A furnace combustion system
By improving the burner arrangement and refractory brick structure of the galvanizing furnace combustion system, and combining it with an intelligent control system, the problems of high gas consumption and poor heat insulation performance were solved, achieving more efficient energy utilization and safer production.
Patent Information
- Application Number
- CN202521832889.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-27
- Publication Date
- 2026-08-25
- Estimated Expiration
- 2035-08-27
AI Technical Summary
Traditional galvanizing furnace combustion systems suffer from high gas consumption, low energy efficiency, and poor insulation performance due to thermal expansion and contraction of refractory bricks, which affects product quality and increases safety hazards.
The burner arrangement has been improved to a diagonal setting, a high-speed pulse burner has been adopted, an aluminum silicate ceramic fiber insulation structure has been added, the refractory brick structure has been optimized to a mother-and-child brick structure and fixed by anchor rods, and an intelligent control system and a sound safety protection mechanism have been combined.
It improves the uniformity of zinc pot heating and heat preservation, reduces energy consumption and production costs, extends equipment life, and enhances production efficiency and safety.
Smart Images
Figure CN224681240U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of furnace and kiln equipment technology, and specifically to a furnace and kiln combustion system. Background Technology
[0002] Currently, traditional galvanizing furnace combustion systems have many drawbacks. Taking the original combustion systems of galvanizing lines 9 and 10 as an example, their burners adopt a parallel direct-fired configuration, which results in high gas consumption and low energy efficiency.
[0003] Meanwhile, the entire furnace body is insulated with refractory bricks. Over time, these bricks undergo repeated thermal expansion and contraction, leading to increased gaps between some bricks, poor insulation performance, and significant heat loss. This results in uneven heating of the zinc pot, affecting product quality and increasing production costs. In severe cases, refractory bricks may even bulge, posing a safety hazard. Utility Model Content
[0004] This invention provides a furnace combustion system to solve the technical problems in the prior art.
[0005] To solve the above problems, the furnace combustion system provided by this utility model adopts the following technical solution: furnace shell; Also includes: A heat-insulating structure is installed inside the furnace shell, and the heat-insulating structure is attached to the inner wall of the furnace shell; Refractory bricks are placed on the inside of the insulation structure; There are at least four burners, which are arranged diagonally inside the furnace to ensure that the flame is evenly distributed within the furnace chamber.
[0006] As a further improvement, the furnace shell is a steel structure furnace shell, with vertically arranged hollow steel welded to the outside of the furnace shell to improve the stability of the furnace shell.
[0007] As a further improvement, the insulation structure is an insulation blanket or insulation board.
[0008] As a further improvement, the insulation structure is an aluminum silicate ceramic fiber blanket or an aluminum silicate ceramic fiber board.
[0009] As a further improvement, the thickness of the insulation structure is not less than 450mm.
[0010] As a further improvement, the refractory brick is a mother-daughter brick, which includes a daughter brick with protrusions on the left and right sides, and a mother brick with grooves on the left and right sides that fits with the daughter brick. The daughter brick and the mother brick interlock to reduce heat loss and prevent the refractory brick from bulging or falling off in some places.
[0011] As a further improvement, the refractory bricks are fixedly connected to the furnace shell by anchor bolts to enhance their stability.
[0012] As a further improvement, the burner is a high-speed pulse burner.
[0013] The beneficial effects of the above-mentioned technical solution of this utility model are as follows: 1. This utility model adjusts the arrangement of the burners to make the flame distribution in the furnace more uniform and the heat transfer more efficient, effectively improving the uniformity of zinc pot heating, thereby improving product quality and reducing energy waste.
[0014] By adding insulation structures and improving the existing refractory brick structure, the insulation effect of the furnace and kiln has been greatly improved, energy consumption has been reduced, and safety hazards have been reduced.
[0015] 2. Through the above measures, energy conservation and consumption reduction are significant, and natural gas consumption is markedly reduced. Compared with the original galvanizing production line, natural gas consumption per ton of production capacity has decreased from 27 cubic meters / ton of output to 23 cubic meters / ton of output, saving an average of 50,400 yuan in natural gas costs per month, effectively reducing production costs.
[0016] Furthermore, improvements such as the diagonal arrangement of burners have made the zinc pot heating more uniform, increasing production efficiency and thus boosting production capacity. The production of guardrail panels can be increased by approximately 20-30 tons per day.
[0017] In addition, it extends the life of the equipment. The optimized combustion system and reinforced insulation structure reduce thermal shock and corrosion to the furnace equipment, which helps to extend the service life of zinc pots and other equipment and reduce equipment maintenance costs. Attached Figure Description
[0018] The above and other objects, features, and advantages of the present invention will become readily understood by reading the following detailed description of exemplary embodiments with reference to the accompanying drawings. In the drawings, several embodiments of the present invention are shown by way of example and not limitation, and like or corresponding reference numerals denote like or corresponding parts, wherein: Figure 1 This is a schematic diagram of the furnace combustion system of this utility model; Figure 2 This is a schematic diagram of the structure of Embodiment 2 of the furnace combustion system of this utility model; Figure 3 This is a schematic diagram of the structure of Embodiment 3 of the furnace combustion system of this utility model.
[0019] Explanation of reference numerals in the attached figures: 1. Furnace shell; 2. Insulation structure; 3. Refractory bricks; 301. Sub-bricks; 302. Mother bricks; 4. Burners; 5. Anchor bolts. Detailed Implementation
[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Those skilled in the art should understand that the embodiments described below are only some, not all, of the embodiments disclosed. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the scope of protection of the present utility model.
[0021] In existing technologies, the burners in traditional furnace combustion systems are arranged in a parallel, direct-fired configuration. This layout results in high gas consumption and low energy efficiency. Furthermore, with prolonged use, refractory bricks undergo multiple thermal expansion and contraction processes, leading to increased gaps between some bricks, poor insulation performance, and significant heat loss. This results in poor overall heating uniformity of the zinc pot, affecting product quality and increasing production costs.
[0022] To address the aforementioned issues, improvements will be made to the existing furnaces and kilns in three aspects: First, the burner arrangement was improved by changing the original side-by-side arrangement to a diagonal arrangement, resulting in a more even distribution of the flame within the furnace. The burners were also upgraded from the original high-power ordinary burners to high-speed pulse burners, which can precisely control the combustion process according to production needs, achieving energy savings.
[0023] Secondly, the furnace insulation was optimized. First, insulation blankets were added to reduce heat loss and prevent heat from escaping to the outside of the furnace, causing thermal shock and corrosion to pipes, wiring, and other equipment. Second, the refractory brick structure was optimized. The interlocking mother-and-child bricks extend the heat loss path, reducing heat dissipation. Furthermore, the interlocking of the refractory bricks prevents localized bulging, improving the internal stability of the furnace.
[0024] Thirdly, intelligent upgrades were implemented, introducing a high-speed pulse automatic control system for the combustion system. This system features rapid switching between manual and automatic modes. Through the combustion system's PLC, parameters such as air pressure, gas pressure, and exhaust pressure are monitored in real time. PID control enables automatic temperature regulation by the PLC, ensuring the furnace operates under optimal conditions. Simultaneously, a comprehensive safety interlock protection system was established, including overvoltage, overcurrent, short-circuit protection, and zinc temperature over-temperature protection, effectively ensuring production safety.
[0025] In addition, the supporting facilities have been improved. For example, the furnace shell has been reinforced, and the furnace top fire channel cover plate has been sealed with insulation blankets to further optimize the insulation effect.
[0026] After introducing the basic principles of this utility model, various non-limiting embodiments of this utility model are described in detail below. Any quantity of elements in the accompanying drawings is for illustrative purposes only and not for limitation, and any naming is for distinction only and has no limiting meaning.
[0027] The principles and spirit of this utility model will be explained in detail below with reference to several representative embodiments.
[0028] Example 1 of the furnace combustion system provided by this utility model: like Figure 1 As shown, the furnace combustion system includes, from the outside to the inside, a furnace shell 1, an insulation structure 2, refractory bricks 3, and burners 4 arranged diagonally inside the furnace.
[0029] The insulation structure 2 is disposed inside the furnace shell 1 and is attached to the inner side wall of the furnace shell 1. The insulation structure 2 is an insulation blanket or insulation board. In this embodiment, the insulation blanket (or insulation board) is made of high-purity aluminum silicate ceramic fiber 1260 folded block and the thickness of the insulation blanket (or insulation board) is not less than 450mm. In this embodiment, the thickness is 500mm.
[0030] Refractory bricks 3 are placed on the inside of the insulation structure 2; Four burners 4 are provided, arranged diagonally inside the furnace, with two burners 4 arranged on each side corner to ensure uniform flame distribution within the furnace chamber. In this embodiment, the burners 4 are high-speed pulse burners 4 with a power of 440KW.
[0031] The furnace shell 1 is a steel structure furnace shell 1, with vertically arranged hollow steel welded to the outside of the furnace shell 1 to improve the stability of the furnace shell 1.
[0032] In this embodiment, the combustion system employs a high-speed pulse automatic control system with rapid switching between manual and automatic modes. The combustion control system PLC uses a Siemens 1200 module to achieve precise control of the combustion process. The system can monitor parameters such as air pressure, gas pressure, and flue gas pressure in real time, and achieves automatic temperature control via PID regulation to ensure the furnace operates under optimal conditions. Simultaneously, a comprehensive safety interlock protection system is implemented, including overvoltage, overcurrent, short-circuit protection, and zinc temperature over-temperature protection, effectively ensuring production safety.
[0033] Example 2 of the furnace combustion system provided by this utility model: Its main difference from Example 1 is: In this embodiment, the refractory brick 3 is a mother-daughter brick, which includes a daughter brick 301 with protrusions on the left and right sides, and a mother brick 302 with grooves on the left and right sides that cooperate with the daughter brick 301. The daughter brick 301 and the mother brick 302 are interlocked to reduce heat loss and prevent the refractory brick 3 from bulging or falling off in some places.
[0034] Example 3 of the furnace combustion system provided by this utility model: Its main difference from Example 1 is: In this embodiment, the refractory bricks 3 are fixedly connected to the furnace shell 1 by anchor rods 5 to improve the stability of the refractory bricks 3. Since the refractory bricks 3 on each side are interlocked, only 2-3 anchor rods 5 are needed on each side. The anchor rods 5 are L-shaped, and the corresponding refractory bricks 3 have vertical blind holes. The other end of the anchor rods 5 is connected to the furnace shell 1 by bolts for easy disassembly.
[0035] While this specification has shown and described numerous embodiments of the present invention, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Many modifications, alterations, and alternatives will occur to those skilled in the art without departing from the spirit and intent of the present invention. It should be understood that various alternatives to the embodiments of the present invention described herein may be employed in the practice of the present invention. The appended claims are intended to define the scope of protection of the present invention and therefore cover the modular compositions, equivalents, or alternatives within the scope of these claims.
Claims
1. A furnace combustion system, comprising: Furnace shell (1); Its characteristic is that it further includes: The heat insulation structure (2) is installed inside the furnace shell (1) and the heat insulation structure (2) is attached to the inner wall of the furnace shell (1); Refractory bricks (3) are placed inside the insulation structure (2); Burners (4) are provided at least four times. The four burners (4) are arranged diagonally in the furnace so that the flames are evenly distributed in the furnace.
2. The furnace combustion system according to claim 1, characterized in that: The furnace shell (1) is a steel structure furnace shell (1), and vertically arranged hollow steel is welded on the outside of the furnace shell (1) to improve the stability of the furnace shell (1).
3. The furnace combustion system according to claim 1, characterized in that: The insulation structure (2) is an insulation blanket or insulation board.
4. The furnace combustion system according to claim 3, characterized in that: The insulation structure (2) is an aluminum silicate ceramic fiber blanket or an aluminum silicate ceramic fiber board.
5. The furnace combustion system according to claim 4, characterized in that: The thickness of the insulation structure (2) is not less than 450 mm.
6. The furnace combustion system according to claim 1, characterized in that: The refractory brick (3) is a mother-daughter brick, which includes a daughter brick (301) with protrusions on the left and right sides, and a mother brick (302) with grooves on the left and right sides that fit with the daughter brick (301). The daughter brick (301) and the mother brick (302) interlock to reduce heat loss and prevent the refractory brick (3) from bulging or falling off in some places.
7. The furnace combustion system according to claim 6, characterized in that: The refractory brick (3) is fixedly connected to the furnace shell (1) by anchor bolts (5) to improve the stability of the refractory brick (3).
8. The furnace combustion system according to claim 1, characterized in that: The burner (4) is a high-speed pulse burner (4).