At present, the construction methods of refractory insulation materials for the melting part and the heat storage chamber can be divided into cold insulation and hot insulation.
The characteristics of refractory insulation materials are to reduce heat dissipation, improve the thermal efficiency of the melting furnace, and also ensure the life of the melting furnace. After the refractory insulation material is used for insulation, the temperature of the outer surface of the main body brick will increase significantly, which requires that the quality of the main body brick must be excellent, and high-quality mud must be used. This mud should have a certain degree of adhesion at room temperature, so that the bricks are more firmly bonded during the kiln baking process, and the arch bricks do not sink or draw. Only in this way can the melting furnace after insulation be in a good operating state and achieve the purpose of insulation.
Specific implementation process of this insulation method
1. Cold construction
(1) Melting section arch and heat storage chamber top arch
After the arch is built, use high-quality silica mud slurry to fill the joints and tighten the tie bars. Remove the arch tire. After 24-48 hours of cold observation to confirm stability, clean the arch top and lay stones with high-quality silica mud with a thickness of 10-20mm. At the same time, lay a layer of lightweight insulation bricks on the top, but do not lay insulation bricks in the middle of the arch about 1.5-2m wide and at the expansion joints of each arch.
(2) Melting section breast wall
Lay lightweight insulation bricks in cold state.
2. Construction of hot insulation layer
(1) Melting section crown and heat storage chamber top crown
Since the insulation coating is in paste form and is very convenient to construct, it can be implemented after the kiln is baked, the expansion joints and the middle part of the crown are sealed and the lightweight insulation bricks are laid. Since a large amount of water vapor will be discharged during the insulation drying process, if it is applied too thickly at one time, it will easily fall off. Therefore, the thickness of one layer should be controlled within 10mm, and the coating thickness can be gradually increased until it meets the specified requirements, and then it can be smoothed with one layer.
(2) Side wall
Since the insulation coating is in paste form and has a large slurry density, if the thickness of one layer of vertical surface is too thick, a large amount of water vapor will be released during the internal drying process, resulting in large-scale shedding. Therefore, when the surface temperature exceeds 50℃, the thickness of one layer is generally not more than 2~3mm. After one layer is dried, the second layer is applied, and its thickness is controlled at about 10mm. From the third layer, it can be appropriately thickened until the specified thickness is reached. Then level it once, and perform another calendering treatment when the water evaporates about 60% to ensure a smooth and beautiful surface. This kind of material generally does not need waterproofing for indoor use.
From the above two methods, it can be seen that the refractory insulation materials used in glass melting furnaces are mainly lightweight insulation bricks and insulation coatings. After the insulation is implemented, the heat dissipation is effectively reduced and the thermal efficiency of the melting furnace is improved.
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