Product Description
1300C 68 Meters Gas Heating Toilet Sintering Tunnel Kiln Tableware sintering tunnel kiln
| Item |
Name |
Parameter |
| 1 |
Model |
DM-TK68 |
| 2 |
Usage |
Sintering Sanitary Ware |
| 3 |
Annual Output |
≥250,000 Pieces/Year |
| 4 |
The Effective Length of Kiln |
68 Meters |
| 5 |
Dehumidification Section |
12 Meters |
| 6 |
Oxidation Section |
16 Meters |
| 7 |
Sintering Section |
12 Meters |
| 8 |
Cooling Section |
28 Meters |
| 9 |
Inner Width of Sintering Section |
2.2 Meters |
| 10 |
Product Loading Height |
900mm |
| 11 |
Firing Cycle |
About 16-20 hours |
| 12 |
Cart Speed |
20-25 Minutes/Car |
| 13 |
Kiln Car Size |
1400*2000mm(Length*Width) |
| 14 |
Total Number of Kiln Cars |
70 Sets |
| 15 |
Product Sintering Temperature |
About ≤1250ºC |
| 16 |
Product Energy Consumption |
1000 Kcal/Kg |
| 17 |
Sintering Atmosphere |
Oxidation |
| 18 |
Fuel Type |
Natural Gas or Liquefied Gas |
| 19 |
Fuel Calorific Value |
About 8300KCal/m³ |
| 20 |
Number of Burners |
68 Sets |
| 21 |
Control Loop |
11 Groups |
| 22 |
Control Method |
PID Intelligent Instrument + Industrial Computer |
| 23 |
Work Method of Kiln Car |
Automatic |
| 24 |
Fan Control |
Inverter |
| 25 |
Temperature Difference |
±5ºC(Sintering Zone) |
| 26 |
Exhaust Fan |
2 Sets /18.5Kw(1 for Use /1 for Spare Parts) |
| 27 |
Stirring Fan |
1 Set/7.5Kw |
| 28 |
Combustion Fan |
1 Set/18.5Kw |
| 29 |
Quench Fan |
1 Set/15Kw |
| 30 |
Pumping Heat Fan |
2 Sets/22Kw (1 for Use /1 for Spare Parts) |
| 31 |
Tail Cooling Fan |
4 Units/ 0.55Kw Per Unit/ Total 2.2Kw |
| 32 |
Undercar Air Cooler |
1 Set/5Kw |
| 33 |
Drying Kiln Exhaust Fan |
1 Set/11Kw |
| 34 |
Total Installed Power |
100Kw |
| 35 |
Drying Kiln |
20Meters |
1. Kiln Basics
The kiln is an advanced light assembly structure. The thickness of the concrete foundation is required to be 350mm, from top to bottom, it is 150mm thick plain concrete and 200mm thick reinforced concrete, and the kiln body is placed on the concrete. The upper plane of the track is the reference plane, the elevation is ±0.000, and the elevation requirement of the upper surface of the foundation is -0.002 (the foundation at the bottom of the foundation needs to be filled).
2. Kiln Body Structure
The total length of this kiln is 68m, divided into 34 standard units, and the unit length is 2m/section. According to material, temperature and process flow, it is divided into preheating zone, firing zone and cooling zone. The kiln body is made of metal frame and refractory insulation material masonry through strict craftsmanship. The metal frame is an assembled unit structure, which is welded and drawn by high-quality steel; the surface of the kiln body is inlaid with painted decorative steel plates, which is beautiful and elegant; each unit is connected by bolts.
The masonry part of the kiln wall is built with high-grade lightweight refractory insulation materials. The lining body below 1000°C is made of high-quality light materials such as light-weight high-alumina and poly-light-high-alumina, and the lining in the temperature zone above 1000°C uses light mullite bricks; the kiln exterior wall masonry uses aluminum silicate wool according to different temperatures. Board and felt insulation, not only good thermal insulation, energy saving, but also long service life. A 20mm expansion joint is reserved between each unit masonry and filled with high-aluminum fiber blanket.
The kiln adopts a flat ceiling structure, and the ceiling height is set in different sections, which can not only meet the safe operation of the products, but also reduce the temperature difference between the upper and lower sides. At the same time, this structure is also convenient for the adjustment of various systems in the kiln. There is a sand seal structure between the kiln wall and the kiln car, and a pair of sand hoppers are installed along the length of the kiln. The steel frame of the kiln car is provided with a 5mm thick sand-sealing steel plate. The sand-sealing groove is a "U"-shaped structure.
A hyperbolic sealing structure is installed between the kiln car masonry and the kiln wall, and the gap between the curved sealing is 20mm. The outer bricks on both sides of the kiln car adopt a fractured independent masonry structure (easy to replace). The kiln wall curved sealing brick is a heavy material, and the kiln car curved sealing brick is a light material. If foreign matter falls into the curved sealing gap, friction will not damage the kiln wall, thereby prolonging the service life of the kiln. At the same time, a high-temperature blanket is attached to the curved surface between the kiln car and the kiln car to ensure a good seal between the car and the car.
3. Kiln Car Operation System
The frame of the kiln car is welded by section steel, the wheels are made of cast steel, the axles are made of 45# steel, and the bearings are made of special high-temperature clearance bearings for kilns. The bearing is resistant to high temperature, has a long service life, and does not need to be filled with any lubricating oil.
In order to reduce the heat storage of the kiln car and save energy consumption, the masonry of the kiln car adopts a brick-wool mixed structure. The high-temperature lightweight thermal insulation bricks around the kiln car are made of high-temperature adhesive, the middle part is filled with high-temperature refractory fiber cotton, and the surface layer is covered with cordierite-mullite cover. Phenomenon. The curved seal between the steel frame of the kiln car and the steel frame is sealed by asbestos rope.
According to the process requirements, in addition to setting up the inner lane of the kiln, one return lane and two ferry lanes are also set up. The whole kiln is equipped with automatic hydraulic propeller and manual in and out kiln car system. The outer carriage return line is manually pushed and pulled back, and there are artificial push and pull shuttles on the ferry tunnel.
4. Combustion System
The control mode of the combustion system of the whole kiln is the proportional control of the actuator, and the combustion-supporting air adopts the hot air of the tail-cooling heat exchanger as the combustion-supporting air.
Burner product features:
a. Adopt the current market energy-saving products;
b. Complete combustion and high combustion efficiency;
c. It can achieve high-intensity combustion, and the volumetric heat intensity can reach 1.2×104kcal/m3
d. High speed, long range, stable flame, no coking, no clogging.
e. The combustion is sufficient, no black smoke is emitted, and there are few pollutants in the combustion products, which are lower than the national environmental protection indicators.
5.Ventilation and Exhaust System
5.1 The exhaust air duct is made of 304 stainless steel
5.2 Combustion duct 304 stainless steel
5.3 Quench air duct 304 stainless steel
5.4 Waste heat duct Part of stainless steel
5.5 Cooling duct main pipe Ordinary iron plate
5.6 The air supply and exhaust pipes of the drying kiln are made of 304 stainless steel
All hot air pipes are insulated with aluminum silicate fiber blankets and wrapped with asbestos cloth outside.
6. Auxiliary Equipment and Electronic Control Instruments
1. Double-cylinder double-integrated hydraulic jacking machine: 1 set, working stroke 2m
2. Manual shuttle bus: 2
3. Ferry car tunnel: 2
4. Return lane: 1, 68m
5. Repair lanes: 2 (installed at both ends of the kiln)
6. Gas pressure regulating system: 1 set
7. Main Fan
Fans in each system are equipped with frequency converters
7.1 Smoke exhaust fan: 2 sets of Y9-38 18.5KW
7.2 Combustion fan: 9-26 18.5KW 1 set
7.3 Quench cooling fan: 9-26 15KW 1 set
7.4 Exhaust hot air blower: 2 sets of Y9-38 22KW
7.5 Stirring fan: T4-72 7.5KW 1 set
7.6 Fan under the car: 9-26 5KW 1 set
7.7 Tail cooling fan: 4 sets of axial flow 0.55KW
7.8 Drying kiln exhaust fan: 9-38 11KW 1 set
8. Automatic Control System
The electric control system of this kiln is a distributed control composed of PID intelligent instrument, pressure sensor and programmable logic device.
8.1 Temperature and Pressure Control
The combustion control system includes the comprehensive control of the main gas main equipment, the gas branch pipe equipment, the combustion-supporting air supply equipment and the burner.
The gas main pipe is provided with an electromagnetic cut-off valve, and the branch pipe is provided with an interval solenoid valve, which can realize the functions of safety interlock and automatic cut-off of the gas circuit in case of power failure.
There are a total of 68 burners in the whole kiln, which are divided into 10 branches and are equipped with electric actuators. The gas pressure and flow of the branch can be automatically adjusted according to the temperature change of each section, so as to maintain the stability of various systems in the kiln.
8.2 Security Alarm
(1) Fan interlock and power failure automatically close the solenoid valve of the gas main pipe;
(2) The upper and lower limits of gas pressure are detected and alarmed, the combustion air underpressure alarm, and the natural gas main solenoid valve is closed;
(3) Alarm for smoke exhaust, quenching, combustion support and waste heat fan;
(4) Kiln temperature over-limit detection and automatic alarm;
(5) Overpressure alarm of car jacking machine;
(6) Monitoring the operation of kiln head or kiln tail kiln car;
8.3 Preheat Utilization System
The product process requires product drying, and the preheating of the slow cooling section of the kiln is the most ideal heat source. The air source of the drying kiln adopts the residual hot air from the tail to dry directly.
9. Furnace Lining
9.1 Dehumidification section
Side wall: 115mm high-alumina polylight ball brick, 230mm lightweight thermal insulation brick, 50mm ordinary blanket, 50mm ordinary fiber blanket felt.
Top: flat top cordierite mullite two-piece set (mullite shed board, mullite I-shaped brick), 150mm ordinary fiber blanket.
9.2 Medium temperature section
Side wall: 115mm JM23 lightweight mullite + 230mm lightweight poly-light brick at the front, 230mm JM26 mullite + 115mm poly-light brick at the rear 10 meters, 200mm fiber blanket.
Top: 230mm poly light brick ceiling for the first 10 meters, 230mm JM26 light mullite ceiling for the rear 10 meters, 40mm fiber blanket.
9.3 High temperature section
Side wall: 230mmJM28 mullite, 115mm polylight brick, 200mm fiber blanket.
Top: ceiling 250mmJM28 mullite, 100mm fiber blanket.
9.4 Quench section
Same as medium temperature section (including transition section)
9.5 Cooling section
Side wall: 115mm high-alumina polylight ball brick, 230mm lightweight thermal insulation brick.
Top: 230mm poly light brick ceiling, 40mm fiber blanket.
9.6 Kiln car
The refractory column is directly supported on the steel frame of the trolley, and the customized high-temperature crack-resistant special-shaped bricks are used around the car body to reduce the heat storage of the kiln car and save energy consumption. The masonry of the kiln car adopts a brick-wool mixed structure. The middle part is filled with high-temperature refractory fiber cotton, and the surface layer is covered with a cordierite-mullite cover.
High quality and heat preservation, but also reduce the phenomenon of dirt. The curved seal between the steel frame of the kiln car and the steel frame is sealed by asbestos rope. It forms a hyperbolic sealing structure with the kiln wall, and forms an effective air shield together with the wide and deep sand sealing groove. The double-curved sealing kiln car has been carefully designed to achieve good sealing effect and low maintenance rate of the kiln car. The kiln wheels are cast steel wheels. The downwind of the car is designed in the sand sealing groove, which can not only balance the pressure from the furnace, but also seal the hot air flowing down the string.
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