Repair System and Repair Method

Abstract

To provide a repair system and a repair method which efficiently sort and collect crushed pieces generated upon repairing a structure having a refractory layer and facilitate their reutilization.SOLUTION: Provided is a repair system for a structure having a refractory layer on an inner face. The repair system comprises: a three-dimensional shape measurement device for measuring a three-dimensional shape of the inner face in the structure; a calculation device for determining a range to be removed in the refractory layer by dividing the same into plural layers in a depth direction based on the three-dimensional shape measured by the three-dimensional shape measurement device; a crushing device for crushing the refractory layer per layer based on the result calculated by the calculation device; and a separation and collection device for sorting crushed pieces crushed by the crushing device per crushed layer and collecting the same.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a repair system for a structure having a refractory layer on its inner surface. The present invention also relates to a method for repairing a structure having a refractory layer on its inner surface.

Background Art

[0002] In a structure for holding a high-temperature content, in order to protect the structure from the heat of the content, a refractory layer is generally provided as a lining on the inner surface of the structure. Examples of such a structure having a refractory layer include a container for holding molten metal (hereinafter referred to as "molten metal container") and a trough for molten metal such as a blast furnace trough.

[0003] However, when such a structure is used, the refractory layer gradually deteriorates due to wear caused by contact with the high-temperature content and spalling (cracking, peeling) caused by thermal shock or the like. Therefore, in order to maintain the function of the refractory layer, it is necessary to perform repairs regularly.

[0004] As a method for repairing a refractory layer, a method of spraying an amorphous refractory is generally used. However, when an amorphous refractory is sprayed on a deteriorated refractory layer, an interface between the deteriorated refractory layer and the new refractory layer remains inside the repaired refractory layer. In addition, slag (build-up) such as molten metal or slag attached to the surface of the deteriorated refractory layer may be attached when the structure was in use. Therefore, when cracks occur in the new refractory layer on the surface side during use of the repaired structure, molten metal or the like may penetrate through the cracks to the interface between the deteriorated refractory layer and the new refractory layer, causing the new refractory layer to peel off.

[0005] Therefore, in order to prevent the above peeling, when repairing the refractory layer, the surface of the repair portion is chipped to remove the deteriorated refractory layer and the deposits attached to the surface of the refractory layer, and then an amorphous refractory is sprayed.

[0006] For example, Patent Document 1 describes that when spray-repairing the lining of the inner surface of a molten metal container, the deteriorated layer on the surface of the refractory layer is crushed and removed over the entire surface in advance by a crushing tool.

Prior Art Document

Patent Document

[0007]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0008] However, in actual structures, the thickness of the buildup adhering to the surface of the refractory layer and the thickness of the deteriorated layer are not necessarily constant. Also, as a result of a part of the deteriorated refractory layer peeling off, there may be cases where the deteriorated layer is partially thin. Therefore, if the deteriorated layer is removed by the method described in Patent Document 1, sound refractory that is not deteriorated will also be removed, resulting in an increase in the amount of monolithic refractory required for repair and waste in the repair cost. On the contrary, in parts where the deteriorated layer is thick, there may be cases where the deteriorated layer remains without being completely removed.

[0009] Therefore, the inventors have devised a technique for measuring the three-dimensional shape of the inner surface of a structure and determining the range (depth) for removing the refractory layer based on the obtained three-dimensional shape. According to the said technique, it is possible to accurately remove the buildup and the deteriorated layer adhering to the surface of the refractory layer, and to reduce the amount of the non-deteriorated refractory layer removed. Therefore, according to the said technique, in addition to improving the repair quality, it is possible to reduce the amount of monolithic refractory used and the repair cost.

[0010] However, when the refractory layer is crushed and removed as in the above-described technique, a large amount of crushed pieces are generated. Disposing of these crushed pieces as industrial waste not only requires a great deal of cost but is also undesirable from the perspective of resource conservation. Therefore, it is required to reuse the refractory recovered as crushed pieces.

[0011] However, as described above, since build-ups such as slag and metal adhere to the surface of the refractory layer, components other than the refractory are mixed in the crushed pieces recovered by crushing. Therefore, it is difficult to reuse the crushed pieces as they are.

[0012] After collecting the crushed pieces, it is also conceivable to separate the components using a specific gravity separator or a magnetic separator. However, separation is difficult if there is not enough difference in physical properties such as magnetism and specific gravity between the refractory and other mixed components. For example, it is difficult to separate build-ups composed of slag or the like from the refractory because the difference in physical properties is small.

[0013] The present invention has been made in view of the above circumstances, and an object thereof is to efficiently separate and recover crushed pieces generated when repairing a structure having a refractory layer and to facilitate reuse.

Means for Solving the Problems

[0014] The present invention has been made to solve the above problems, and the main configuration is as follows.

[0015] 1. A repair system for a structure having a refractory layer on its inner surface, a three-dimensional shape measuring device that measures the three-dimensional shape of the inner surface of the structure, an arithmetic device that determines the range to be removed from the refractory layer by dividing it into a plurality of layers in the depth direction based on the three-dimensional shape measured by the three-dimensional shape measuring device, a crushing device that crushes the refractory layer for each of the layers based on the result calculated by the arithmetic device, and a separation and recovery device that separates and recovers the crushed pieces crushed by the crushing device for each of the crushed layers.

[0016] 2. Further, a control device is provided that measures the load applied to the crushing device and adjusts the range to be crushed for each layer based on the measured load. The repair system according to 1 above.

[0017] 3. Further, a color information acquisition device for acquiring the color information of the inner surface of the structure is provided. The arithmetic unit determines the plurality of layers in consideration of the color information acquired by the color information acquisition device in addition to the three-dimensional shape measured by the three-dimensional shape measurement device. The repair system according to 1 or 2 above.

[0018] 4. Further, a sorting device is provided that further sorts at least one of the fractions recovered by the separation and recovery device based on the physical properties of the crushed pieces contained in the fraction. The repair system according to any one of 1 to 3 above.

[0019] 5. A method for repairing a structure having a refractory layer on its inner surface, A three-dimensional shape measurement step of measuring the three-dimensional shape of the inner surface of the structure, An arithmetic step of determining, based on the three-dimensional shape measured in the three-dimensional shape measurement step, the range to be removed from the refractory layer by dividing it into a plurality of layers in the depth direction, A crushing step of crushing the refractory layer for each layer based on the result calculated in the arithmetic step, A separation and recovery step of separating and recovering the crushed pieces crushed in the crushing step for each crushed layer. The repair method includes these steps.

[0020] 6. Further, a control step of measuring the load in the crushing step and adjusting the range to be crushed for each layer based on the measured load is included. The repair method according to 5 above.

[0021] 7. Further, a color information acquisition step of acquiring the color information of the inner surface of the structure is included. In the calculation step, in addition to the three-dimensional shape measured in the three-dimensional shape measurement step, the plurality of layers are determined in consideration of the color information obtained in the color information acquisition step, according to the repair method described in 5 or 6 above.

[0022] 8. Further, the repair method according to any one of 5 to 7 above includes a sorting step of further sorting at least one of the fractions recovered in the separation and recovery step based on the physical properties of the crushed pieces contained in the fraction.

Advantages of the Invention

[0023] According to the present invention, it is possible to separate and recover crushed pieces having different compositions without mixing them. Therefore, according to the present invention, the recovered crushed pieces can be easily reused. Further, if the separated and recovered fractions are further sorted, the components can be separated with even higher accuracy.

Embodiments for Carrying Out the Invention

[0024] Hereinafter, examples of embodiments of the present invention will be specifically described. Note that the following description is illustrative of embodiments of the present invention, and the present invention is not limited to the following embodiments in any way.

[0025] [Structure] The present invention is for repairing a structure having a refractory layer on its inner surface. As the structure, any structure can be targeted as long as it has a refractory layer on at least its inner surface. The structure may be, for example, a structure for molten metal. Examples of the structure for molten metal include molten metal containers such as hot metal ladles, steel tapping ladles, and refining vessels, and molten metal troughs such as blast furnace troughs.

[0026] The present invention can be applied to refractory layers having any material and structure. Therefore, the refractory layer provided on the inner surface of the structure may have any material and structure as long as it is a layer composed of refractory.

[0027] In addition, it is also common practice to configure the refractory layer as the lining with a layer of standard refractories called perma bricks and a layer of unshaped refractories. For example, a typical structure for molten metal includes a metal structure body called an iron skin, a layer of standard refractories (perma bricks) provided on the inner surface of the metal structure body, and a layer of unshaped refractories provided on the inner surface of the standard refractory layer. The refractory layer is composed of the standard refractory layer and the unshaped refractory layer. The present invention can also be suitably used for repairing a refractory layer having the above structure.

[0028] In the following embodiments, mainly as a typical example, the case where the structure is a molten metal container will be described. However, as described above, the present invention is applicable not only to molten metal containers but also to any structure.

[0029] (First Embodiment) The repair system according to an embodiment of the present invention includes a three-dimensional shape measuring device, a computing device, a crushing device, and a separation and recovery device. Further, the repair method according to an embodiment of the present invention includes a three-dimensional shape measurement step, a computing step, a crushing step, and a separation and recovery step.

[0030] [Three-Dimensional Shape Measurement] In the present invention, the three-dimensional shape of the inner surface of the structure is measured, and based on the result, the area to be removed from the refractory layer is divided into a plurality of layers in the depth direction. Therefore, prior to removing the refractory layer, the three-dimensional shape of the inner surface of the structure is measured.

[0031] The three-dimensional shape measuring device (hereinafter sometimes simply referred to as the "measuring device") used for measuring the three-dimensional shape is not particularly limited, and any device can be used as long as it can measure the three-dimensional shape of the inner surface of the structure. Preferred measuring devices that can be used include, for example, a three-dimensional laser scanner, a three-dimensional shape measuring device using the photogrammetry method, a three-dimensional shape measuring device using the pattern projection method, etc. Among them, it is preferable to use a three-dimensional laser scanner.

[0032] The measurement of the three-dimensional shape may be performed once or multiple times. When the entire measurement range fits within the field of view of the measurement device to be used, three-dimensional shape data of the entire structure can be obtained by a single measurement. For example, when the structure is a container, a three-dimensional laser scanner is arranged on the central axis of the container and at the height of the container opening, and by performing a 360° laser scan around the central axis of the container, the three-dimensional shape of the inner surface of the container can be acquired by a single measurement. On the other hand, when performing measurement by photogrammetry, due to the measurement principle that the measurement range is limited to the camera field of view, the inner surface of the structure is measured multiple times while changing the orientation and position of the measurement device (camera), and the three-dimensional shape data of the entire inner surface of the structure can be obtained by synthesizing the data in post-processing.

[0033] The measurement device may be provided in a crushing device described later, or may be provided as a separate body from the crushing device. When the measurement device is provided as a separate body from the crushing device, the measurement device can also be installed in the equipment using the target structure. For example, when the structure is a container (ladle) for transporting molten steel in a steelworks, each time the container is used for one charge, the three-dimensional shape of the inner surface of the container is measured with the measurement device installed in the equipment, and it is also possible to determine whether repair is necessary as described below. Here, "charge" refers to the cycle from receiving molten metal from a converter or the like into the container, passing through a secondary refining process to remove impurities in the molten steel, and sending the molten metal to a casting facility or the like in the next process until the container becomes empty.

[0034] Further, the repair method according to an embodiment of the present invention may further include a repair necessity determination step of determining whether to perform repair based on the three-dimensional shape obtained in the measurement step before proceeding to the following calculation step. Similarly, a repair system according to an embodiment of the present invention may further include a repair necessity determination device that determines whether to perform repair based on the three-dimensional shape obtained in the measurement step. The determination of whether repair is necessary can be made, for example, based on the three-dimensional shape, to determine that repair is to be performed when the thickness of the refractory layer has reached a certain level (threshold).

[0035] [Calculation] Next, based on the three-dimensional shape of the inner surface of the obtained structure, the range to be removed from the refractory layer is determined by dividing it into a plurality of layers in the depth direction. That is, since the three-dimensional shape of the inner surface of the structure is the profile of the surface including the refractory layer and the buildup adhering to its surface, in this profile, the portions that are convex are likely to have a thick buildup adhering, and therefore it can be determined that the removal amount needs to be large for those portions. On the contrary, the portions that are concave in this profile are likely to be concave as a result of the deteriorated refractory layer peeling off, and therefore, the removal amount for those portions may be reduced. Thus, based on the three-dimensional shape of the inner surface of the structure, the range to be removed from the refractory layer in each part can be determined.

[0036] Furthermore, in the present invention, the separated and recovered by a separation and recovery device described later. For this purpose, in the above calculation, it is important to determine the range to be removed from the refractory layer by dividing it into a plurality of layers in the depth direction.

[0037] For example, in the case of the refractory layer of a molten metal container, cracks occur on the surface of the refractory layer by contacting with high-temperature molten metal. Then, a deteriorated layer is formed by the infiltration of the molten metal into the cracks. The thickness of the deteriorated layer gradually increases in the depth direction starting from the surface of the original refractory layer. On the other hand, a buildup such as slag adheres to the surface of the refractory layer to form a buildup layer. The thickness of the buildup layer gradually increases in the outward direction (opposite to the growth direction of the deteriorated layer) starting from the surface of the original refractory layer.

[0038] The deteriorated layer is mainly composed of refractories and partially contains infiltrated metal. On the other hand, the build-up layer is composed of slag such as oxides and metal. Thus, since the deteriorated layer and the build-up layer have different compositions, it is desirable to separate and recover them. Therefore, in that case, in the calculation process, it is preferable to divide the range to be removed from the refractory layer into the deteriorated layer and the build-up layer based on the three-dimensional shape measured by the three-dimensional shape measuring device.

[0039] In the above example, the case of dividing the range to be removed from the refractory layer into two layers, namely the build-up layer and the deteriorated layer, has been described. However, the number of layers is not limited to 2 and can be any number according to the actual state of the refractory layer. However, if the number of layers is excessively large, it becomes difficult to distinguish layers with different compositions, and in addition, the device structure becomes complicated. Therefore, the number of layers is preferably 5 or less, and more preferably 4 or less. In a typical structure, the number of layers is about 2 to 3. For example, in a structure that handles molten metal such as a molten metal container, a sheet-like metal layer may be formed between the build-up layer and the deteriorated layer. In that case, it can be divided into three layers: the build-up layer, the metal layer, and the deteriorated layer in order from the surface side. Also, when a part of the non-deteriorated refractory layer (hereinafter referred to as the sound layer) is also removed, it can be divided into three layers: the build-up layer, the deteriorated layer, and the sound layer in order from the surface side. Furthermore, it may be divided into four layers: the build-up layer, the metal layer, the deteriorated layer, and the sound layer in order from the surface side.

[0040] In other words, in the calculation process, the total range (depth) for finally crushing and removing the refractory layer is determined, and the boundary where the composition changes significantly within the range is specified, and the range to be removed can be divided into a plurality of layers with the boundary as the boundary. Thereby, it becomes possible to perform crushing for each layer and separate and recover the generated crushed pieces.

[0041] Regarding the depth of the deteriorated layer, for example, it is also possible to estimate it from the usage history of the container (number of uses, specified time, etc.). Therefore, in the above calculation, the estimated thickness of the deteriorated layer estimated from the usage history of the container can also be used. Also, the thickness of the formed deteriorated layer tends to saturate to a certain extent (for example, 30 to 40 mm, etc.). Therefore, the saturation thickness of the known deteriorated layer can be input into the arithmetic unit in advance and used for the above calculation. Also, in the above calculation, the calculation may be performed with reference to the three-dimensional shape (initial shape) of the inner surface of the structure before use.

[0042] Furthermore, the refractory layer may partially peel off during use. For example, when a thermal shock is applied to the refractory layer in a state where cracks have occurred and deterioration has progressed as described above, the deteriorated layer partially peels off due to differences in the coefficient of thermal expansion between the normal refractory layer and the deteriorated layer. As a result, at the portion where peeling has occurred, the non-deteriorated refractory layer is exposed on the surface. If the structure continues to be used in that state, a new deteriorated layer and build-up layer grow starting from the surface of the refractory layer exposed by the peeling. Therefore, in order to more accurately determine the range where the refractory layer should be removed, it is desirable to consider the occurrence of the above peeling.

[0043] For that purpose, it is preferable to periodically measure the three-dimensional shape of the inner surface of the structure over the entire period of use of the structure and use the measurement data for the above calculation. By referring to the measurement data, it is possible to determine the occurrence of peeling and identify the peeled site and the position of the surface exposed by the peeling.

[0044] In the above calculation process, it is also preferable to determine the path for scanning the crushing device in order to sequentially crush and remove each layer.

[0045] In addition, in determining the range for removing the refractory layer, it is also preferable to use in combination three-dimensional shape data (hereinafter referred to as removal limit data) representing the removal limit position prepared in advance. Here, the removal limit position refers to a position beyond which (deeper than this position) removal should not be performed. When determining the range for removing the refractory layer, by referring to the removal limit data, it is possible to prevent excessive removal of the refractory layer and damage to parts other than the refractory layer (such as the container body) by tools.

[0046] For example, as described above, when the refractory layer is composed of a layer of regular refractory called perma bricks and a layer of amorphous refractory, it is preferable to remove only the layer of amorphous refractory and not remove the layer of regular refractory. Therefore, in such a case, by using the three-dimensional shape data of the state where only the layer of regular refractory is provided and the layer of amorphous refractory is not provided as the removal limit data, it is possible to prevent the layer of regular refractory from being removed.

[0047] [Crushing] Next, based on the result calculated in the calculation step, the refractory layer is crushed layer by layer. The repair system of the present invention includes a crushing device used for the crushing.

[0048] As the crushing device, any device can be used without particular limitation as long as it can crush regular refractory. Typically, a crushing device that crushes the refractory layer by applying one or both of a rotational force and an impact force to a crushing tool in contact with the refractory layer is used. When applying the impact force, a reciprocating motion that moves the crushing tool forward and backward with respect to the surface of the refractory layer may be performed. As the crushing tool, for example, a hydraulic drifter can be preferably used.

[0049] In the crushing process, the surface of the refractory layer is crushed using the crushing device. At this time, it is preferable to perform the crushing while moving the crushing device along the surface of the refractory layer. In other words, the crushing device preferably includes a moving means for moving the crushing tool. Further, in order to perform the removal while scanning the tool along the inner surface of the container, the crushing device preferably includes a moving means for three-dimensionally moving the crushing tool and an attitude control means for controlling the attitude (orientation) of the crushing tool. As the moving means and the attitude control means, for example, the arm of a heavy machine can also be used. As the heavy machine, for example, it is preferable to use a heavy machine including a vehicle body main body driven by a caterpillar or the like and an arm capable of positioning a tool with six degrees of freedom (position / rotation in three axial directions) or more degrees of freedom.

[0050] When performing the removal while scanning the crushing tool along the inner surface of the container, the scanning pattern is not particularly limited and may be determined according to the crushing device to be used and the shape of the container to be targeted. Considering that the cutting powder falls downward, it is preferable to repeat the operation of removing while scanning in the circumferential direction of the inner surface of the container from the bottom upward.

[0051] Further, when performing the crushing while scanning the crushing tool along the inner surface of the container, the scanning can be performed any number of times. In the present invention, since the refractory layer is crushed layer by layer, each layer can be crushed by scanning any number of times, but typically it is preferable to crush each layer by one scan.

[0052] The crushing device may be provided with the three-dimensional shape measuring device described above. When the crushing device is provided with the three-dimensional shape measuring device, the three-dimensional shape of the inner surface of the container can be measured by the three-dimensional shape measuring device, and the crushing device can be controlled based on the result.

[0053] Further, the crushing device may be provided with a second measuring device that measures the three-dimensional shape of the inner surface of the container, which is different from the three-dimensional shape measuring device (hereinafter referred to as the first measuring device). When the crushing device is provided with the second measuring device, alignment of the crushing device can be performed using the measurement result of the second measuring device. For example, after installing the crushing device at the position for crushing, measurement is performed by the second measuring device, and alignment can be easily performed by using the result. As a more specific example, the three-dimensional shape of the inner surface of the structure is measured using the first measuring device installed in the facility (such as a factory) using the structure, and the first three-dimensional shape data is obtained. Then, the second three-dimensional shape data is obtained using the second measuring device provided in the crushing device, and alignment (origin setting) of the crushing device can be performed by comparing the first three-dimensional shape data and the second three-dimensional shape data. As a method of comparing the first three-dimensional shape data and the second three-dimensional shape data, for example, a method of fitting one to the other can be mentioned. It is also possible to obtain the coordinate transformation matrix between the coordinate system of the first three-dimensional shape data and the coordinate system of the second three-dimensional shape data.

[0054] [Separation and recovery] In the present invention, the crushed pieces crushed in the crushing step are separated and recovered for each of the crushed layers. By performing separation and recovery in this way, it is possible to separate and recover the crushed pieces such as refractories crushed by the crushing device without mixing them. The repair system in one embodiment of the present invention includes a separation and recovery device for performing the above separation and recovery.

[0055] As the separation and recovery device, any device can be used without particular limitation as long as it can separate and recover the crushed pieces. For example, the separation and recovery device preferably includes a plurality of recovery containers, transfer means for transferring the crushed pieces crushed by the crushing device to the recovery containers, and switching means for switching which recovery container to recover the crushed pieces transferred by the transfer means to.

[0056] The transfer means may be a chute or the like that transfers by utilizing the self-weight of the crushed pieces, but it is preferably configured to suck and transfer. For example, a method may be considered in which a suction nozzle is provided below the crushing tool, the suction nozzle and the recovery container are connected by a duct, and negative pressure is applied to the duct to suck air. Note that the crushed pieces that could not be recovered may be allowed to fall directly to the bottom of the structure, and after the crushing and removal of the refractory are completed, they may be recovered and put into the recovery container.

[0057] In addition, the number of fractions separated and recovered in this separation and recovery step may usually be the same as the number of layers determined in the above calculation step. For example, in the calculation step, when the range to be removed is determined by dividing it into two layers, namely, a deteriorated layer and a build-up layer, in the separation and recovery step, the crushed pieces generated by crushing the build-up layer may be recovered as the first fraction, and the crushed pieces generated by crushing the deteriorated layer may be recovered as the second fraction into separate recovery containers.

[0058] As the recovery container, any container can be used as long as it can accommodate the crushed pieces. The number of the recovery containers is not particularly limited and can be any number. The number of recovery containers may be the same as the number of fractions, but one fraction may be divided and recovered into a plurality of containers.

[0059] The switching of the recovery destination can be performed by any method. Typically, the recovery destination may be switched by operating the switching means in accordance with the timing when the layer to be crushed changes. As the switching means, any means can be used as long as it can switch which recovery container to recover into. For example, the transfer destination by the transfer means can be branched into a plurality of recovery containers, and switching can be performed by operating a valve provided at the branch portion. The switching may be manually performed by an operator or automatically performed using a solenoid valve or the like. Also, the switching may be performed by replacing the recovery container connected to the transfer means. Regarding the replacement of the recovery container, it may be manually performed by an operator or automatically performed by a replacement means.

[0060] (Second Embodiment) The repair system in the second embodiment of the present invention further includes a control device that monitors the load applied to the crushing device and adjusts the range of crushing for each layer based on the load.

[0061] Also, the repair method in the second embodiment of the present invention further includes a control step of measuring the load in the crushing step and adjusting the range of crushing for each layer based on the measured load.

[0062] As described above, a build-up may adhere to the surface of the refractory layer. However, since the materials of the refractory and the build-up are different, their physical properties (such as hardness) are different. Also, even in the same refractory layer, the physical properties are different between the part where the molten metal has infiltrated and deteriorated (deteriorated layer) and the part that has not deteriorated (sound layer). Therefore, by measuring the load applied to the crushing device during removal, it is possible to know the change in the physical properties of the part being removed at present. Therefore, by adjusting the range of removing the refractory layer based on the load, the removal can be performed more accurately.

[0063] The specific method of adjustment is not particularly limited. For example, it is also possible to detect the change in the part being removed (for example, from the build-up layer to the deteriorated layer, from the deteriorated layer to the sound layer) based on the change in the load, and determine whether to continue or end the removal at that site based on this. As another example, an appropriate threshold value is set in advance, and by comparing the load with the threshold value, it is possible to determine which of the build-up layer, deteriorated layer, and sound layer the part being removed at present is, and determine whether to continue or end the removal in that layer based on this.

[0064] By performing such adjustment, in addition to enabling more accurate removal of the build-up layer and deteriorated layer than when performing removal based only on the measurement result of the three-dimensional shape, it is possible to further reduce the amount of the non-deteriorated refractory layer that is removed.

[0065] For example, when the process of removing the tool while scanning it with a constant cutting amount in the depth direction is repeated two passes (twice) or more, the load value is evaluated every time one pass (once) of scanning is completed, and if it is determined that the sound layer has been reached, subsequent passes can be omitted.

[0066] Note that as the load to be measured, any load can be used as long as it reflects the change in the physical properties of the crushed part. Typically, it is preferable to use the load applied to the actuator that drives the crushing tool. For example, when the crushing tool is rotated by a motor, the load applied to the motor can be monitored. If the motor is a hydraulic motor, the hydraulic pressure can be monitored.

[0067] (Third Embodiment) The repair system in the third embodiment of the present invention further includes a color information acquisition device that acquires the color information of the inner surface of the structure, and the arithmetic device determines the plurality of layers in consideration of the color information acquired by the color information acquisition device in addition to the three-dimensional shape measured by the three-dimensional shape measurement device.

[0068] Further, the repair method in the third embodiment of the present invention further includes a color information acquisition step of acquiring the color information of the inner surface of the structure, and in the arithmetic step, the plurality of layers are determined in consideration of the color information acquired in the color information acquisition step in addition to the three-dimensional shape measured in the three-dimensional shape measurement step.

[0069] As described above, build-up may adhere to the surface of the refractory layer. However, since the refractory and the build-up are made of different materials, their color tones are different. Also, even in the same refractory layer, the color tones of the deteriorated part (deteriorated layer) and the non-deteriorated part (sound layer) are also different. For example, the non-deteriorated sound layer maintains the original color of the refractory (typically bright brown), while the deteriorated layer deteriorated by contact with molten metal has changed to a color darkened by penetration of the metal. Therefore, by acquiring the color information of the inner surface of the structure, the material of the relevant part can be known. Thus, when performing calculations to determine the range for removing the refractory layer, in addition to the three-dimensional shape, by considering the color information, it becomes possible to perform the removal more accurately.

[0070] The method of using the color information is not particularly limited, but it is preferable to set a threshold value in advance and compare the threshold value with the color information to determine whether the relevant part is a build-up layer, a deteriorated layer, or a sound layer.

[0071] As the color information acquisition device, any device can be used as long as it can acquire the color information of the inner surface of the container. Typically, a digital camera can be used. When using a color information acquisition device, the color information acquisition device and the measuring device used for measuring the three-dimensional shape may be separate or integrated. In other words, the measuring device used for measuring the three-dimensional shape may also serve as the color information acquisition device. For example, some laser scanners for measuring three-dimensional shapes have a built-in digital camera for taking color images, and it is possible to map color information (RGB) to each point included in the three-dimensional point cloud data obtained by the laser scanner. Such a digital camera built-in type laser scanner can be suitably used as a measuring device and a color information acquisition device.

[0072] When using the color information acquisition device, in the first-pass scanning based on the measured three-dimensional shape, the build-up layer adhering to the inner surface of the container is removed, and then the color information acquisition device acquires color information, and based on the result, it is also possible to determine whether the exposed surface is a deteriorated layer or a sound layer. Thereby, the removal amount in the second pass can be determined in consideration of the determination result based on the color information.

[0073] (Fourth Embodiment) The repair system in the fourth embodiment of the present invention further includes a sorting device that further sorts at least one of the fractions recovered by the separation and recovery device based on the physical properties of the crushed pieces contained in the fraction.

[0074] Also, the repair method in the fourth embodiment of the present invention further includes a sorting step of further sorting at least one of the fractions recovered by the separation and recovery device based on the physical properties of the crushed pieces contained in the fraction.

[0075] As described above, the fractions separated and recovered layer by layer are composed of different components. Typically, the build-up layer, which is the layer located on the surface side, is composed of slag such as oxides adhered when using the structure, or metal. On the other hand, the deteriorated layer located under the build-up layer has a refractory as the main component and partially contains infiltrated metal.

[0076] Therefore, among the respective fractions recovered in the separation and recovery step, a plurality of components are mixed, such as refractory and metal, slag and metal. Therefore, by further sorting the fractions obtained in the separation and recovery step, components such as metal, slag, and refractory can be separated with higher accuracy. The crushed pieces separated and sorted in this way can be reused in a wider range of applications.

[0077] As the sorting device, any device can be used without particular limitation. For example, when the metal contained in the crushed pieces is a magnetic material, a magnetic separator can be used to separate the magnetic metal from the slag and refractory materials that are non-magnetic materials. When the metal is a non-magnetic material, a specific gravity separator can be used. The sorting accuracy can also be improved by combining two or more types of sorting machines.

[0078] In addition, when the size of the recovered crushed pieces is large and it is difficult to directly feed them into the sorting machine, it is preferable to first finely crush the crushed pieces through a crusher and then perform sorting.

[0079] Next, an example of a more preferred embodiment of the present invention will be described below.

[0080] (1) Measure the three-dimensional shape (shapes 1 to N) of the inner surface of the structure from the start of use (shape 1) to the end of use (shape N). (2) Based on the history of the three-dimensional shapes obtained by the above measurement, determine the scanning range for crushing the build-up layer and the deteriorated layer for each layer, and scan the crushing tool to remove the build-up layer on the inner surface of the container (first pass). (3) Collect the crushed pieces generated by crushing the build-up layer into the first collection container. (4) Measure the three-dimensional shape (shape N + 1) of the inner surface of the structure after crushing and removing the build-up layer, and determine from the difference between shape N and shape N + 1 which of the following states each part of the inner surface of the structure is in after the second pass of removal. A) The state where the build-up layer and the deteriorated layer are peeled off integrally (the surface of the sound layer is exposed) B) The surface where only the build-up layer is crushed (the surface of the deteriorated layer is exposed) C) The state where there was originally no build-up but peeling of the deteriorated layer occurred (the surface of the sound layer is exposed) D) The state where there was originally no build-up and no peeling occurred (the surface of the deteriorated layer is exposed) Here, "peeling" refers to the peeling of the layer of the uncrushed part due to vibration during crushing or the like. *Difference between Shape N and Shape N+1: A > B > C > D *Degree of indentation in Shape N+1: A ≒ C > B ≒ D Color information can also be used to determine whether the sound layer is exposed. (5) Based on the above determination result, determine the scanning range for removing the deteriorated layer, and scan the crushing tool to crush the inner surface of the structure again (the second pass). At this time, the part where the sound layer is exposed is not removed. (6) Collect the crushed pieces generated by crushing the deteriorated layer into the second collection container. (7) Sort the respective crushed pieces collected in (3) and (6) above according to physical properties such as magnetism and specific gravity to sort metals, slag, and refractories.

Claims

1. A repair system for a structure having a refractory layer on its inner surface, comprising: a three-dimensional shape measuring device for measuring the three-dimensional shape of the inner surface of the structure; an arithmetic unit for determining, based on the three-dimensional shape measured by the three-dimensional shape measuring device, a range to be removed from the refractory layer by dividing it into a plurality of layers in the depth direction; a crushing device for crushing the refractory layer for each of the layers based on the result calculated by the arithmetic unit; a separation and recovery device for separating and recovering the crushed pieces crushed by the crushing device for each of the crushed layers.

2. The repair system according to claim 1, further comprising a control device that measures the load applied to the crushing device and adjusts the crushing range for each of the layers based on the measured load.

3. The repair system according to claim 1 or 2, further comprising a color information acquisition device for acquiring color information on the inner surface of the structure, wherein the arithmetic unit determines the plurality of layers in consideration of the color information acquired by the color information acquisition device in addition to the three-dimensional shape measured by the three-dimensional shape measuring device.

4. The repair system according to claim 1 or 2, further comprising a sorting device for further sorting at least one of the fractions recovered by the separation and recovery device based on the physical properties of the crushed pieces contained in the fraction.

5. A repair method for a structure having a refractory layer on its inner surface, comprising: a three-dimensional shape measuring step of measuring the three-dimensional shape of the inner surface of the structure; an arithmetic step of determining, based on the three-dimensional shape measured in the three-dimensional shape measuring step, a range to be removed from the refractory layer by dividing it into a plurality of layers in the depth direction; a crushing step of crushing the refractory layer for each of the layers based on the result calculated in the arithmetic step; a separation and recovery step of separating and recovering the crushed pieces crushed in the crushing step for each of the crushed layers.

6. The repair method according to claim 5, further comprising a control step of measuring the load in the crushing step and adjusting the crushing range for each of the layers based on the measured load.

7. The repair method according to claim 5 or 6, further comprising a color information acquisition step of acquiring color information on the inner surface of the structure, wherein in the arithmetic step, the plurality of layers are determined in consideration of the color information acquired in the color information acquisition step in addition to the three-dimensional shape measured in the three-dimensional shape measuring step.

8. Furthermore, the repair method according to claim 5 or 6 includes a sorting step of further sorting at least one of the fractions recovered in the separation and recovery step based on the physical properties of the crushed pieces contained in the fraction.