浅 谈 隧 道 窑 窑 车_隧道窑窑车
浅 谈 隧 道 窑 窑 车由刀豆文库小编整理，希望给你工作、学习、生活带来方便，猜你可能喜欢“隧道窑窑车”。
浅 谈 隧 道 窑 窑 车
【摘要】隧道窑窑车是隧道窑系统中最昂贵的组成部分,并且对隧道窑的安全运转和能量消耗都有重要影响。【关键词】窑车
砂封
耐火材料
隧道窑窑车经常出现一些技术问题,它们是影响隧道窑烧成质量、运转可靠性、经济效益的主要因素。窑车与隧道窑之间的密封不好,一方面热空气会从隧道窑内串到窑车下,对窑车钢结构，尤其是窑车车轮轴承的损害非常大,直接影响到隧道窑的安全运转。另一方面冷空气从窑车底串到隧道窑内,将使隧道窑内横断面上下的温差增大,影响制品的烧成质量。窑车衬砌耐火材料重量越大,窑车在焙烧过程中热交换越高,隧道窑在焙烧过程中热交换比例就越大,也就是说笨重的窑车灵活性小、热损失大。所以,窑车一方面要有足够好的密封性能,另一方面窑车重量必须尽可能地减轻,以使能耗降低,并且要有足够的耐久性,保证窑车的安全运行。窑车的机械或热力学上的缺陷都会对砖厂日常生产成本有一定的影响。要降低成本,降低保养费和能耗,提高使用寿命,必须对窑车的问题加以重视。
注意避免让不必要的冷空气进入窑内,还要避免窑内的热空气串到窑下,这点很重要。主要漏风渠道之一是砂封结构。砂封并不能获得完全密封,仅能部分阻挡空气气流,最大的空气泄露是在窑车与窑车之间的砂封搭处。在设计和加工时,为避免顶推力传到砂封板上,砂封板不应当接触太紧,此外还有允许误差、砂封板的变形、不同的热膨胀率、磨损等因素。因此,一窑车与另一窑车连接处的砂封板并不密封,即使每辆车有2c㎡的漏风面积,这看起来也许很小,但总共有60左右辆窑车在窑内,这将产生大约漏120c㎡风面积,这对于工作在一定压力状态下的隧道窑会造成很大影响,是不可忽视的。曾有人设法努力采取补救措施。例如采取砂封板重复搭接密封件和类似措施等,实践证明都不适用,在连续使用后经常损坏,因此应该寻找更好的砂封结构。
根据国外30～40年积累的经验证明,水是一种良好的密封材料。有人采用充水砂槽,水槽带有膨胀接缝并填充砂子,但100多米长的水槽在热胀冷缩条件下不可能持久,无法保证水槽的密封。法国赛利克公司更前进了一步,将窑车底面全部浸在水里,使这种密封系统更完美了。另有一种简单而有效的设计是双砂封,下
部砂封是我们常用的砂封结构。上部砂封结构是由一条C形槽钢和侧墙形成一体,与之相配合的窑车上是T形结构。T形下部与C形槽钢下部形成砂封。T形上部和窑车面层侧面又形成一道砂封, C形槽上端插入其中。主要优点是形成的砂封在窑车通过窑内时一直保持着密封,能与窑车相搭扣。实践证明,如此密封即使在长的隧道窑内,也不需再补充砂子。
上述砂封系统大大地减少了从窑下来的不必要的冷空气和进入窑下的热空气,可以防止窑车边框耐火材料以下部分工作在高温状态,这种砂封结构花费较少,对窑车无损伤,对窑车车轮、轴承和其他部件却有很好的保护作用。窑车重量的减轻,是通过窑车衬采用轻质耐火材料(轻质耐火纤维砌块,轻质混凝土)实现的。窑车边框材料可采用外壁厚度适中的轻质窑车边框砖,这样可降低边缘的重量,但必须非常结实,抗热冲击性能要好,耐火度及荷重软化点要满足要求。多数情况下,窑车边缘要求机械性能稳定。边框砖材料大部分采用粘土质耐火砖,现在也有采用轻质耐火混凝土做边框砖的,这样可以减轻窑车的重量,降低窑车造价,但轻质耐火混凝土的机械性能不是很好,边框砖容易损坏。
隔热层在窑车衬砌结构中所占的体积比例最大。现在我们普遍采用的是填充水泥膨胀蛭石,水泥膨胀蛭石容重、热导率都比较大,这样不但会造成窑车重量的加大,并且造成窑车的蓄热能力加大,向下传导的热量多。如改用其他便宜的轻质隔热材料(如粉煤灰、膨胀珍珠岩),就完全可以减轻窑车的重量,并且不会提高整车的造价。
窑车面是隧道窑构造中问题最多的组成部分。窑的两侧墙、窑顶和窑车面形成窑的四个面,窑车面应消耗最少的热量,因为另外三个面在窑加热后温度保持恒定不变,它们的热消耗仅限于向外传导的热损失。可是窑车是在冷态下推入隧道窑的,窑车面除了向下传导的热量以外,它还将吸收并贮存热量,因为它的表面应当达到焙烧带的最终温度,当窑车从隧道窑出来以后,温度又会降到室温,造成了热量损失,所以高质量的隔热材料是防止热损失的必要条件。
窑车面越厚,向下传导的热损失越少。对于贮存热量,其原则是:台面层越薄,贮存热量的比例越小。每一种窑车面均有其最佳厚度,如果没有达到,那将导致向下传导的热量加大。如果超过了,蓄热能力就加大了。窑车面将大致达到最终焙烧温度。因此窑车面将从常温加热升温到1000℃左右,它将对蓄热起到决定性的影响。因此,顶层材料应由尽可能轻的耐火材料所组成,下层材料仅达到较低的温度,它们对蓄热的影响较小。因此它们的重量不如顶层那么关键。窑车面层除了应具有最小的热耗外,也应满足其他一些要求。它的底部必须保证密封,它必须安全地承载输送砖坯,并承受塌方的考验。还应具有机械稳定性(牢固、经久耐用、不变形、耐风化等),除此之外,窑车面层暴露在经常不断的温度变化之下,其必须能承受这种不断变化的热流影响。因此,所用的耐火材料应能抵抗这种温差的冲击。
由于生产中,每日要清理窑车,再加上燃烧对窑车的严重侵蚀,所以,窑车面要结实耐用。对生产厂家而言,迫切需要轻质且机械性能皆好的窑车面。通过设计及技术安全测量手段,或在生产工艺中运用适当的技术原理防止焙烧坯体倒塌,从而避免对窑车机械性能的损坏。
隧道窑花费最大的部分是窑车部分,应当尽量少花钱,而且在常期使用时少花维修费,在某种程度上讲,这些要求似乎互相矛盾,理想的解决法似乎不可能,只能不断寻求协调,使缺点尽可能减少。
为了配合国家关于禁止黏土实心砖推广空心砖墙改政策的实施,适应广大中小砖厂技术改造,《砖瓦》杂志社设备窑炉技术开发部通过对市场的调查和多年从事建厂经验绘制出不同规模、不同类型、适合不同原料的新型《隧道干燥室通用图纸》和高效节能《轮窑通用图纸》。该图纸汇集不同原料、不同规模的黏土、页岩、煤矸石及粉煤灰烧结砖及空心砖轮窑及干燥室施工图。
推出的所有图纸均是在生产中经过长期实践的成熟技术资料,在绘制过程中不仅吸收了国内外业内的先进技术使其结构更加合理,适应面更广,还增加了大量结构详图和文字说明以便使用单位施工方便。《砖瓦》杂志社设备窑炉技术开发部还同时推出与图纸相应配套的GSJ-Ⅲ型系列干燥室送热节能风机和ZFJ系列轮窑高温防腐节能引风机(见《砖瓦》杂志彩色广告),以及干燥车、窑车、顶车机、摆渡车等,并提供从干燥室、轮窑的技术咨询、改造调试到各类相应配套设备的整套优惠服务。
Of tunnel kiln cars
【Abstract】 tunnel kiln tunnel kiln car system is the most expensive component of the tunnel kiln and the safety of operation and have an important impact on energy consumption.【Key Words】 kiln car refractory sand seal Tunnel kiln cars are often a number of technical problems, which affect the quality of the tunnel kiln firing, operation reliability, cost-effectivene of the main factors.Kiln tunnel kiln cars and the seal between the well, on the one hand, hot air from the tunnel kiln to the kiln car series, the steel structure of the kiln cars, in particular, kiln car wheel bearings for damage is very large, direct impact on the tunnel kiln the safety of operation.On the other hand, the cold air from the kiln car into the tunnel kiln at the end of string, up and down will make the tunnel cro-section of the kiln temperature increases, the impact of the burning quality products.The weight of the kiln car refractory lining of the bigger cars in the roasting kiln heat exchange proce the higher the tunnel kiln in the roasting proce the greater the heat exchange ratio, meaning that heavy vehicles flexibility small kiln, large heat lo.Therefore, the kiln cars on the one hand, there must be enough good sealing performance, on the other hand, kiln cars to be as much as poible to reduce weight in order to reduce energy consumption and durability sufficient to ensure the safe operation of the kiln car.Kiln cars thermodynamic machinery or defects will be day-to-day cost of production of the factory
have a certain impact.To reduce costs, reduce maintenance costs and energy consumption.if we want to improve the life of the kiln must be attention to the iue of cars.Attention to avoid unneceary cold air into the kiln, but also to avoid the hot air kiln to kiln string, this is very important.One of the main channels of air is leakage sealing structure of sand.Sand can not be completely closed and sealed and only partially block the air flow, the largest air leaks in the kiln and kiln cars car ride between the Department of the sand seal.In the design and proceing, in order to avoid closure top thrust plate spread sand, sand dam should not be too tight contacts, in addition to allowable error, sand dam deformation, different thermal expansion, wear and tear and other factors.Therefore, a kiln car with another car kiln sand junction closure plate is not sealed, even if the vehicle has 2c ㎡ area of air leakage, which may seem small, but about a total of 60 cars in the kiln cars, This will generate approximately 120c ㎡ air leakage area, which is working under a certain preure on the tunnel kiln will cause a significant impact, can not be ignored.There have been efforts to try to take remedial measures.For example, take the sand dam seals overlap and duplication of similar measures, the practice of proof does not apply in the frequent damage after continuous use, it should find a better structure of the sand seal.According to 30 ~ 40 years of experience have proven that water is a good sealing material.It was the use of water-filled sand chutes, water tank and filled with sand expansion joints, but more than 100 meters long in the sink can not be sustained under the conditions of, there is no guarantee of the sealed
tank.French Cup Malik company have a step forward, the bottom of all kiln cars submerged in the water, making the system more perfect seal.Another simple and effective design is double sand seal, seal the lower part of sand that we used the structure of the sand seal.Closed structure of the upper part of sand by a C-shaped channel and the formation of one side wall, with matching kiln car is T-shaped structure.T-shaped C-shaped channel and the lower part of the lower part of the formation of sand closures.The top insert is T-shaped upper surface and the side of the kiln cars and sand together to form letters, C-shaped slot in which t.The main advantage is the formation of letters in the sand through the kiln when the kiln cars have maintained sealed with kiln cars with hasp.Practice has proved that such a seal even in the long tunnel kiln, but also do not need to add sand.Sand closed the above system greatly reduces unneceary down from the kiln and the cold air into the furnace of hot air, you can prevent the kiln car to be refractoried the following part of the border in high-temperature state, the structure of sand le costly closure of the kiln car without injury on the kiln car wheels, bearings and other parts are very good protection.Reduce vehicle weight of kiln, the kiln cars through the use of lightweight refractory lining(refractory fiber block light, light-weight concrete)realization.Kiln car frame material may be outside the wall of light moderate brick kiln car frame, so that reduces the weight of the edge, but it must be very strong, better thermal shock resistance, refractorine and softening point load to meet the requirements.In most cases, the edge of the kiln car mechanical properties and stability requirement.Most of
the use of brick material frame clay refractory bricks, and now there are so light-weight fire-resistant concrete brick borders, so that the kiln can reduce vehicle weight, lower cost of the kiln car, but the light of the mechanical properties of fire resistance of concrete is not very good, border tiles easily damaged.Insulation lining in the kiln cars share the largest proportion of the volume.Now, we commonly used cement to fill the expansion of vermiculite, cement vermiculite expansion weight, larger than the thermal conductivity, so that will not only result in increasing the weight of the kiln cars and trucks caused by the kiln to increase the storage capacity, down conduction more heat.If the light switch to other cheaper insulation materials(such as fly ash, expanded perlite), it is entirely poible to reduce the weight of the kiln car, and does not increase the cost of vehicles.Kiln tunnel kiln car surface is constructed in the largest component of the problem.Both sides of the wall of the kiln, kiln car tops and kiln kiln surface to form the four side of the kiln car should consume at least face the heat, because the other three surface heated in the kiln to maintain constant temperature, their heat consumption limited to outside the conduction of heat lo.However, the kiln car is to push down in the cold tunnel kiln, and kiln cars surface in addition to heat conduction down outside, it will absorb and store heat, as it should be to reach the surface with the final calcination temperature, when the cars from the tunnel kiln after the kiln temperature will be reduced to room temperature, resulting in heat lo, so high-quality insulation materials to prevent heat lo is a neceary condition.Thicker surface kiln cars, heat conduction loes down the le.For the storage of energy, its principle is: the more thin surface layer, the smaller the proportion of heat storage.Kiln cars each side has its best thickne, if not met, it will lead to increased downward heat conduction.If exceeded, increased storage capacity.Kiln cars to achieve the final surface will be roughly the calcination temperature.Therefore kiln car surface heating from room temperature to about 1000 ℃, it will play a decisive impact on storage.Therefore, the top material of the refractory material should be as light as poible the composition of the lower material to reach only the lower temperature, they are le affected by storage.So they weight le than the top of the key.Apart from the kiln car surface should have the smallest heat consumption, but also a number of other requirements to be met.It must be sealed at the bottom, it must safely transport carrying brick and cave-bearing test.Should also have the mechanical stability(solid, durable, non-deformation, weathering resistance, etc.)In addition, the kiln car surface is constantly exposed to temperature changes, the it must be capable of sustaining the heat of this ever-changing effects of.Therefore, the refractory material used should be able to resist the impact of this difference.Due to the production of daily to clear the kiln cars, coupled with the burning of the kiln cars serious erosion, therefore, the kiln car a firm and durable surface.To the manufacturer, the urgent need for the mechanical properties of light and kiln cars are a good side.Through measurement of design and technical security means, or in the production proce of the
principle of the use of appropriate technology to prevent the collapse of roasting green body so as to avoid the mechanical properties of the kiln car damage.Tunnel kiln is the most expensive part of the kiln car parts, should be as little as poible to spend money, but when used in the regular period of le maintenance costs, to a certain extent, these seemingly contradictory requirements, it seemed an ideal solution can not only Coordination will continue to seek to minimize the shortcomings.In line with the country on the Prohibition of the promotion of hollow clay brick implementation of the policy change, to adapt to Medium Small brick wide technological transformation, “brick” magazine furnace technology equipment on the market through years of investigation and experience to engage in mapping different plant scale, different types of materials suitable for a new type of “tunnel drying chamber general drawings” and energy efficient “general-purpose drawing kiln.” Drawing together the different materials, different sizes of clay, shale, coal gangue and fly ash sintered brick and hollow brick kiln drying chamber and working drawings.The introduction of all the drawings are in production after a long-term practice of a mature technology, in mapping the course of the industry not only absorbed the advanced technology at home and abroad make it more reasonable structure to adapt to broader, but also increased a great deal of structural details and text Note the use of units in order to facilitate construction.“Brick” magazine furnace equipment technology development and also the introduction of drawings at the same time supporting the GSJ series delivery and hot dry room ZFJ series of energy-efficient fans
and high-temperature kiln energy-saving anti-corrosion primer fan(see “brick” color magazine ad), and dry cars, kiln cars, top car machines, car ferry, and from the dry room, round kiln technology consulting, transformation debugging equipment to all types of the corresponding service package of conceions.
