CN113686142A - 一种改进辊道窑,实现仿古青砖连续生产的方法 - Google Patents
一种改进辊道窑,实现仿古青砖连续生产的方法 Download PDFInfo
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Abstract
本发明公开了一种辊道窑改进方法,此法改进之辊道窑能连续生产仿古青砖。循环气流分割辊道窑成高温高湿、干燥烧成、还原降温3段。窑炉尾气被分成两路,一路由高温高湿段尾部引出,经换热器冷凝排水后排放,另一路由干燥烧成段头部引出,经换热器后去余热锅炉。循环水经两级热交换产生蒸汽,该蒸汽分两段喷入窑炉还原降温段,产生连续的还原气氛。该高湿气流至窑尾后被引风机引入窑头,湿热的蒸汽能快速提升砖坯内部温度,提高干燥效率。窑炉内增加了风压毫帕传感器,使用了气动开度阀调整蒸汽流量。引入的蒸汽不仅产生了还原气氛,同时也提升了烘干、冷却的效率。经改造窑炉尾气溢出减少。仿古青砖与普通烧结砖比较,具有明显的产品与价格优势,本发明成品/能耗比提升约12%。经济效益明显。
Description
技术领域
本发明公开了一种改进辊道窑,实现仿古青砖连续生产的方法,属硅酸盐专业,是陶瓷烧结辊道窑改进方法,是在辊道窑中实现连续还原气氛,连续生产仿古青砖的方法。
背景技术
古青砖砌筑的祠堂、庙宇,亭台楼阁,虽历经沧桑却依旧完好,在现代建筑群中更显古朴典雅。青砖比红砖在抗氧化、水化,大气侵蚀方面明显优秀。古青砖烧制法与现代红砖烧制法略有不同,红砖是自然冷却,青砖是淋水冷却。古法称之“闷青”,是在坯体烧结后高温态时淋水、闷制,实则是创造了还原气氛,并在此还原气氛中冷却。不难理解,三氧化二铁被还原成四氧化三铁,由于四氧化三铁的颜色使红砖变青砖,由于四氧化三铁更稳定,因此青砖具备了耐风化,耐水等特性,所以青砖的建筑物寿命更长。仿古青砖是用现代配方、工艺技术生产古青砖的类似产品。其技术核心是创造与“闷青”相同的还原气氛冷却方法,并且能够自动化的连续生产。
中国专利CN 1101026A《用隧道窑生产青砖瓦的新方法及设备》阐述了“经过预热、焙烧、熏烧、缺氧冷却、空气直接冷却过程,其特征在于缺氧冷却的冷却气体是从预热带抽出并经处理的无氧循环气体”。明确“焙烧是在950℃~1100℃温度的还原性气氛下进行”。进一步明确“从预热带抽出的循环气体是经过脱氧处理的。脱氧的气体是用水雾化成水蒸汽来降温至300℃左右再鼓入隧道窑中的”。
中国专利CN 203534159U《一种气氛保护青砖隧道窑》阐述了“窑体(10)依次分隔为预热区(3)、有氧烧成区(4)、烧成保温区(5)、还原烧成区(6)和冷却区,预热区(3)的窑体内壁设置有排烟口,排烟口与设置在窑体上的窑墙夹层(302)连通,窑墙夹层(302)依次通过排烟管路(301)和风机(2)与窑体(10)外部连通,有氧烧成区(4)、烧成保温区(5)和还原烧成区(6)均包括设置在窑体(10)上的烧嘴(407)和设置在窑体(10)下部的送风口(411),烧嘴(407)通过阀门(406)分别与天然气总管(401)和风分管(405)连通,送风口(411)通过设置在窑体上的窑体中空夹层(409)与车下压力平衡风机(410)连通”。“冷却区包括无氧急冷冷却区(7),无氧急冷冷却区(7)包括设置在窑体上的氮气支管(702)和换热支管(704),换热支管(704)一端与冷风源连通,换热支管(704)另一端与风分管(405)连通,氮气支管(702)与氮气源连通”。“冷却区还包括无氧缓冷冷却区(8),无氧缓冷冷却区(8)包括设置在窑体(10)上的换热器列管(802),换热器列管(802)一端通过鼓冷风分管(804)与冷风源连通,换热器列管(802)另一端通过热风分管(801)与风分管(405)连通”。“冷却区还包括有氧冷却区(9),有氧冷却区(9)的窑体上开设有冷却抽风风管(903)和与窑体外部连通的格孔(901)”。
中国专利CN104402405A《一种利用分体式隧道窑烧制青砖的方法》明确“先往冷却室通入体积比为90:10的氮气和氧气的混合气体,再用还原焰烧制1-1.5小时,然后注入水蒸汽冷却”。
中国专利CN 106747303A《一种仿古青砖及其制备工艺》明确“将需要进行还原处理的青砖放置在窑体内,窑体内的温度为900-1000℃,通过第一进水管和第二进水管向窑体内通水,水进入窑体后在高温下将发生汽化现象,水汽化后将使窑体内的压力增大,该压力通过定位孔作用在导向杆上,使导向杆下端克服第一弹簧的作用力并沿第一导向孔移动,导向杆上端沿凹槽移动,在凹槽上壁斜度的作用下,导向杆使第一进水管克服弹性橡胶垫的作用并向上转动,第一进水管向上转动的同时使得钢球沿第一锥度孔的孔壁向第一锥度孔锥度结构的小端移动,使得钢球与第一锥度孔之间的间隙减小,第一进水管水的流速减小,进而减小进入窑体内水的流速,当窑体内的压力减小时,导向杆在第一弹簧的作用下复位,导向杆的上端沿凹槽复位,进而使得第一进水管复位,第一进水管水的流速增大,进而增大进入窑体内水的流速。”
中国专利CN 108424117A《一种青砖及其生产方法》明确“干燥城市淤泥,分别收集淤泥尾渣以及干燥过程中产生的尾气,混合所述尾渣、砂土和氧化铝厂赤泥,得混合原料,然后球磨、榨泥、练泥、成型以及烧成,烧成过程中通入所述尾气,得青砖;优选地,所述尾气的通入量为180-200m3/min。”
中国专利CN112250433A《一种耐久型烧结青砖及其制备方法》明确“将烘干后的样坯利用隧道窑进行烧结,烧结温度850℃,烧结时间12h,得到烧结青砖;”“所得的烧结青砖浸泡在石英砂水溶液中自然养护30天,即得”。
发明内容
首先,研究了坯体在高温态喷入水、雾、蒸汽产生还原气氛的方法,优选了喷入蒸汽的方案,研究了蒸汽喷入的位置,在1100℃~900℃区间得到了在1000℃±50℃为优选的蒸汽喷入点。其次,研究了用高湿气流干燥砖坯的方法,得到了理想的结果。不难理解,干燥的热气流会快速带走砖坯表层水分,坯体内外的水分差、温度差太大,造成砖坯干燥中的n多问题,解决的方法就是延长工艺时间。而改用高温高湿气流使坯体内外的水分差、温度差缩小,在后段干燥时内外同时脱水,干燥时间缩短。研究了用气流等压法分段辊道窑循环气流的方法,在辊道窑内安装风压毫帕传感器,实现了循环气流将辊道窑分割成1高温高湿、2干燥烧成、3还原降温3段的目标。在干燥烧成段后,喷入蒸汽,该蒸汽膨胀形成的气压顶住烧嘴燃烧产生的风压,在窑尾300℃位置安装排风口,引风机将该风口排出的湿热气流引入摇头,用于砖坯内外同时升温。在窑头200℃位置分段,划分出高温高湿段、干燥烧成段,该位置分别安装尾气出口,尾气分别经换热器输出,干燥烧成段尾气去余热锅炉,高温高湿段尾气已接近100℃可直接排放。高温高湿段尾气冷凝出的冷凝水进入循环水箱,循环水箱中的水,首先进入高温高湿段尾气换热器,通过单向阀,再进入干燥烧成段尾气换热器,形成蒸汽并循环使用。
辊道窑经上述改造后的首次开机,并不成功。生产的青砖在窑炉中部又被氧化,窑炉产出的依旧是红砖。继续增加蒸汽喷入量,烧结段明显降温。经反复实验、改进,最后在还原降温段中部,增加第二蒸汽喷入口,经试生产,得到了连续产出的仿古青砖。
一种改进辊道窑,实现仿古青砖连续生产的方法,其区别特征是:循环气流将辊道窑分割成1高温高湿、2干燥烧成、3还原降温3段,其区别特征还在于:高温高湿段1排烟出口连接换热器G1,干燥烧成段2排烟出口连接换热器G2,水从H2入G1,经换热成高温水,高温水通过单向阀F2进入换热器G2成蒸汽,蒸汽经F3、F4控制,由Z1、 Z2口喷入辊道窑还原降温段3,还原降温段3尾部的湿热气流,经管路由可调速引风机Y3引入高温高湿段1,其区别特征还在于:干燥烧成段2安装有烧嘴S1、S2、S3,S1、S2、S3燃烧产生的热气流由干燥烧成段3头部引出,经换热器G2排出,其区别特征还在于:换热器G1、G2烟气出口安装有可调速引风机Y1、Y2,辊道窑1、2、3段安装有热电偶T1、T2、T3、T4、T5,辊道窑1、2段之间,2、3段之间安装有风压毫帕表m1、m2、m3、m4,上述改进辊道窑由以下步骤①窑炉预热:打开并点燃烧嘴S1、S2、S3,打开蒸汽阀F4,30min后打开引风机Y1、Y2调整转速频率30Hz,2h后打开蒸汽阀F3,调整F4到2/3开度,再调整F3使m3、m4接近,②窑炉风压调整:调整F4、Y3使m1、m2接近,调整Y1、Y2转速到m1≤m2,m4≤m3,③连续生产:预热2h 待T3稳定在1100℃后从辊道窑in端连续投入砖坯,微调Y1、Y2、Y3始终满足m1≤m2,m4≤m3,5h后在辊道窑out端连续产出仿古青砖;上述G1、G2是液-气换热器;上述风压毫帕表是安装在窑炉内的耐高温风压毫帕传感器;可调速引风机Y1、Y2、Y3是由变频调速器驱动的耐高温引风机;上述F3、 F4是气动开度阀。
附图说明
图1改进之辊道窑示意图,图2水、蒸汽循环示意图
附图标注:1辊道窑高温高湿段;2辊道窑干燥烧成段;3还原降温段;F1上水阀;F2单向截止阀;F3蒸汽气动开度阀;F4蒸汽气动开度阀;G1;G2液-气换热器;L1冷凝水管; H1上水口、H2循环水槽;m1、m2、m3、m4风压毫帕表;T1、T2、T3、T4、T5热电偶;S1、 S2、S3燃气烧嘴;P1排烟出口;Y1、Y2、Y3耐高温引风机;Z1、Z2蒸汽喷口。
具体实施例1
以实际生产为例,结合图1、图2,详细说明辊道窑改进与仿古青砖连续生产方法。
辊道窑改进,现有126m辊道窑,拆除所以循环风管道。以摇头为0点,单排3只烧嘴S1、S2、S3在70~76m位置,在80m位置划分干燥烧成段结束和还原降温段开始,在此位置安装m3、m4风压毫帕表,相距1m,在84m 处Z1位置安装蒸汽管Φ75mm 3根单,层通入。94m处Z2位置安装蒸汽管Φ75mm 2根单,层通入。在120m位置安装风管引出窑外,安装引风机Y3将引出的蒸汽送入距窑头6m的高温高湿段开始位置。在26m位置划分高温高湿段结束和干燥烧成段开始,在此位置安装m1、m2风压毫帕表相距1m,在25m位置安装出风口连接换热器G1,在27m位置安装出风口连接换热器G2,分别安装Y1、Y2引风机Y1出口P1去尾气净化入口,Y2出口P2去余热锅炉入口。Y1冷凝水通过管路L1入循环水槽H2。循环水与换热器G1、G2见图2水、蒸汽循环示意图。
仿古青砖连续生产,①窑炉预热:打开并点燃烧嘴S1、 S2、S3,打开蒸汽阀F4,30min后打开引风机Y1、Y2调整转速频率30Hz,2h后打开蒸汽阀F3,调整F4到2/3开度,再调整F3使m3、m4接近,②窑炉风压调整:调整F4、Y3使m1、m2接近,调整Y1、Y2转速到m1≈m2,m4≈m3,③连续生产:预热2h 待T3稳定在1100℃后从辊道窑in端连续投入砖坯,微调Y1、Y2、Y3始终满足m1≈m2,m4≈m3,5h后在辊道窑out端连续产出仿古青砖。
Claims (1)
1.一种改进辊道窑,实现仿古青砖连续生产的方法,其区别特征是:循环气流将辊道窑分割成1高温高湿、2干燥烧成、3还原降温3段,其区别特征还在于:高温高湿段1排烟出口连接换热器G1,干燥烧成段2排烟出口连接换热器G2,水从H2入G1,经换热成高温水,高温水通过单向阀F2进入换热器G2成蒸汽,蒸汽经F3、F4控制,由Z1、 Z2口喷入辊道窑还原降温段3,还原降温段3尾部的湿热气流,经管路由可调速引风机Y3引入高温高湿段1,其区别特征还在于:干燥烧成段2安装有烧嘴S1、S2、S3,S1、S2、S3燃烧产生的热气流由干燥烧成段3头部引出,经换热器G2排出,其区别特征还在于:换热器G1、G2烟气出口安装有可调速引风机Y1、Y2,辊道窑1、2、3段安装有热电偶T1、T2、T3、T4、T5,辊道窑1、2段之间,2、3段之间安装有风压毫帕表m1、m2、m3、m4,上述改进辊道窑由以下步骤①窑炉运行:预热好的窑炉,打开并点燃烧嘴S1、 S2、S3,打开蒸汽阀F4,10min后打开引风机Y1、Y2调整转速频率30Hz,1h后打开蒸汽阀F3,调整F4到2/3开度,再调整F3使m3、m4接近,②窑炉风压调整:调整F4、Y3使m1、m2接近,调整Y1、Y2转速到m1≤m2,m4≤m3,③连续生产:烧成段T3稳定在1100℃后从辊道窑in端连续投入砖坯,微调Y1、Y2、Y3始终满足m1≤m2,m4≤m3,5h后在辊道窑out端连续产出仿古青砖;上述G1、G2是液-气换热器;上述风压毫帕表是安装在窑炉内的耐高温风压毫帕传感器;可调速引风机Y1、Y2、Y3是由变频调速器驱动的耐高温引风机;上述F3、 F4是气动开度阀。
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