks. 玻 The actual temperature T at the liquid level line inside the pool wall bricks of the measured part was obtained by CFD numerical simulation calculation. 内实 Then, combined with the conclusions of the dynamic erosion experiment in the laboratory, the actual remaining life of the furnace pool wall was calculated.

[0010] In step S3, the design remaining life of the furnace pool wall bricks is t. （设） The actual remaining lifespan of the furnace wall bricks is t. （x） Compare t under the same running time （设） With t （设） Size.

[0011] In step S3, when t （设） = t （x） At this time, it is the reasonable operating condition for the pool wall bricks to operate, and this operating condition should be maintained; in step S3, when t （设） ≠ t （x） First, the melting process temperature of the furnace is calibrated. If the melting process temperature is unreasonable, it is adjusted. After the furnace temperature stabilizes, the actual thickness of the pool wall is calculated again, and then the actual remaining life of the pool wall is calculated. Finally, the design remaining life (t) of the furnace pool wall bricks is compared again. （设） The actual remaining lifespan (t) of the furnace pool wall bricks （x） The size of t, if t （设） =t （x） If t （设） ≠t （x）Continue to verify the melting process temperature of the furnace until the melting process temperature of the furnace meets the requirements, at which point the design remaining service life (t) of the furnace tank wall bricks is reached. （设） This still does not equal the actual remaining lifespan (t) of the furnace wall bricks. （x） Then, the cooling air parameters of the pool wall are adjusted.

[0012] In step S3, if the melting process temperature of the furnace is suitable, but t （设） ≠ t （x） At that time, the cooling air parameters on the outside of the pool wall should be adjusted.

[0013] In step S3, when t （设） > t （x） At the same time, increasing the cooling air velocity on the pool wall (optimizing the cooling air direction and distance) increases the convective heat transfer coefficient on the outer side of the pool wall, enhances the cooling of the pool wall bricks, reduces the temperature of the inner wall surface, slows down the erosion rate of the pool wall, and ensures that the erosion rate of the pool wall bricks is lower than the designed erosion rate value, ultimately extending the actual lifespan of the pool wall bricks. （x） Adjust to the maximum extent possible to match the remaining design life of the pool wall. （设） Consistent.

[0014] In step S3, when t （设） < t （x） At this time, reducing the cooling air velocity of the pool wall (at which point there is energy waste of electrical and fuel heat energy) reduces the convective heat transfer coefficient on the outer side of the pool wall, weakens the cooling of the pool wall bricks, and increases the temperature of the inner wall surface of the pool wall bricks, so that the erosion rate of the pool wall bricks is equal to the designed erosion rate value of the pool wall bricks at the same time, ultimately extending the actual lifespan of the pool wall bricks to t. （x） Adjust to the maximum extent possible to match the remaining design life of the pool wall. （设） Consistent.

[0015] Compared with the prior art, the present invention has the following beneficial effects: (1) By introducing a feedback mechanism based on the dynamic comparison between the actual remaining life and the design remaining life, the cooling air parameters are precisely controlled, avoiding the problems of over-cooling or under-cooling caused by traditional experience-based operation.

[0016] (2) Based on the different operating periods of the furnace wall, formulate reasonable inner temperature values ​​of the wall bricks to slow down the erosion rate of the wall bricks, predict the remaining service life of the wall, accurately determine the hot repair time of the furnace wall, maximize the development of the remaining value of the furnace wall, and improve the output and quality of glass products.

[0017] (3) Under the premise of ensuring the safety of the pool wall structure, it can effectively reduce unnecessary cooling energy consumption, reduce natural gas and electricity consumption, meet the technical requirements of green and low-carbon development in the glass industry, achieve energy saving and consumption reduction and reduce environmental pollution, and provide reference data for the use of electricity and natural gas. Attached Figure Description

[0018] Figure 1 This is an overall flowchart of the method of the present invention.

[0019] Figure 2 This is a graph showing the trend of wind speed and convective heat transfer coefficient in this invention.

[0020] Figure 3 This is a graph showing the trend of distance and convective heat transfer coefficient in this invention.

[0021] Figure 4 This is a graph showing the trend of wind direction and convective heat transfer coefficient in this invention.

[0022] Figure 5 This is a graph showing the relationship between ambient temperature and inner wall temperature in this invention. Detailed Implementation

[0023] To make the above-mentioned objectives, features and advantages of the present invention more readily understood, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0024] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0025] Secondly, the term "an embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places throughout this specification does not necessarily refer to the same embodiment, nor is it a single embodiment or an embodiment selectively excluded from other embodiments.

[0026] Example 1, as Figure 1 As shown, A method for controlling the cooling air of a glass melting furnace wall includes the following steps: S1. Determine the design remaining life of the melting furnace wall at a certain operating time point, and formulate the annual erosion amount of the wall based on the design life of the melting furnace wall. When formulating the annual erosion amount, the erosion mechanism of the wall bricks (glass liquid composition, drawing amount, melting process temperature and thermal properties of the wall bricks) and the cooling effect of different wall brick thicknesses should be taken into account. S2. Determine the actual remaining lifespan of the furnace wall at a certain operating time point; firstly, determine the actual thickness of the furnace wall; secondly, determine the actual remaining lifespan of the furnace wall. S3. Compare the design remaining life value of the furnace wall bricks with the actual remaining life value of the furnace wall bricks under the same operating time, and adjust the cooling air parameters (air volume, air direction and air distance). S4. If the actual remaining lifespan is less than the designed remaining lifespan, increase the cooling air velocity (optimize the cooling air direction and distance) to enhance the cooling effect on the pool wall and slow down the erosion rate; if the actual remaining lifespan is greater than or equal to the designed remaining lifespan, maintain or appropriately reduce the cooling air parameters to avoid excessive cooling leading to increased energy consumption or abnormal stress on the pool wall.

[0027] S5. When the difference between the designed remaining lifespan of the furnace wall bricks and the actual remaining lifespan of the furnace wall bricks is greater than 5 days under the same operating time, the cooling air parameters of the furnace wall should be adjusted. If the difference is less than or equal to 5 days, they are considered equal and no adjustment is required.

[0028] 2. In step S1, the annual erosion amount varies. The erosion of the pool wall bricks is faster in the early stage of operation and slower in the later stage. The annual erosion amount of the pool wall bricks is determined based on the drawing amount of the melting furnace, the structural dimensions of the melting furnace, the thermophysical properties of the melting furnace pool wall bricks, the composition of the molten glass, the melting process temperature of the molten glass, the cooling effect of different pool wall brick thicknesses, the erosion mechanism of the pool wall bricks, and the total design life of the melting furnace pool wall. The erosion is 50mm-150mm in the first year, 40mm-100mm in the second year, 30mm-80mm in the third year, 20mm-60mm in the fourth year, and 10mm-40mm from the fifth year onwards. The average daily erosion is calculated for each year. Based on the actual operating time of the furnace wall and the average daily erosion at that operating time, the design remaining life of the wall bricks is estimated. Finally, the design remaining life of the furnace wall is compared with the actual life. If they are equal, operation continues. If they are not equal, the cooling air parameters of the wall are adjusted to regulate the process, ultimately ensuring that the actual remaining life of the wall equals its design expected life.

[0029] In step S2, the actual thickness of the furnace wall is determined, and the outer temperature T of the tested furnace wall bricks is collected using an infrared thermometer. 实 The temperature T of the molten glass corresponding to the wall bricks of the tested area. 玻 The cooling wind speed V of the pool wall was collected using an anemometer. 冷 Use a protractor to measure the angle α between the cooling airflow direction and the pool wall bricks, and use a ruler to measure the distance L between the cooling air vent and the pool wall. 风 The ambient temperature T on the outside of the test pool wall was collected using a mercury thermometer. 环Using CFD thermal heat transfer simulation technology, the simulated temperature T on the outer side of the tested furnace wall was obtained. 模 Then, the actual outer wall temperature T of the corresponding part of the melting furnace pool was measured with an infrared meter. 实 Perform a size comparison, if T 模 ≠T 实 The pool wall thickness value in the 3D model was further corrected, and the simulation temperature T on the outer side of the pool wall was continuously adjusted. 模 When T 模 =T 实 At this time, the thickness value of the furnace pool wall in the three-dimensional model is equal to the actual thickness value of the furnace pool wall.

[0030] In step S2, the actual remaining lifespan of the furnace wall is determined by the cooling wind speed V. 冷 The angle α between the cooling airflow direction and the pool wall bricks, and the distance L between the cooling air vent and the pool wall. 风 The ambient temperature T outside the pool wall 环 The convective heat transfer coefficient on the outer side of the tested pool wall was obtained by CFD numerical simulation, and then combined with the glass melt temperature T corresponding to the tested pool wall bricks. 玻 The actual temperature T at the liquid level line inside the pool wall bricks of the measured part was obtained by CFD numerical simulation calculation. 内实 Furthermore, the actual remaining lifespan of the furnace wall is calculated by combining the results of dynamic erosion experiments in the laboratory. Further, dynamic erosion experiments in the laboratory show that the erosion rate of the zirconium corundum bricks in the molten sodium-calcium-silica glass, i.e., the actual erosion amount of the furnace wall bricks, is related to the temperature of the molten glass, the scouring speed of the molten glass on the furnace wall bricks, and the erosion time as follows: The actual erosion amount F of the furnace wall bricks is calculated by combining the three formulas from paragraphs

[0051] ,

[0062] , and

[0073] of the applicant's earlier application with application number "202311053913.5" entitled "A Method for Detecting the Erosion Thickness of Refractory Material in Furnace Walls". 实 formula: Actual erosion of pool wall bricks F 实 formula: Erosion amount Y1=a1*[e (b1*Tgl) ] In the formula: Y1 is the amount of erosion of the zirconium corundum rod at different temperatures, in mm; Tgl is the temperature value of the zirconium corundum rod, in °C; a1 and b1 are coefficient values, which are different for different types of zirconium corundum bricks and different glass liquids. Erosion amount Y2=a2*t In the formula: Y2 is the amount of erosion of the zirconium corundum rod under different erosion times, in mm; t is the erosion time of the zirconium corundum rod, in hours; a2 is a coefficient value, which varies for different types of zirconium corundum bricks and different glass liquids. Erosion amount Y3=a3*n 2 +b3*n+c3 In the formula: Y3 is the erosion amount of the zirconium corundum rod under different erosion velocities, in mm; n is the erosion velocity of the zirconium corundum rod, in revolutions per minute; a3, b3, and c3 are coefficient values, which vary for different types of zirconium corundum bricks and different glass liquids.

[0031] In step S3, the design remaining life of the furnace pool wall bricks is t. （设） The actual remaining lifespan of the furnace wall bricks is t. （x） Compare t under the same running time （设） With t （设） The size; in step S3, when t （设） = t （x） At this time, the pool wall bricks are in a reasonable operating condition, and this operating condition should be maintained; when t （设） ≠ t （x） First, the melting process temperature of the furnace is calibrated. If the melting process temperature is unreasonable, it is adjusted. After the furnace temperature stabilizes, the actual thickness of the pool wall is calculated again, and then the actual remaining life of the pool wall is calculated. Finally, the design remaining life (t) of the furnace pool wall bricks is compared again. （设） The actual remaining lifespan (t) of the furnace pool wall bricks （x） The size of t, if t （设） =t （x） If t （设） ≠t （x） Continue to verify the melting process temperature of the furnace until the melting process temperature of the furnace meets the requirements, at which point the design remaining service life (t) of the furnace tank wall bricks is reached. （设） This still does not equal the actual remaining lifespan (t) of the furnace wall bricks. （x） Then, the cooling air parameters of the pool wall are adjusted.

[0032] In step S3, if the melting process temperature of the furnace is suitable, but t （设） ≠ t （x） At that time, the cooling air parameters on the outside of the pool wall should be adjusted.

[0033] In step S3, when t （设） > t （x） At the same time, increasing the cooling air velocity on the pool wall (optimizing the cooling air direction and distance) increases the convective heat transfer coefficient on the outer side of the pool wall, enhances the cooling of the pool wall bricks, reduces the temperature of the inner wall surface, slows down the erosion rate of the pool wall, and ensures that the erosion rate of the pool wall bricks is lower than the designed erosion rate value, ultimately extending the actual lifespan of the pool wall bricks. （x） Adjust to the maximum extent possible to match the remaining design life of the pool wall. （设） Consistent.

[0034] In step S3, when t （设） < t （x） At this time, reducing the cooling air velocity of the pool wall (at which point there is energy waste of electrical and fuel heat energy) reduces the convective heat transfer coefficient on the outer side of the pool wall, weakens the cooling of the pool wall bricks, and increases the temperature of the inner wall surface of the pool wall bricks, so that the erosion rate of the pool wall bricks is equal to the designed erosion rate value of the pool wall bricks at the same time, ultimately extending the actual lifespan of the pool wall bricks to t. （x） Adjust to the maximum extent possible to match the remaining design life of the pool wall. （设） Consistent.

[0035] Example 2: A study on the relationship between the cooling air velocity and the convective heat transfer coefficient of the outer wall of a glass melting furnace. The vertical distance between the cooling air inlet and the outer wall surface of the furnace wall bricks is 30mm-50mm. The ambient temperature of the cooling air is constant (40℃), and the angle between the cooling air direction and the furnace wall surface is constant (75°). The study focuses solely on the relationship between the cooling air velocity and the convective heat transfer coefficient of the outer wall. Cooling air velocities of 10m / s, 20m / s, 30m / s, 40m / s, 50m / s, 60m / s, and 70m / s were set. The results of CFD numerical simulation are as follows: Table 1: Corresponding values ​​of wind speed and convective heat transfer coefficient.

[0036]

[0037] As shown in Table 1, the corresponding values ​​of wind speed and convective heat transfer coefficient are obtained by fitting. Figure 2 The trend chart shown.

[0038] like Figure 2 As shown, the convective heat transfer coefficient h of the outer wall of the pool is related to the cooling air velocity v of the pool wall as follows: h=-0.0117*v 2 +3.3291*v+33.619 In the formula: h is the convective heat transfer coefficient of the outer wall of the pool, with units of W / (m²). 2 k) v is the cooling air velocity of the pool wall, in m / s.

[0039] When the cooling wind speed of the pool wall is increased from 50m / s to 70m / s, the temperature of the inner side of the pool wall is less than 5℃. Only when the pool wall thickness is less than 50mm can the wind speed be increased to 50m / s-70m / s. When the pool wall thickness is 50mm-250mm, the wind speed should be controlled at 10m / s-50m / s.

[0040] Example 3: Study on the relationship between the cooling air distance and the convective heat transfer coefficient of the outer wall of the pool. Specifically, this study investigates the relationship between the distance from the cooling air duct outlet to the pool wall surface and the convective heat transfer coefficient. With a constant cooling air velocity (40 m / s), a constant ambient temperature (40°C), and a constant angle between the cooling air direction and the pool wall surface (75°), only the relationship between the cooling air distance and the convective heat transfer coefficient of the outer wall is investigated. Cooling air distances of 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, and 100 mm were set, and the results were obtained using CFD numerical simulation: Table 2: Corresponding values ​​of wind distance and convective heat transfer coefficient.

[0041]

[0042] The linear convection heat transfer coefficients in Table 2 are the extended interface between the molten glass surface and the outer wall of the pool. The surface convection heat transfer coefficient is the exposed portion of the upper 280mm of the outer wall (the part without insulation bricks on the outside). The results are obtained by fitting the data as shown below. Figure 3 The graph shows the trend of wind distance and convective heat transfer coefficient.

[0043] like Figure 3 As shown, the distance between the cooling air vent and the pool wall bricks can be 20-80mm, with the optimal distance being 30-50mm. When the linear convection heat transfer coefficient and the surface heat transfer coefficient differ significantly, the surface cooling of the pool wall bricks is uneven, which can easily generate thermal stress and cause the pool wall bricks to crack. When both the linear convection heat transfer coefficient and the surface convection heat transfer coefficient are small, the cooling effect on the pool wall bricks is not good and cannot achieve the effect of slowing down the erosion rate of the pool wall bricks.

[0044] Example 4: Study on the relationship between the cooling air direction and the convective heat transfer coefficient of the outer wall of the pool. Specifically, this study investigates the relationship between the angle between the cooling air blowing direction and the pool wall bricks and the convective heat transfer coefficient. With a constant cooling air velocity (40 m / s), a constant ambient temperature (40°C), and a constant air distance (50 mm), only the relationship between the cooling air direction and the convective heat transfer coefficient of the outer wall is studied. Cooling air directions were set to 20°, 30°, 40°, 50°, 60°, 70°, 80°, and 90°. CFD numerical simulations yielded the following results: Table 3: Corresponding values ​​of wind direction and convective heat transfer coefficient.

[0045]

[0046] The linear convection heat transfer coefficients in Table 3 are the extended interface between the molten glass surface and the outer wall of the pool. The surface convection heat transfer coefficient is the exposed portion of the upper 280mm of the outer wall (the part without insulation bricks on the outside). The results are obtained by fitting the data as shown below. Figure 4The graph shows the trend of wind distance and convective heat transfer coefficient.

[0047] like Figure 4 As shown, the optimal angle between the cooling air direction of the pool wall and the outer wall surface is 70°–80°. The maximum value of the convective heat transfer coefficient occurs between 70° and 80°. In this range, both the convective and linear convective heat transfer coefficients are relatively large and not significantly different, which can better achieve cooling of the pool wall and reduce thermal stress.

[0048] Example 5: Research on the relationship between cooling air velocity and inner wall temperature drop under different wall thicknesses. Specifically, this study investigates the relationship between cooling air velocity and inner wall temperature under different wall thicknesses. The temperature of the molten glass inside the furnace is 1590℃, the ambient temperature of the cooling air is constant (40℃), and the cooling air distance is constant (50mm). The cooling air velocity is increased from 10m / s to 70m / s. The study only examines the temperature change at the liquid surface line on the inner wall under different wall thicknesses. Wall thicknesses of 250mm, 210mm, 180mm, 160mm, 150mm, 140mm, 130mm, 120mm, 110mm, 100mm, 90mm, 80mm, 70mm, 60mm, 50mm, and 20mm were used for CFD numerical simulation, yielding the following results: Table 4: Corresponding values ​​of cooling wind speed and inner wall temperature for different pool wall thicknesses.

[0049]

[0050] From Table 4: Column 1 shows the thickness of the pool wall (in mm); Column 3 shows the temperature at the liquid level on the inner side of the pool wall (in °C) under a cooling air velocity of 10 m / s; Column 4 shows the temperature at the liquid level on the inner side of the pool wall (in °C) under a cooling air velocity of 20 m / s; Column 5 shows the temperature at the liquid level on the inner side of the pool wall (in °C) under a cooling air velocity of 30 m / s; Column 6 shows the temperature at the liquid level on the inner side of the pool wall (in °C) under a cooling air velocity of 40 m / s; Column 7 shows the temperature at the liquid level on the inner side of the pool wall (in °C) under a cooling air velocity of 50 m / s; Column 8 shows the temperature at the liquid level on the inner side of the pool wall (in °C) under a cooling air velocity of 60 m / s; Column 8 shows the temperature at the liquid level on the inner side of the pool wall (in °C) under a cooling air velocity of 60 m / s; Column 9 shows the temperature at the liquid level on the inner side of the pool wall (in °C) under a cooling air velocity of 60 m / s; Column 10 shows the temperature at the liquid level on the inner side of the pool wall (in °C) under a cooling air velocity of 50 m / s; Column 10 shows the temperature at the liquid level on the inner side of the pool wall (in °C) under a cooling air velocity of 60 m / s; Column 11 shows the temperature at the liquid level on the inner side of the pool wall (in °C) under a cooling air velocity of 60 m / s; Column 12 shows the temperature at the liquid level on the inner side of the pool wall (in °C) under a cooling air velocity of 60 m / s; Column 13 shows the temperature at the liquid level on the inner side of the pool wall (in °C) under a cooling air velocity of 60 m / s; Column 14 The table shows the temperature values ​​(in °C) at the liquid level line inside the pool wall under the condition of s. Column 9 shows the temperature values ​​(in °C) at the liquid level line inside the pool wall under the condition of a cooling air velocity of 70 m / s. Column 10 shows the temperature decrease (in °C) at the liquid level line inside the pool wall when the cooling air velocity increases from 10 m / s to 50 m / s. Column 11 shows the temperature decrease (in °C) at the liquid level line inside the pool wall when the cooling air velocity increases from 50 m / s to 70 m / s. The horizontal rows in Table 4 represent the corresponding temperature values ​​(in °C) at the liquid level line inside the pool wall under different pool wall thicknesses.

[0051] From the data in Table 4, we can summarize that: when the pool wall thickness is 150mm-250mm, the cooling air velocity should be controlled at 10m / s-30m / s; when the pool wall thickness is 90mm-150mm, the cooling air velocity should be controlled at 30m / s-40m / s; when the pool wall thickness is 20mm-90mm, the cooling air velocity should be controlled at 40m / s-50m / s. The cooling air velocity has a significant impact on the temperature inside the pool wall, so sufficient cooling air velocity is needed to slow down the erosion rate of the pool wall. When the air velocity increases from 50m / s to 70m / s, the impact on the temperature inside the pool wall is less than 5℃. Only when the pool wall thickness is less than 50mm can the air velocity be increased to 50m / s-70m / s. When the pool wall thickness is 50mm-250mm, the air velocity should be controlled at 10m / s-50m / s.

[0052] Example 6: Study on the relationship between the ambient temperature on the outside of the furnace wall and the temperature on the inside of the furnace wall. Specifically, this study investigates the relationship between different ambient temperatures on the outside of the furnace wall and the temperatures on the inside of the furnace wall. The temperature of the molten glass inside the furnace wall is 1590℃, the cooling air velocity is constant (40m / s), the cooling air distance is constant (50mm), and the furnace wall thickness is constant (50mm). The study only examines the relationship between different ambient temperatures and the temperature at the liquid surface line on the inside of the furnace wall. Ambient temperatures of 10℃, 20℃, 30℃, 40℃, 50℃, 60℃, 70℃, 80℃, 90℃, and 100℃ were set, and the results of CFD numerical simulations are as follows: Table 5: Corresponding values ​​of different ambient temperatures and temperatures at the liquid level line on the inner wall of the pool.

[0053]

[0054] The first row of Table 5 represents the ambient temperatures outside the pool wall at 10℃, 20℃, 30℃, 40℃, 50℃, 60℃, 70℃, 80℃, 90℃, and 100℃. The second row represents the temperature values ​​(in °C) at the liquid level line inside the pool wall under different ambient temperature conditions. The results were obtained through fitting. Figure 5 The graph shows the trend of changes in ambient temperature and the temperature inside the pool wall.

[0055] like Figure 5 As shown, as the ambient temperature gradually increases from 10℃ to 100℃, the temperature at the liquid level line on the inner side of the pool wall does not increase much, only by 7℃. Therefore, the ambient temperature has little effect on the temperature of the inner wall of the pool.

[0056] Example 7: Controlling the actual remaining lifespan of the furnace wall using the method of the present invention includes the following steps: Step 1: Determine the design remaining life at the liquid level line on the furnace wall at a certain operating time point; The 650-ton glass melting furnace in this embodiment is planned to operate for 4 years. Based on the experimental research results on the erosion mechanism of zirconium corundum bricks and the cooling effect of the furnace wall cooling air on the furnace wall, the planned annual erosion amount and design remaining life of the 650-ton glass melting furnace wall in this embodiment are designed, as shown in Table 6 below: Table 6: Annual planned erosion of glass melting furnace walls and corresponding values ​​for design remaining life.

[0057]

[0058] Table 6 shows the design operating time (in years) of the furnace wall in the first row, representing 0 years (start-up), 1 year (1 full year of operation), 2 years (2 full years of operation), 3 years (3 full years of operation), and 4 years (4 full years of operation). The second row shows the remaining wall thickness after each year of operation. For example, in the first 0 years after start-up, the wall thickness is 250mm (the original brick thickness). After 1 year of operation, the remaining wall thickness is 150mm; after 2 years, it is 100mm; after 3 years, it is 60mm; and after 4 years, it is 30mm (when the wall thickness reaches 30mm, hot repair of the supporting bricks is required, thus completing the original wall brick's service life). When designing the annual erosion rate of the wall bricks, a reasonable design must be made based on the erosion mechanism and cooling effect of the wall bricks. The third line shows the annual erosion of the furnace wall bricks. The erosion is 0 mm when the furnace is first put into operation in year 0, 100 mm in year 1, 50 mm in year 2, 40 mm in year 3, and 30 mm in year 4. The erosion decreases annually from the start of operation. The fourth line shows the average daily erosion, calculated by dividing the annual erosion by 365 days (in mm / day). The fifth line shows the design remaining life of the furnace wall (in days), calculated based on the actual operating time of the furnace wall bricks.

[0059] At the time of inspection, the furnace wall had been in operation for 1 year and 9 months (635 days). There were 95 days remaining until the furnace wall reached its 2-year operating period. As shown in Table 6, the remaining design life of the furnace wall at the inspection point was: 95 + 365 * 2 = 825 days. Step 2: Determine the actual remaining lifespan of the furnace wall bricks at a specific operating time point; (1) Determine the actual thickness of the furnace pool wall.

[0060] The temperature T on the outer side of the wall bricks of the tested pool was collected using an infrared thermometer. 实 =323℃, the temperature of the molten glass corresponding to the wall bricks of the tested area, T. 玻 =1590℃, cooling wind speed V on the pool wall was collected using an anemometer. 冷=37m / s, use a protractor to measure the angle α = 75° between the cooling air direction and the pool wall bricks, and use a ruler to measure the distance L between the cooling air vent and the pool wall. 风 =50mm, and the ambient temperature T on the outside of the tested pool wall was collected using a mercury thermometer. 环 =40℃, using CFD thermal heat transfer simulation technology, the simulated temperature T on the outer side of the tested melting furnace wall was obtained. 模 The pool wall thickness value in the 3D model was further corrected, and the simulation temperature T on the outer side of the pool wall was continuously adjusted. 模 When T 模 =T 实 At 323℃, the thickness of the furnace wall in the 3D model is equal to the actual thickness of the furnace wall, which is 116mm.

[0061] (2) Determine the actual remaining life of the furnace pool wall.

[0062] a. Calculate the actual temperature value at the liquid level line on the inner side of the pool wall bricks at the measured location. Substituting the empirical formulas for cooling wind velocity and convective heat transfer coefficient from the study of "Research on Cooling Wind Velocity and Convective Heat Transfer Coefficient of Glass Melting Furnace Wall" into the same operating conditions: h=-0.0117*v 2 +3.3291*v+33.619 In the formula: h is the convective heat transfer coefficient of the outer wall of the pool, with units of W / (m²). 2 k) v is the cooling air velocity of the pool wall, measured in m / s. The convective heat transfer coefficient on the outer side of the tested pool wall was found to be 140.8 W / (m²). 2 k), and then combined with the glass melt temperature T corresponding to the wall bricks of the tested pool. 玻 =1590℃, the actual temperature T at the liquid level line inside the pool wall bricks of the measured part was obtained by CFD numerical simulation calculation. 内实 =1498℃.

[0063] b. Calculate the scouring velocity of the molten glass on the liquid level line of the pool wall. The calculation of the scouring velocity *n* of the molten glass on the surface of the tank wall can be found in "The Influence of Molten Glass Flow on Glass Quality" by Wei Lifang, Issue 6, 2017, pages 18-19, of the journal *Glass*. The result is as follows: S = F * G / (24 * r * h * b) Where: S – glass melt flow velocity (m / h); F – flow coefficient (taken as 9.29); G – drawing amount (650 tons); r – average density of glass melt (2.16 g / cm³). 3 h - thickness of the molten glass surface (429 mm); b - width of the furnace (13.2 m). That is: S = 9.29 * 650 / (24 * 2.16 * 0.429 * 13.2) = 20.57 m / h The diameter D of the pool wall brick sample used in the dynamic experiment in the laboratory is 30 mm, therefore, n = S * 1000 / (π * D * 60) = 20.57 * 1000 / (3.14 * 30 * 60) = 3.639 revolutions per minute; In the formula: n is the rotational speed (rpm) of the zirconium corundum rod sample used in the laboratory dynamic experiment, S is the flow rate of the glass melt (m / h), and D is the diameter (mm) of the zirconium corundum rod sample used in the dynamic experiment. c. Remaining erosion of the furnace pool wall in the second year The remaining erosion of the furnace wall in the second year is equal to the actual thickness of the furnace wall, 116 mm, minus the designed remaining thickness of the furnace wall at the end of the second year. That is, 116 mm - 100 mm = 16 mm.

[0064] Furthermore, considering the conclusions of the dynamic erosion experiments on 33# zirconium corundum bricks and molten sodium-calcium silicate glass, and referring to paragraphs

[0105] -

[0122] of the applicant's earlier application with application number "202411379786.2" entitled "A Method for Controlling the Erosion Rate of Melting Furnace Wall Bricks": Erosion amount Y1 = (1E-10)*e （0.015*Tgl） In the formula: Y1 is the amount of erosion of 33# zirconium corundum rod at different temperatures, in mm; Tgl is the temperature value of 33# zirconium corundum rod, in °C; Erosion amount Y2 = 0.0133 * t In the formula: Y2 is the amount of corrosion of 33# zirconium corundum rod under different corrosion times, in mm; t is the corrosion time of 33# zirconium corundum rod, in days; Erosion amount Y3 = 0.0006 * n 2 - 0.0015*n + 0.591 In the formula: Y3 is the erosion amount of 33# zirconium corundum rod under different erosion velocities, in mm; n is the erosion velocity of 33# zirconium corundum rod, in revolutions per minute; Meanwhile, referring to paragraphs

[0112] -

[0118] of the applicant's earlier application with application number "202311053913.5" and title "A Method for Detecting the Erosion Thickness of Refractory Material in Kiln Pool Walls", the effects of temperature and erosion rate on the erosion of zirconium corundum rods are revised as follows: Based on Y2=0.0133*t, the effect of temperature on zirconium corundum rods is corrected; By Y 修1 =0.0133*24*t*1*10 -10*Y1=0.3192*10 -10 *t*e (0 .015×Tgl) In the formula: Y 修1 It refers to the amount of erosion of zirconium corundum bricks under specific scouring speeds, different temperatures, and different erosion times; In Y 修1 Based on this, the effect of scouring velocity on the erosion amount of zirconium corundum bricks was modified: From segments

[0113] -

[0116] , we can obtain: Y 修2 =Y 修1 *(0.0006*n 2 -0.0015×n+0.591) / 0.665=0.3192*10 -10 *t*e (0.015×Tgl) *(0.0006*n 2 -0.0015×n+0.591) / 0.665=0.48*e 0.015*T 内 *(0.0006*n 2 -0.0015*n+0.591)*t / 10 10 In the formula: Y 修2 It refers to the amount of erosion of zirconium corundum bricks under different scouring speeds, temperatures, and erosion times; Therefore: t 实 =F 实 *10 10 / (0.48*e 0.015*T 内 *(0.0006*n 2 -0.0015*n+0.591) In the formula, F 实 The actual erosion amount of the pool wall bricks, i.e., the erosion amount of 33# zirconium corundum bricks in molten sodium-calcium-silica glass, is expressed in mm and T. 内 ... 实 The time taken after precise control of the pool wall brick erosion rate is implemented, in days; F 实 =16mm, T 内 =1498℃, n=3.639 rpm, substitute into t 实 In the calculation formula, The actual remaining lifespan of the furnace pool wall was calculated as follows: t 实 +365*2=98+730=828 days S3. Compare the design remaining life value of the furnace wall bricks with the actual remaining life value of the furnace wall bricks under the same operating time, and adjust the cooling air speed accordingly.

[0065] The design remaining life of the furnace wall at the time of testing is: 95 + 365 * 2 = 825 days. The actual remaining lifespan of the furnace pool wall is calculated to be 828 days. Compare the design remaining life value and the actual remaining life value of the furnace wall bricks under the same operating time. Since the difference between the design remaining life value and the actual remaining life value of the furnace wall bricks is less than 5 days at the detection time point, no adjustment is required.

[0066] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for controlling the cooling air of a glass melting furnace tank wall, characterized in that, The method includes the following steps: S1. Determine the design remaining life of the melting furnace wall at a certain operating time point, and formulate the annual erosion amount of the wall based on the design life of the melting furnace wall. When formulating the annual erosion amount, the erosion mechanism of the wall bricks (glass liquid composition, drawing amount, melting process temperature and thermal properties of the wall bricks) and the cooling effect of different wall brick thicknesses should be taken into account. S2. Determine the actual remaining lifespan of the furnace wall at a certain operating time point; firstly, determine the actual thickness of the furnace wall; secondly, determine the actual remaining lifespan of the furnace wall. S3. Compare the design remaining life value of the furnace wall bricks with the actual remaining life value of the furnace wall bricks under the same operating time, and adjust the cooling air parameters (air volume, air direction and blowing distance). S4. If the actual remaining lifespan is less than the design remaining lifespan, increase the cooling air velocity (optimize the cooling air direction and distance) to enhance the cooling effect on the pool wall and slow down the erosion rate; if the actual remaining lifespan is greater than or equal to the design remaining lifespan, maintain or appropriately reduce the cooling air parameters to avoid excessive cooling leading to increased energy consumption or abnormal stress on the pool wall. S5. When the difference between the designed remaining lifespan of the furnace wall bricks and the actual remaining lifespan of the furnace wall bricks is greater than 5 days under the same operating time, the cooling air parameters of the furnace wall should be adjusted. If the difference is less than or equal to 5 days, they are considered equal and no adjustment is required.

2. The method for controlling the cooling air of the glass melting furnace wall according to claim 1, characterized in that, In step S1, the annual erosion amount varies. The erosion of the furnace wall bricks is faster in the early stages of operation and slower in the later stages. The annual erosion amount is determined based on the furnace's drawing capacity, structural dimensions, thermophysical properties of the furnace wall bricks, the composition of the molten glass, the melting temperature of the molten glass, the cooling effect of different wall brick thicknesses, the erosion mechanism of the wall bricks, and the total design life of the furnace wall. The erosion amount is 50-150 mm in the first year, 40-100 mm in the second year, and 30-... The erosion is 80mm in the first year, 20-60mm in the fourth year, and 10-40mm in the fifth year and beyond. The average daily erosion is calculated for each year. Based on the actual operating time of the furnace wall and the average daily erosion at that operating time, the design remaining life of the wall bricks is estimated. Finally, the design remaining life of the furnace wall is compared with the actual life. If they are equal, operation continues. If they are not equal, the cooling air parameters of the wall are adjusted to regulate the process, ultimately ensuring that the actual remaining life of the wall equals the design expected life.

3. The method for controlling the cooling air of the glass melting furnace wall according to claim 1, characterized in that, In step S2, the actual thickness of the furnace wall is determined, and the outer temperature T of the tested furnace wall bricks is collected using an infrared thermometer. 实 The temperature T of the molten glass corresponding to the wall bricks of the tested area. 玻 The cooling wind speed V of the pool wall was collected using an anemometer. 冷 Use a protractor to measure the angle α between the cooling airflow direction and the pool wall bricks, and use a ruler to measure the distance L between the cooling air vent and the pool wall. 风 The ambient temperature T on the outside of the test pool wall was collected using a mercury thermometer. 环 Using CFD thermal heat transfer simulation technology, the simulated temperature T on the outer side of the tested furnace wall was obtained. 模 Then, the actual outer wall temperature T of the corresponding part of the melting furnace pool was measured with an infrared meter. 实 Perform a size comparison, if T 模 ≠T 实 The pool wall thickness value in the 3D model was further corrected, and the simulation temperature T on the outer side of the pool wall was continuously adjusted. 模 When T 模 =T 实 At this time, the thickness value of the furnace pool wall in the three-dimensional model is equal to the actual thickness value of the furnace pool wall.

4. The method for controlling the cooling air of the glass melting furnace wall according to claim 1, characterized in that, In step S2, the actual remaining lifespan of the furnace wall is determined by the cooling wind speed V. 冷 The angle α between the cooling airflow direction and the pool wall bricks, and the distance L between the cooling air vent and the pool wall. 风 The ambient temperature T outside the pool wall 环 The convective heat transfer coefficient on the outer side of the tested pool wall was obtained by CFD numerical simulation, and then combined with the glass melt temperature T corresponding to the tested pool wall bricks. 玻 The actual temperature T at the liquid level line inside the pool wall bricks of the measured part was obtained by CFD numerical simulation calculation. 内实 Then, combined with the conclusions of the dynamic erosion experiment in the laboratory, the actual remaining life of the furnace pool wall was calculated.

5. The method for controlling the cooling air of the glass melting furnace wall according to claim 1, characterized in that, In step S3, the design remaining life of the furnace pool wall bricks is t. （设） The actual remaining lifespan of the furnace wall bricks is t. （x） Compare t under the same running time （设） With t （设） Size.

6. The method for controlling the cooling air of the glass melting furnace wall according to claim 1, characterized in that, In step S3, when t （设） = t （x） At this time, the pool wall bricks are in a reasonable operating condition, and this operating condition should be maintained; when t （设） ≠ t （x） First, the melting process temperature of the furnace is calibrated. If the melting process temperature is unreasonable, it is adjusted. After the furnace temperature stabilizes, the actual thickness of the pool wall is calculated again, and then the actual remaining life of the pool wall is calculated. Finally, the design remaining life (t) of the furnace pool wall bricks is compared again. （设） The actual remaining lifespan (t) of the furnace pool wall bricks （x） The size of t, if t （设） =t （x） If t （设） ≠t （x） Continue to verify the melting process temperature of the furnace until the melting process temperature of the furnace meets the requirements, at which point the design remaining service life (t) of the furnace tank wall bricks is reached. （设） This still does not equal the actual remaining lifespan (t) of the furnace wall bricks. （x） Then, the cooling air parameters of the pool wall are adjusted.

7. The method for controlling the cooling air of the glass melting furnace wall according to claim 1, characterized in that, In step S3, if the melting process temperature of the furnace is suitable, but t （设） ≠ t （x） At that time, the cooling air parameters on the outside of the pool wall should be adjusted.

8. The method for controlling the cooling air of the glass melting furnace wall according to claim 1, characterized in that, In step S3, when t （设） > t （x） At the same time, increasing the cooling air velocity on the pool wall (optimizing the cooling air direction and distance) increases the convective heat transfer coefficient on the outer side of the pool wall, enhances the cooling of the pool wall bricks, reduces the temperature of the inner wall surface, slows down the erosion rate of the pool wall, and ensures that the erosion rate of the pool wall bricks is lower than the designed erosion rate value, ultimately extending the actual lifespan of the pool wall bricks. （x） Adjust to the maximum extent possible to match the remaining design life of the pool wall. （设） Consistent.

9. The method for controlling the cooling air of the glass melting furnace wall according to claim 1, characterized in that, In step S3, when t （设） < t （x） At this time, reducing the cooling air velocity of the pool wall (at which point there is energy waste of electrical and fuel heat energy) reduces the convective heat transfer coefficient on the outer side of the pool wall, weakens the cooling of the pool wall bricks, and increases the temperature of the inner wall surface of the pool wall bricks, so that the erosion rate of the pool wall bricks is equal to the designed erosion rate value of the pool wall bricks at the same time, ultimately extending the actual lifespan of the pool wall bricks to t. （x） Adjust to the maximum extent possible to match the remaining design life of the pool wall. （设） Consistent.

10. The method for controlling the cooling air of the glass melting furnace wall according to claim 1, characterized in that, In step S3, the vertical distance between the cooling air outlet and the outer wall surface of the pool wall brick is 30mm-50mm; the angle between the cooling air direction and the outer wall surface of the pool wall is 70°-80°.

11. The method for controlling the cooling air of the glass melting furnace wall according to claim 1, characterized in that, In step S3, when the pool wall thickness is between 150mm and 250mm, the cooling air velocity should be controlled between 10m / s and 30m / s; when the pool wall thickness is between 90mm and 150mm, the cooling air velocity should be controlled between 30m / s and 40m / s; and when the pool wall thickness is between 20mm and 90mm, the cooling air velocity should be controlled between 40m / s and 50m / s.

12. The method for controlling the cooling air of the glass melting furnace wall according to claim 1, characterized in that, In step S3, when the cooling wind speed of the pool wall increases from 50m / s to 70m / s, the effect on the temperature value of the inner side of the pool wall is less than 5℃. Only when the pool wall thickness is less than 50mm can the wind speed be increased to 50m / s-70m / s. When the pool wall thickness is 50mm-250mm, the wind speed is controlled at 10m / s-50m / s.

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