Common problems and use and maintenance of glass kiln regenerator system
Proper use and maintenance of the regenerator system is one of the most important tasks for a glass enterprise after it is put into production. There is no numerical standard for whether its use and maintenance are reasonable and optimal. Its irrationality takes months or even years to become apparent. Many companies have learned a profound lesson in this regard.
, Common problems in regenerator systems and their consequences
If we cannot use and maintain the regenerator system correctly, the following situations will occur:
(1) The combustion air and fire ratio is unreasonable and energy consumption increases.
(2) Increased energy consumption results in increased wind and fire openings, intensified kiln erosion, serious burning losses, and shortened kiln life.
(3) If the energy consumption is high, the melting will be unreasonable and the quality of the glass will decrease. It does not mean that the quality of the glass is good if the energy consumption is high.
(4) When energy consumption is high, the flame of some small furnaces will be too long, and the burning loss of the regenerator will intensify. Eventually, the partition walls between the regenerators will collapse, the back wall of the regenerator will tilt inward or outward, and the checkered bricks will appear. Serious blockage, blockage of the regenerator bars, etc.
(5) In the end, various abnormal phenomena occurred. Energy consumption, output, quality, kiln maintenance, cost, selling price, capital chain and other issues restricted each other, forming a vicious circle, and the company was on the verge of suspending production.
2. How to correctly use and maintain the thermal storage system
The flat glass industry has developed on a large scale for decades, and regenerators have been used for hundreds of years. But why does this problem persist? On the surface, it is a simple technical issue, but it actually contains the connotation of corporate management and corporate culture. ,To completely solve this problem, we must take it seriously from a certain height.
2.1 Stimulate the enthusiasm of employees from the enterprise management system
People are the basic factor that determines everything. The hysteresis of regenerator problems determines that prevention should be the first priority and predictability should be used in the use of regenerators. At present, various management systems coexist in my country's glass industry, and the management system directly affects the enthusiasm of employees at all levels. Therefore, we should maximize the enthusiasm of employees at all levels in the system, so that the interests, rights and interests of each employee are consistent, and mobilize the enthusiasm of (senior) employees who are specifically responsible for the heat storage system.
2.2 Strengthen theoretical training for enterprise employees and improve the theoretical level of all employees, especially senior employees.
The process of corporate employee training is a self-improvement process for the trainer. After nearly 30 years of changes, a large amount of private capital has entered the glass industry, causing the glass industry to expand rapidly. Unfortunately, our employee education and training work has not been followed up in time. On the contrary, the training work of some companies has become ineffective and has declined. When problems arise in production, this kind of enterprise has no theoretical guidance and cannot systematically propose solutions to the problems. It only relies on production experience to tentatively solve the problems, and the problem is solved slowly. Finally, it uses "thousands of tons of whole glass liquid, circulating convection" "Slow" is used to prevaricate, so people often say "I don't know how good production is, and I don't know how bad it is."
At present, my country's glass enterprises have implemented computer control. The formulation of various process plans has a theoretical basis. More than 90% of production problems can be solved using theoretical guidance. Only by strengthening the vocational training of employees, especially senior employees , we can develop a set of reasonable and complete regenerator system use and maintenance measures.
2.3 Develop reasonable process plans and strengthen monitoring
Problems in the regenerator do not occur overnight due to unreasonable workmanship. Its occurrence requires a long process. But there is one thing that is certain that the fundamental reason for the deformation and collapse of bricks is that the heating temperature of the bricks exceeds their load softening point. Therefore, all process plans must be based on the fact that the temperature of the regenerator and flue should not be too high.
(1) About the use of 1# small furnace gate
Since the 1# small furnace is located close to the front face of the melting furnace, and the front face is not tightly sealed, when the gate opening of the 1# small furnace on the exhaust gas side is large, the kiln pressure at the front face will be too small and air leakage will occur. Therefore, the gate opening of small furnace 1# is usually smaller than that of other small furnaces. At the same time, the suction force of small furnace 1# is smaller than that of other small furnaces.
As mentioned before, for the furnace where the exhaust gas is reversed into a flue reversal, the opening of each small furnace gate is in a normally open state, and the opening of the small furnace gate will cause the suction force of each small furnace. The difference will lead to the generation of secondary combustion air, which directly affects the actual air volume of the corresponding small furnace. Therefore, when the gate opening of small furnace 1# is small, the actual supply of combustion air to the small furnace is less than the computer set value, resulting in the combustion state of the flame of small furnace 1 (unreasonable air and fire ratio) and local energy consumption. On the high side. In actual production, the flame of small furnace #1 is always turbid.
In response to this phenomenon, it is recommended that the exhaust gas reversal be a flue reversal system. It is best for the 1# small furnace gate to also participate in the reversal and link with the reversing system. This can avoid the problem of the 1# small furnace gate. The smaller opening of the plate affects the actual air volume of the small furnace.
(2) Regarding the setting of the gate opening of other small furnaces, formulate a reasonable gate curve for small furnaces
There is still some debate about the opening size of the small furnace gate. However, I think the exhaust side gate has only one fundamental function, which is to extract waste gas. Therefore, according to this point of view, the opening size of each small furnace gate should be determined according to the amount of waste gas generated in the corresponding part of the furnace.
(3) Set up early warning temperature values for the temperatures at the top of the regenerator and the flue top
Problems such as grid blockage and partition wall collapse in the regenerator cannot be caused in one day. Their occurrence requires a process, which requires us to pay special attention to the changes in these two temperature values in daily production and set up an early warning. temperature value. When the temperature reaches or approaches this temperature value, the process must be adjusted to prevent accidents in the regenerator.
(4) Regularly conduct joint inspections of the regenerator system and make relevant records
From the day it is put into operation, each enterprise must set up a kiln protection team to conduct joint inspections of the furnace on a regular basis and keep relevant records.
(5) Clean the ash under the furnace bars in the regenerator in a timely manner to ensure smooth ventilation and waste gas removal under the furnace bars.
According to the inspection results of the furnace by the kiln maintenance team, the furnace ash under the heat storage furnace bar must be cleaned in time. During the cleaning process of the furnace ash, do not spray water into the heat storage furnace, otherwise the water vapor will corrode the heat storage chamber. Magnesia bricks.
(6) Replacement of checker bricks in the regenerator
Some companies do not pay attention to the protection of heat storage rate in the early stages of production, resulting in clogging and damage of checker bricks. At this time, the checker bricks need to be replaced. When replacing, it is recommended that the number of layers of checker bricks after replacement should be consistent with the original design, and the heat storage capacity of the replaced regenerator should be kept the same as that of other regenerators to the greatest extent, so as to ensure that the preheating temperature of the combustion air remains unchanged and improve Combustion efficiency.
(7) Develop a reasonable combustion curve
When formulating the combustion curve of the furnace, the protection of the regenerator must be taken into consideration, and individual flames must not be overly long, especially the 4# small furnace, which will directly cause the partition wall of the small furnace to collapse.
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