Refractory brick production system

Abstract

The utility model relates to the field of firebrick production technology, concretely is firebrick production system. Including breaker, breaker is connected with the washing magnetic separation pool through the inclination vibrator, the washing magnetic separation pool is connected with the mixer through the high temperature resistant conveyer, the mixer is connected with the chamber dryer through the friction brick press, the chamber dryer is connected with the tunnel kiln through the pipeline, the tunnel kiln is connected with the heat storage tank through the pipeline, the high temperature resistant conveyer passes through the box -type dryer. The raw material recovery device is equipped under the box -type dryer. The system can process the relatively thick powder that is flatly accumulated into the 'M type' wave shape material layer by setting the first level material turning plate and the second level material turning plate in the box -type dryer. The structure design makes the powder heating area increase, the hot air penetration efficiency improves, the drying time is greatly shortened, the final moisture content of the powder can be controlled below 1%, and the mixing caking problem caused by moisture is completely solved.

Description

Technical Field

[0001] This utility model relates to the field of refractory brick production technology, specifically to a refractory brick production system. Background Technology

[0002] Refractory bricks are special ceramic products that can maintain structural stability and resist high-temperature erosion and physical wear in high-temperature environments (usually above 1000℃). They are widely used in metallurgy, building materials, chemical industry, energy and other fields, such as blast furnace linings, cement kiln firing zones, and gasifier linings. The performance of refractory bricks directly affects the service life and operational safety of high-temperature equipment, therefore, extremely high requirements are placed on their chemical composition uniformity, structural density and high-temperature stability.

[0003] Existing refractory brick production systems often experience uneven material dispersion during the mixing process, leading to significant density differences in the formed brick blanks (density differences can reach over 5%). This, in turn, causes fluctuations in key properties such as refractoriness and thermal shock resistance. Analysis reveals that one of the main contributing factors is incomplete raw material drying: traditional drying devices (such as single hot air circulation drying kilns) are inefficient at drying thickly packed powder materials, resulting in residual moisture content exceeding 8%. This damp powder easily forms clumps in the mixer, hindering uniform mixing. Furthermore, existing systems have low thermal efficiency, especially in the firing stage: high-temperature exhaust gases (reaching 300-500℃) generated during tunnel kiln firing are typically emitted directly without effective recovery, resulting in high energy consumption (500-800 kg of standard coal per ton of refractory bricks). This not only increases production costs but also causes energy waste and environmental pollution. Utility Model Content

[0004] To address the shortcomings of existing technologies, the purpose of this invention is to provide a refractory brick production system. By incorporating a primary and secondary turning plate inside a box dryer, a thick, flatly piled powder can be continuously turned into an "M-shaped" wavy layer. This structural design increases the heated area of ​​the powder, improves hot air penetration efficiency, significantly shortens drying time, and allows the final moisture content of the powder to be controlled below 1%, completely solving the problem of material mixing and clumping caused by moisture.

[0005] This utility model is achieved using the following technical solution:

[0006] The refractory brick production system includes a crusher connected to a washing and magnetic separation tank via an inclined vibrator. The washing and magnetic separation tank is connected to a mixer via a high-temperature resistant conveyor belt. The mixer is connected to a chamber dryer via a friction brick press. The chamber dryer is connected to a tunnel kiln via a pipeline. The tunnel kiln is connected to a heat storage tank via a pipeline. The high-temperature resistant conveyor belt passes through a box dryer. A raw material recovery device is installed below the box dryer.

[0007] The inclined vibrator is equipped with a vibrating screen inside, and a large particle material recovery bin is connected to the inclined vibrator. The large particle material recovery bin is connected to the crusher through a pipeline.

[0008] The box-type dryer is equipped with a primary tilting plate and a secondary tilting plate. The primary tilting plate has tilting teeth below it, and the lower part of the primary tilting plate is tangent to the upper surface of the high-temperature resistant conveyor belt. The primary and secondary tilting plates have identical structures, and their tilting teeth are staggered.

[0009] The mixer is equipped with a stirring paddle driven by a stirring shaft, and a crushing paddle is mounted on the stirring shaft, with the crushing paddle located above the stirring paddle.

[0010] The tunnel kiln is connected to a gas inlet pipe, and the heat storage tank is equipped with a coil. The tunnel kiln is connected to the coil through a coil inlet pipe.

[0011] The heat storage tank is connected to the preheater via an inlet pipe, and the preheater is connected to the box dryer via a connecting pipe.

[0012] The working principle of this utility model is as follows:

[0013] Raw materials (high-alumina bauxite and clay) are crushed to a particle size ≤50mm by a crusher and then screened by an inclined vibrator. The vibrating screen (5mm aperture) inside the inclined vibrator separates the material into fine particles <5mm and coarse particles ≥5mm. The coarse particles enter the large particle recovery bin and are returned to the crusher for further processing. The jaw plate gap of the crusher is adjusted to 10-15mm, the inclined vibrator tilt angle is 15°, and the vibration frequency is 20-30Hz. The screened fine particles fall into a washing and magnetic separation tank, where impurities (such as quartz sand) are removed from the clay-based raw materials by hydraulic washing, while iron-containing impurities are adsorbed and removed by magnetic separation. The washing water flow rate is 10-15m³ / h, and the magnetic separation magnetic field strength is 1000-1500 Gauss. The washed raw materials are then conveyed by a high-temperature resistant conveyor belt and dried in a box-type dryer. The primary tipping plate (with a 30mm tooth spacing between the lower tipping plates) is tangential to the conveyor belt surface, tumbling the powder into an "M" shape. The secondary tipping plate further loosens the material, and hot air (120-150℃) passes through the material layer from the bottom. The conveyor belt runs at a speed of 0.5-0.8 m / min, the drying time is 24 hours, and the output moisture content is ≤1%. After drying, the raw materials are metered according to the formula (e.g., 60% Al2O3, 30% clay, 10% corundum) and fed into the mixer, along with 5% pulp waste liquor binder. The stirring shaft rotates at 35 rpm, driving the stirring paddle and crushing paddle to rotate. The crushing paddle first breaks up the lumps, and then the stirring paddle mixes them evenly. The mixing time is 20 minutes, and the material moisture content is controlled at 6%-8%. The mixture is then pressed into shape by a friction brick press (pressing pressure 150-200 MPa). The brick blanks enter a chamber dryer for secondary drying to remove moisture introduced during the molding process. The pressing and holding time is 15 seconds, the chamber drying temperature is 80-100℃, and the drying time is 12 hours. The dried brick blanks are then fed into a tunnel kiln via pipelines, passing through a preheating zone (200-900℃), a firing zone (1500-1600℃, adjusted according to brick type), and a cooling zone (cooling down to below 100℃) for firing. High-temperature gas phase (300-500℃) from the tunnel kiln enters the heat storage tank via a gas phase entry pipeline. After absorbing heat in the coils, the hot gas is sent to a box-type dryer via a preheater and connecting pipelines. The temperature fluctuation in the tunnel kiln firing zone is ±5℃, the firing cycle is 48 hours, and the medium temperature in the heat storage tank is maintained at 200-250℃.

[0014] Compared with the prior art, the beneficial effects of this utility model are:

[0015] (1) By setting a primary and a secondary turning plate inside the box dryer, the thick powder material that is piled up flat can be continuously turned over and processed into an "M-shaped" wavy material layer. This structural design increases the heating area of ​​the powder material, improves the hot air penetration efficiency, greatly shortens the drying time, and the final moisture content of the powder material can be controlled below 1%, completely solving the problem of mixing and clumping caused by moisture.

[0016] (2) The crushing paddle (located above the mixing paddle) added to the mixing shaft inside the mixer can perform secondary crushing of the dry powder entering the mixer. The crushing paddle adopts a serrated blade design (blade angle 60°), which, together with the rotational motion of the mixing paddle (speed 35-40rpm), can completely crush residual lumps (particle size > 5mm) to less than 1mm, greatly improving the uniformity of material mixing and significantly improving the density consistency of brick blanks.

[0017] (3) The high-temperature gas phase generated by the tunnel kiln is introduced into the heat storage tank through the gas phase entry pipeline. The coil structure inside the tank (using a spiral arrangement with a heat exchange area of ​​50㎡) can store the heat in the heat storage medium. The stored heat energy is transported to the preheater through the preheater pipeline, and then stably supplied to the box dryer through the connecting pipeline, so that the temperature fluctuation of the drying hot air is controlled within ±5℃. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the refractory brick production system of this utility model;

[0019] Figure 2 This is a schematic diagram of the structure of the box-type dryer of this utility model;

[0020] In the diagram: 1. Crusher; 2. Inclined vibrator; 3. Washing magnetic separator; 4. High-temperature resistant conveyor belt; 5. Box dryer; 6. Mixer; 7. Friction brick press; 8. Chamber dryer; 9. Tunnel kiln; 10. Heat storage tank; 11. Preheater; 12. Vibrating screen; 13. Large particle material recovery bin; 14. Coil; 15. Primary tipping plate; 16. Secondary tipping plate; 17. Gas phase inlet pipe; 18. Coil inlet pipe; 19. Preheater inlet pipe; 20. Connecting pipe; 21. Tipping plate teeth; 22. Agitator shaft; 23. Agitator paddle; 24. Crushing paddle. Detailed Implementation

[0021] To make the objectives and technical solutions of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings.

[0022] Example 1

[0023] like Figure 1As shown, the refractory brick production system includes a crusher 1. The crusher 1 is connected to a washing and magnetic separation tank 3 via an inclined vibrator 2. The washing and magnetic separation tank 3 is connected to a mixer 6 via a high-temperature resistant conveyor belt 4. The mixer 6 is connected to a chamber dryer 8 via a friction brick press 7. The chamber dryer 8 is connected to a tunnel kiln 9 via a pipeline. The tunnel kiln 9 is connected to a heat storage tank 10 via a pipeline. The high-temperature resistant conveyor belt 4 passes through a box dryer 5. The crusher adopts a jaw crushing structure, with jaw plates made of high-manganese steel (hardness HB≥300). The crushing chamber is deep and has no dead zones. The inclined vibrator 2 has a vibrating screen 12 inside, and a large particle recovery bin 13 is connected to the inclined vibrator 2. The large particle recovery bin 13 is connected to the crusher 1 via a pipeline. Figure 2 As shown, the box dryer 5 has a primary tilting plate 15 and a secondary tilting plate 16 inside. Tilting plate teeth 21 are located below the primary tilting plate 15, and the lower part of the primary tilting plate 15 is tangent to the upper surface of the high-temperature conveyor belt 4. The primary and secondary tilting plates 15 and 16 have identical structures, with their tilting plate teeth arranged alternately. The mixer 6 has an internal stirring paddle 23 driven by a stirring shaft 22. A crushing paddle 24 is mounted on the stirring shaft 22 and is located above the stirring paddle 23. A gas phase inlet pipe 17 is connected to the tunnel kiln 9. A coil 14 is located inside the heat storage tank 10, and the tunnel kiln 9 is connected to the coil 14 via an inlet pipe 18. The heat storage tank 10 is connected to the preheater 11 via an inlet pipe 19, and the preheater 11 is connected to the box dryer 5 via a connecting pipe 20.

[0024] The above-mentioned refractory brick production system includes the following steps during operation:

[0025] (1) The raw material is crushed to ≤50mm by crusher 1, and screened by inclined vibrator 2 (5mm screen hole). Coarse material ≥5mm is returned to crusher, and fine material ≤5mm is sent to washing and magnetic separation tank 3. The fine material is hydraulically washed to remove impurities such as quartz sand, magnetically separated to remove iron, and then sent to box dryer 5 by high temperature conveyor belt 4. (2) In the dryer, the first-stage turning plate 15 turns the powder into an "M" shape, and the second-stage turning plate 16 loosens the material. The drying raw material is measured according to the formula (60% Al2O3, 30% clay, 10% corundum) and then put into the mixer. 5% pulp waste liquid is added. The stirring shaft 22 drives the stirring paddle 23 and crushing paddle 24 to mix for 20 minutes with a humidity of 6%-8%. The mixed material is formed by 150-200MPa friction brick press 7, and the brick blanks are put into chamber dryer 8 and dried at 80-100℃ for 12 hours. (3) The dried brick blanks are sent to the tunnel kiln 9, and then through the preheating zone of 200-900℃, the firing zone of 1500-1600℃, and cooled to below 100℃. The firing cycle is 48 hours. The high-temperature gas phase of 300-500℃ in the tunnel kiln enters the heat storage tank 10. The heat storage medium is sent to the box dryer 5 through the preheater 11. The temperature of the medium in the heat storage tank is 200-250℃.

Claims

1. A refractory brick production system, characterized in that, The system includes a crusher (1), which is connected to a washing magnetic separation tank (3) via an inclined vibrator (2). The washing magnetic separation tank (3) is connected to a mixer (6) via a high-temperature resistant conveyor belt (4). The mixer (6) is connected to a chamber dryer (8) via a friction brick press (7). The chamber dryer (8) is connected to a tunnel kiln (9) via a pipe. The tunnel kiln (9) is connected to a heat storage tank (10) via a pipe. The high-temperature resistant conveyor belt (4) passes through a box dryer (5).

2. The refractory brick production system according to claim 1, characterized in that, The inclined vibrator (2) is equipped with a vibrating screen (12) inside. A large particle material recovery bin (13) is connected to the inclined vibrator (2). The large particle material recovery bin (13) is connected to the crusher (1) through a pipe.

3. The refractory brick production system according to claim 1, characterized in that, The box dryer (5) is equipped with a first-stage turning plate (15) and a second-stage turning plate (16) inside. The turning plate teeth (21) are provided below the first-stage turning plate (15), and the lower part of the first-stage turning plate (15) is tangent to the upper surface of the high-temperature resistant conveyor belt (4).

4. The refractory brick production system according to claim 1, characterized in that, The mixer (6) is equipped with a stirring paddle (23) driven by a stirring shaft (22), and a crushing paddle (24) is provided on the stirring shaft (22), with the crushing paddle (24) located above the stirring paddle (23).

5. The refractory brick production system according to claim 1, characterized in that, The tunnel kiln (9) is connected to a gas phase inlet pipe (17), and the heat storage tank (10) is equipped with a coil (14). The tunnel kiln (9) is connected to the coil (14) through the coil inlet pipe (18).

6. The refractory brick production system according to claim 1, characterized in that, The heat storage tank (10) is connected to the preheater (11) through the preheater inlet pipe (19), and the preheater (11) is connected to the box dryer (5) through the connecting pipe (20).

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