Reasonable use and maintenance of the regenerator system is one of the most important tasks for glass enterprises after they are put into production. Whether its use and maintenance are reasonable and optimal, there is no numerical standard. Its irrationality will take months or even years to become apparent. Many companies have learned profound lessons in this regard.
1. Frequent problems and consequences of the regenerator system
If we cannot use and maintain the regenerator system correctly, the following situations will occur:
(1) The ratio of combustion air to fire is unreasonable and energy consumption increases.
(2) The increase in energy consumption results in an increase in the opening of the wind and fire, intensified corrosion of the kiln, serious burning loss, and shortened life of the kiln.
(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 high energy consumption means good glass quality.
(4) When the energy consumption is high, the flames of individual small furnaces will be too long, the burning of the regenerator will increase, and finally the partition wall between the regenerators will collapse, the rear wall of the regenerator will tilt inward or outward, and the checker brick Severe blockage, blockage of the furnace bar in the regenerator, etc.
(5) In the end, various abnormal phenomena occur, and various issues such as energy consumption, output, quality, kiln protection, cost, selling price, and capital chain restrict each other, a vicious circle, and enterprises are on the verge of stopping production.
2. How to use and maintain the regenerator system correctly
The flat glass industry has been developed on a large scale for decades, and the regenerator has been used for hundreds of years. However, why this problem has always existed? On the surface, it is a simple process problem. In fact, it contains the connotation of corporate management and corporate culture. To solve this problem, we must take it seriously from a certain height.
2.1 Stimulate the enthusiasm of employees from the corporate management system
People are the basic factor that determines everything. The hysteresis of the occurrence of regenerator problems determines that prevention and foresight should be the mainstay in the use of regenerators. At present, multiple management systems coexist in China'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 each employee has the same responsibility, rights, and interests, and mobilize the enthusiasm of the (senior) employees who are specifically responsible for the regenerator from the system.
2.2 Strengthen the theoretical training of employees, improve the theoretical level of all employees, especially the level of senior employees
In the process of enterprise employee training, it 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. However, it is a pity that our employee education and training work has not been followed up in time. On the contrary, some corporate training work is useless and has declined. When there is a problem in production, this kind of enterprise has no theoretical guidance and cannot systematically propose a solution to the problem. It only relies on production experience to tentatively solve the problem. The problem is solved slowly. "Slow convection" is used to prevaricate, so people often say "how good production is, I don't know, how bad, I don't know."
At present, China’s glass companies have implemented computer control. The formulation of various process schemes has theoretical basis. More than 90% of production problems can be solved by theory. Only to strengthen the vocational training of employees, especially senior employees , We can work out a set of reasonable and complete measures for the use and maintenance of the regenerator system.
2.3 Develop a reasonable process plan and strengthen monitoring
The problem of the regenerator can not happen overnight if the process is unreasonable, it takes a long process to happen. But one thing is certain, the basic cause of brick deformation and collapse is that the heating temperature of bricks exceeds its softening point under load. Therefore, all process plans should be based on the temperature of the regenerator and the flue not being too high.
(1) About the use of 1# small furnace gate
Because the 1# small furnace is located close to the front face of the melting kiln, 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 pressure of the front face kiln is too small and air leakage occurs. Therefore, usually the opening of the gate of 1# small furnace is relatively smaller than that of other small furnaces. At the same time, the suction force of 1# small furnace is smaller than that of other small furnaces.
As mentioned earlier, for the furnace where the exhaust gas reversal is the branch flue reversal, the opening of each small furnace gate is in the normally open state, and the opening of the small furnace gate will cause the suction of each small furnace The difference, which in turn causes the generation of secondary combustion-supporting air, directly affects the actual air volume of the corresponding small furnace. Therefore, when the opening of the gate of 1# small furnace is small, the actual supply of combustion-supporting air of the small furnace is less than the computer setting value, resulting in the combustion state of the flame of 1# small furnace (unreasonable air-to-fire ratio), and local energy consumption is biased. high. In actual production, the flame of 1# small furnace is always turbid.
In view of this phenomenon, it is recommended that for the exhaust gas reversing system for the branch flue reversing system, it is best that the 1# small furnace gate also participates in the reversing and is linked with the reversing system, so as to avoid the 1# small furnace gate. The decrease in the opening of the plate affects the actual air volume of the small furnace.
(2) Regarding the setting of other small furnace gate openings, formulate a reasonable small furnace gate curve
There is still some controversy about the opening of the small furnace gate. However, I think there is only one fundamental function of the exhaust side gate, which is to extract exhaust gas. Therefore, according to this point of view, the opening of each small furnace gate should be determined according to the amount of exhaust gas generated at the corresponding part of the furnace.
(3) Establish an early warning temperature value for the temperature of the top of the regenerator and the top of the branch flue
The grid blockage of the regenerator, the collapse of the partition wall and other problems cannot be caused in a day. It takes a process to occur, which requires us to pay special attention to the changes of 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
Starting from the day of production, each enterprise shall set up a kiln protection team to conduct joint inspections on the kiln regularly and make relevant records.
(5) Clean the ashes under the furnace bar of the regenerator in time, and keep the air under the furnace bar unobstructed when the exhaust gas is discharged.
According to the inspection results of the kiln protection team on the kiln, the ashes under the furnace bar of the regenerator should be cleaned up in time. During the cleaning of the ashes, do not spray water into the regenerator, otherwise the water vapor will corrode the magnesium in the regenerator. brick.
(6) Replacement of checker bricks in the regenerator
Some enterprises did not pay attention to the protection of the regenerator during the initial stage of production, which caused the checker brick to be blocked and damaged. At this time, the checker brick needs to be replaced. When replacing, it is recommended that the number of layers of checker bricks after replacement should be the same as the original design, and the heat storage capacity of the regenerator after replacement should be kept the same as that of other regenerators to ensure that the preheating temperature of the combustion-supporting air remains unchanged and increased. Combustion efficiency.
(7) Formulate a reasonable combustion curve
When formulating the combustion curve of the furnace, the protection of the regenerator should be taken into consideration, and individual flames should not be too long, especially the 4# small furnace, which will directly cause the partition wall of the small furnace to collapse.
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