A high-efficiency composite structure kiln

Abstract

A high-efficiency composite structure kiln includes a composite foundation, a composite arched canopy, and an outer structural wall. The composite foundation consists of a ring-shaped rigid strip base constructed of refractory bricks and an internal flexible refractory sand and gravel pad. The composite arched canopy is a multi-layered composite structure covering the foundation, with a parabolic variable cross-section. An outer structural wall surrounds the arched canopy, and protective walls are built over both the arched canopy and the space above the outer structural wall. The kiln door opening is equipped with inner and outer sealing layers and a matching sealed kiln door. This invention improves structural stability and anti-settlement properties through the composite foundation, achieves high-efficiency heat preservation through the multi-layered composite arched canopy, and ensures airtightness through a special kiln door design, effectively solving the technical problems of high energy consumption, uneven temperature, and unstable product quality in traditional kilns.

Description

Technical Field

[0001] This utility model relates to the field of industrial kiln technology, and in particular to a high-efficiency and energy-saving kiln that modernizes and intelligently transforms the traditional four-section kiln structure. Background Technology

[0002] Traditional kilns, such as the four-section kiln and the horseshoe kiln, possess unique firing atmospheres and curves, offering advantages that modern kilns cannot replicate in firing specific ceramics, bricks, tiles, and handicrafts. They embody rich traditional techniques and cultural value. However, their inherent structure has significant drawbacks: First, their foundations are typically made of rammed earth or simple brick and stone masonry, resulting in poor seismic resistance and load distribution, making them prone to cracking due to uneven foundation settlement. Second, the traditional arched structure is simple, with insufficient insulation, leading to significant heat loss and extremely high energy consumption. Furthermore, the uneven temperature field within the kiln affects product quality consistency. Third, the kiln door has poor sealing, commonly resulting in fire and heat leakage, wasting energy and posing safety hazards. Simultaneously, heat dissipation at the kiln door causes the temperature in that area to be lower, creating a "temperature dead zone" within the kiln, leading to under-firing or under-firing of products. In addition, the overall structure is bulky, construction is complex, and there is a high dependence on traditional techniques, making it difficult to meet the demands of modern production for energy conservation, high efficiency, stability, and intelligent control. Therefore, how to innovate and modernize the structure of traditional kilns while preserving their unique firing characteristics has become a pressing technical problem in this field. Utility Model Content

[0003] The purpose of this utility model is to provide a high-efficiency composite structure kiln that solves the technical problems of poor foundation stability, insufficient insulation performance of the arched canopy, high energy consumption due to poor sealing of the kiln door, uneven kiln temperature, and unstable product quality in traditional kilns.

[0004] To achieve the above objectives, the present invention adopts the following technical solution.

[0005] A high-efficiency composite structure kiln includes a composite foundation, a composite arch, and an outer structural wall. The composite foundation has a break at its front end, corresponding to the designed kiln door position. The composite arch is mounted on top of the composite foundation, and its cross-section is a downward-facing parabola with a variable cross-section. An outer structural wall surrounds the composite arch. The height of the outer structural wall is greater than the height of the composite foundation but less than the height of the composite arch. An opening is provided on the front side of the outer structural wall, corresponding to the break. Inner tapering layers are provided on both sides of the break. Outer tapering layers are provided on both sides of the opening. The width between the two outer tapering layers gradually increases from the inside out. The gaps between the two inner tapering layers and the two outer tapering layers together form the kiln door opening. A sealed kiln door is provided at the kiln door opening. Protective walls are constructed in the space between the outer structural wall and the composite arch, and above the outer structural wall. A chimney is provided on top of the composite arch.

[0006] Preferably, the composite foundation includes a rigid part and a flexible part; the rigid part is strip-shaped and extends along the circumference; the rigid part is constructed of refractory bricks and is broken at the kiln entrance to form the fracture; the flexible part is paved with refractory sand and gravel, and the thickness of the refractory sand and gravel within the space enclosed by the rigid part is not less than 150 mm.

[0007] Preferably, the composite arched canopy is a multi-layered composite structure, comprising, from the inside out, a refractory mortar plaster layer, a refractory brick layer, a yellow mud plaster layer, and a refractory soil layer; the refractory brick layer is constructed using refractory mortar; the thickness of both the refractory mortar plaster layer and the yellow mud plaster layer is not less than 50 mm; and the thickness of the refractory soil layer is not less than 100 mm.

[0008] Preferably, the cross-sectional height of the composite arched canopy increases and then decreases from front to back, and the cross-sectional width of the composite arched canopy gradually decreases from front to back.

[0009] Preferably, the spacing between the inner closing layers on both sides is not less than 500mm; the width of the inner side of the outer closing layers on both sides is adapted to the width of the inner closing layers on both sides.

[0010] Preferably, the sealed kiln door includes a double-layer steel door body, insulation material filled in the double-layer steel door body, a sealing strip set on the edge of the double-layer steel door body, and an observation window; one side of the sealed kiln door is rotatably connected to one side of the kiln door opening, and the other side of the sealed kiln door is detachably connected to the other side of the kiln door opening.

[0011] Compared with the prior art, the present invention has the following features and beneficial effects.

[0012] 1. This utility model adopts a composite foundation structure that combines rigid strip foundation with flexible sand and gravel cushion layer. The rigid strip foundation can effectively diffuse the upper load, while the flexible cushion layer can uniformly transmit force and absorb and buffer the uneven settlement that may occur in the foundation, which significantly improves the overall stability and durability of the kiln body and extends the service life of the kiln.

[0013] 2. The composite arched canopy adopts a multi-layered gradient insulation structure consisting of a refractory mortar plaster layer, a refractory brick layer, a yellow mud plaster layer, and a refractory soil layer. The material properties of each layer are complementary, forming a highly efficient thermal barrier system, which greatly reduces heat loss from the kiln roof. Compared with the traditional single-structure arched canopy, the thermal efficiency is significantly improved and the energy-saving effect is obvious.

[0014] 3. The cross-section of the composite arch of this utility model is parabolic, and the variable cross-section arch design is more in line with the principle of thermal airflow dynamics, which is conducive to the flow of hot flue gas in the kiln and the uniformity of heat distribution. Combined with excellent heat preservation and sealing performance, it effectively eliminates the temperature dead zone in the kiln, so that the product is heated evenly, and improves the yield and quality stability of the fired product.

[0015] 4. The unique design of the inner and outer sealing layers of the kiln door opening, combined with the double-layer steel kiln door with sealing strips and heat insulation layer, forms multiple sealing barriers, which completely solves the stubborn problems of fire and heat leakage in traditional kiln doors. It not only greatly reduces heat loss and improves safety, but also ensures the temperature in the kiln door area and avoids underfiring of products.

[0016] 5. The design of the inner and outer structural walls and protective walls in this utility model not only protects the internal composite arched canopy and insulation layer, but also creates an aesthetically pleasing overall appearance. The entire kiln structure is scientifically designed, with clearly defined functions for each component, which improves performance while facilitating construction and maintenance. Attached Figure Description

[0017] The present invention will now be described in further detail with reference to the accompanying drawings.

[0018] Figure 1 This is a schematic diagram of the overall structure of the high-efficiency composite structure kiln of this utility model.

[0019] Figure 2 This is a schematic diagram of the vertical cross-section of the high-efficiency composite structure kiln of this utility model.

[0020] Figure 3 This is a side view of the high-efficiency composite structure kiln of this utility model.

[0021] Figure 4 This is a front structural diagram of the composite arched canopy and the outer structural wall in this utility model.

[0022] Figure 5This is a schematic diagram of the horizontal cross-section of the outer structural wall at the kiln door opening location in this utility model.

[0023] Figure 6 This is a schematic diagram of the composite foundation in this utility model.

[0024] Figure 7 This is a schematic diagram of the vertical cross-sectional structure of the composite arched canopy in this utility model.

[0025] Figure 8 This is a schematic diagram of the structure of the sealed kiln door in this utility model.

[0026] Figure 9 This is a schematic diagram of the horizontal cross-section structure of the sealing kiln door in this utility model.

[0027] Attached diagram labels: 1 - Composite foundation, 1.1 - Rigid part, 1.2 - Flexible part, 2 - Composite arch, 2.1 - Refractory mortar plaster layer, 2.2 - Refractory brick layer, 2.3 - Yellow mud plaster layer, 2.4 - Refractory soil layer, 3 - External structural wall, 4 - Fragment, 5 - Opening, 6 - Inner closing layer, 7 - Outer closing layer, 8 - Kiln door opening, 9 - Sealed kiln door, 9.1 - Double-layer steel door, 9.2 - Thermal insulation material, 9.3 - Sealing strip, 10 - Wall retaining wall, 11 - Observation window, 12 - Chimney. Detailed Implementation

[0028] like Figure 1-9 As shown, this high-efficiency composite structure kiln includes a composite foundation 1, a composite arch 2, and an outer structural wall 3. The composite foundation 1 has a break 4 at its front end, corresponding to the designed kiln door position. The composite arch 2 is mounted on top of the composite foundation 1, and its cross-section is a parabolic shape with the opening facing downwards, and the cross-section of the composite arch 2 is a variable cross-section. An outer structural wall 3 surrounds the composite arch 2. The height of the outer structural wall 3 is greater than the height of the composite foundation 1 and less than the height of the composite arch 2. The outer structural wall 3 has a front side... An opening 5 is provided at the position corresponding to the break 4; an inner closing layer 6 is provided on both sides of the break 4; an outer closing layer 7 is provided on both sides of the opening 5; the width between the two outer closing layers 7 gradually increases from the inside to the outside; the gap between the two inner closing layers 6 and the gap between the two outer closing layers 7 together form the kiln door opening 8; a sealed kiln door 9 is provided at the kiln door opening 8; a protective wall 10 is built in the space between the outer structural wall 3 and the composite arch 2 and on the top of the outer structural wall 3; a chimney 12 is provided on the top of the composite arch 2.

[0029] In this embodiment, the composite foundation 1 includes a rigid part 1.1 and a flexible part 1.2; the rigid part 1.1 is strip-shaped and runs along its entire length in the circumferential direction; the rigid part 1.1 is constructed of refractory bricks and is broken at the kiln entrance to form the fracture 4; the width of the rigid part 1.1 is 400~500mm and the height is 1500~1800mm; the flexible part 1.2 is paved with refractory sand and gravel, and the thickness of the refractory sand and gravel within the space enclosed by the rigid part is not less than 150mm; the flexible part 1.2 is later treated with ground treatment to form a kiln bed.

[0030] In this embodiment, the retaining wall 10 is constructed of red bricks and is constructed in a stepped manner.

[0031] In this embodiment, the composite structure kiln is equipped with 500 saggers, and the perimeter of the composite structure kiln is equipped with kiln firewood; the width of the composite structure kiln is not less than 5m~10m, the length is 15m~20m, and the height is 6m~8m.

[0032] In this embodiment, the composite arched canopy 2 is a multi-layered composite structure, comprising, from the inside out, a refractory mortar plaster layer 2.1, a refractory brick layer 2.2, a yellow mud plaster layer 2.3, and a refractory soil layer 2.4; the refractory brick layer 2.2 is constructed using refractory mortar; the thickness of the refractory mortar plaster layer 2.1 and the yellow mud plaster layer 2.3 is not less than 50 mm; and the thickness of the refractory soil layer 2.4 is not less than 100 mm.

[0033] In this embodiment, the cross-sectional height of the composite arched canopy 2 increases first and then decreases from front to back, and the cross-sectional width of the composite arched canopy 2 gradually decreases from front to back.

[0034] In this embodiment, the distance between the two inner closing layers 6 is not less than 500mm; the width of the inner side of the two outer closing layers 7 is adapted to the width of the two inner closing layers 6.

[0035] In this embodiment, the sealed kiln door 9 includes a double-layer steel door body 9.1, insulation material 9.2 filled inside the double-layer steel door body 9.1, a sealing strip 9.3 set on the edge of the double-layer steel door body 9.1, and an observation window 11; one side of the sealed kiln door 9 is rotatably connected to one side of the kiln door opening 8, and the other side of the sealed kiln door 9 is detachably connected to the other side of the kiln door opening 8.

[0036] In this embodiment, the sealed kiln door 9 and the outer structural wall 3 on one side of the kiln door opening 8 are rotatably connected by a door hinge, and the sealed kiln door 9 and the outer structural wall 3 on one side of the kiln door opening 8 are detachably connected by a latch.

[0037] In this embodiment, the external structural wall 3 utilizes the existing site or the walls of an existing abandoned kiln as a foundation. The original structural wall at the selected site is cleaned and reinforced, and a layer of insulation material is laid on its inner side. In this embodiment, by reinforcing and insulating the original structural wall, an external support and partial enclosure structure for the kiln is formed. This significantly reduces the cost of new construction materials and embodies the concept of sustainability.

[0038] The above embodiments are not exhaustive examples of specific implementation methods, and other embodiments may also exist. The purpose of the above embodiments is to illustrate the present utility model, rather than to limit the protection scope of the present utility model. All applications derived from simple variations of the present utility model fall within the protection scope of the present utility model.

Claims

1. A high-efficiency composite structure kiln, characterized in that: It includes a composite foundation (1), a composite arched canopy (2), and an outer structural wall (3); the front end of the composite foundation (1) has a break (4) at the location corresponding to the designed kiln door; the composite arched canopy (2) is set on the composite arched canopy (2), the cross-section of the composite arched canopy (2) is a parabola with the opening facing downwards, and the cross-section of the composite arched canopy (2) is a variable cross-section; an outer structural wall (3) is set around the composite arched canopy (2); the height of the outer structural wall (3) is greater than the height of the composite foundation (1) and less than the height of the composite arched canopy (2); on the front side of the outer structural wall (3), corresponding to the break (4) An opening (5) is provided at the location; an inner closing layer (6) is provided on both sides of the break (4); an outer closing layer (7) is provided on both sides of the opening (5); the width between the outer closing layers (7) on both sides gradually increases from the inside to the outside; the gap between the inner closing layers (6) on both sides and the gap between the outer closing layers (7) on both sides together form the kiln door opening (8); a sealed kiln door (9) is provided at the kiln door opening (8); a protective wall (10) is built in the space between the outer structural wall (3) and the composite arched canopy (2) and above the outer structural wall (3); a chimney (12) is provided on the top of the composite arched canopy (2).

2. The high-efficiency composite structure kiln according to claim 1, characterized in that: The composite foundation (1) includes a rigid part (1.1) and a flexible part (1.2); the rigid part (1.1) is strip-shaped and runs along the circumferential length; the rigid part (1.1) is constructed of refractory bricks and is broken at the kiln doorway to form the fracture (4); the flexible part (1.2) is laid with refractory sand and gravel, and the thickness of the refractory sand and gravel laid in the space enclosed by the rigid part (1.1) is not less than 150 mm.

3. The high-efficiency composite structure kiln according to claim 1, characterized in that: The composite arched canopy (2) is a multi-layered composite structure, comprising, from the inside out, a refractory mortar plaster layer (2.1), a refractory brick layer (2.2), a yellow mud plaster layer (2.3), and a refractory soil layer (2.4); the refractory brick layer (2.2) is constructed using refractory mortar; the thickness of the refractory mortar plaster layer (2.1) and the yellow mud plaster layer (2.3) is not less than 50 mm; and the thickness of the refractory soil layer (2.4) is not less than 100 mm.

4. The high-efficiency composite structure kiln according to claim 1, characterized in that: The cross-sectional height of the composite arched canopy (2) increases first and then decreases from front to back, and the cross-sectional width of the composite arched canopy (2) gradually decreases from front to back.

5. The high-efficiency composite structure kiln according to claim 1, characterized in that: The spacing between the inner closing layers (6) on both sides is not less than 500mm; the width of the inner side of the outer closing layers (7) on both sides is adapted to the width of the inner closing layers (6) on both sides.

6. The high-efficiency composite structure kiln according to claim 1, characterized in that: The sealed kiln door (9) includes a double-layer steel door body (9.1), insulation material (9.2) filled in the double-layer steel door body (9.1), a sealing strip (9.3) set on the edge of the double-layer steel door body (9.1), and an observation window (11); one side of the sealed kiln door (9) is rotatably connected to one side of the kiln door opening (8), and the other side of the sealed kiln door (9) is detachably connected to the other side of the kiln door opening (8).

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