焙烧炉施工手册

经典word整理文档，仅参考，双击此处可删除页眉页脚。本资料属于网络整理，如有侵权，请联系删除，谢谢！CUNSE1酸再生焙烧炉炉衬砌筑操作规程OperatingInstructionsforLiningMasonryofAcidReproductionBakingFurnace一、概述Generalconsiderations焙烧炉炉衬用耐火材料：耐火耐酸砖、刚玉砖、轻质隔热砖、耐酸火泥、刚玉质耐火泥、耐酸重质浇注料、耐酸轻质浇注料、刚玉质耐酸捣打料、硅酸铝纤维板、硅酸铝纤维毯、高温粘结剂。Refractoriesforacidreproductionbakingfurnaceareasfollows:refractoryacid-proofbricks,corundumbricks,lightweightinsulatingbricks,acid-proofmortar,corundummortar,acid-proofheavyweightcastable,acid-prooflightweightcastable,corundumacid-prooframmingmix,aluminumsilicatefiberboard,aluminumsilicatefiberblanketandhightemperatureadhesives.1、耐火材料使用部位：Positionsofapplications:no.123456789CUNSE备注：某种材料的使用与否及使用部位有设计部门确定。2Notes:applicationandapplicationpositionsofmaterialsshallbedeterminedbydesigndepartment.2Physicalpropertiesandchemicalcompositionsofrefractories:(someindexesshallbedesignedaccordingtocustomersdesignrequirements)（1）耐火耐酸砖Refractoryacid-proofbricks℃%Refractorinessunderloadat%%%%232332O2（2）刚玉砖Corundumbricks项Item℃O%23CUNSE3（3）轻质隔热砖Lightweightinsulatingbricks（S11）ItemIndex℃℃%23O%23(4)轻质隔热砖Lightweightinsulatingbricks（S8）项Item℃O%%23O23CUNSE4(5)耐酸火泥Acid-proofmortar项ItemIndex23%23秒s(6)刚玉质耐火泥CorundummortarItem23秒s（7）耐酸重质浇注料Acid-proofheavyweight（1300D）项Item℃O%23%CUNSE5(8)耐酸轻质浇注料Acid-prooflightweightcastable（FL900）项Item℃%23℃℃℃(9)耐酸刚玉捣打料Acid-proofcorundumrammingmix（1-180/m）项ItemCrushingstrength（1500℃×3h）23%23）%约5(10)硅酸铝纤维板Aluminumsilicatefiberboard项Item23O%232%1000℃×24hCUNSE6%（11）硅酸铝纤维毯Aluminumsilicatefiberblanket23O2323、焙烧炉炉衬用耐火耐酸砖砖型（仅供参考）Shapeofrefractoryacid-proofbricksforliningofbakingfurnace(onlyforreference)耐火耐酸砖耐火耐酸砖6940CUNSE7855Shapesofrefractoryacid-proofbricksforcone椎体部位用耐火耐酸砖砖型CUNSE8二、施工InstallationPreparationbeforeinstallation1、材料检查与验收Materialssubjectedtoinspectionandacceptance：施工单位应根据设计要求和焙烧炉用耐火材料采购合同的材料清单、技术要求，对到货的材料进行分逐项检查验收、核对，确认材料是否全部到齐、是否符合标准规定。经确认无误后，可进入下道环节。Installationorganizationsshallinspectandcheckeverydeliverediteminaccordancewithrequirementsofdesignandlistofrefractorymaterialsforbakingfurnaceinpurchasingcontractandtechnicalrequirements.Checkandconfirmifallmaterialsareavailableandcomplywithstandards.Aftertheconfirmationswithoutanymistakes,thenextprocessofinstallationcanbecarriedout.2、施工现场要求Requirementsofinstallation:道路畅通，地面整洁，有动力电源和照明线路及施工用水，具备施工机械和设备的及时、畅通出入，具备施工所需的环境和空间，无设施、设备、人身不安全的事故隐患点、线、面。Theroadsshallbeclearandthegroundmustbeclean.Powersupplyandlightinglinesaswellaswaterforinstallationshallbeavailable.Timelyandunimpededaccesstoinstallationsiteforinstallationmachinesandequipmentsshallbeguaranteed.Necessaryenvironmentandspaceforinstallationshallalsobeavailable.Facilities,equipments,sites-lines-panelsthatmaycausepersonalinsecuritymustbeunavailable.3、施工设备要求Requirementsofinstallation：根据施工需要，检查所用的机械设备：打浆机、强力搅拌机、切砖机等是否具备施工安全要求、正常运转，是否清理干净。Checkallmechanicalequipmentsaccordingtoinstallationrequirements:whetherslurrymashingmachines,powerfulmixersandbrickcuttersmeetsafetyrequirementsofconstruction,operatenormallyorarecleanedup?4、检查焙烧炉壳内部Furnaceshellinteriorsubjectedtoinspection：检查焙烧炉炉壳内部及支撑：尺寸、中心、焊接情况是否符合图纸设CUNSE9计要求，经检查确认符合要求后，可进入下道施工环节。Checktheshellinteriorandsupport:whetherthedimension,centerandweldingshallconformtothedesignrequirementsofdrawingsornot?Thenextprocessofinstallationcanbecarriedoutifinspectioncomplyingwithrequirements.Masonrystepsforinstallation先从锥体下部开始砌筑、然后砌筑燃烧室、烧嘴、人孔和回风管、炉Thestartingofmasonryshallbefromlowerpartofcone,andthencombustionchambers,burners,manholeandairreturnpipe,upperpartsoffurnace(firstinsulatinglining,thenpermanentlining).Masonry1、砌筑说明Masonrydescriptionsa、保温层采用硅酸铝纤维板的：先砌筑纤维板，后砌筑耐酸砖。Fortheinsulatinglayerinstalledbyaluminumsilicatefiberboard:fiberboardislaidfirstandthenacid-proofbricksarelaid.b、保温层采用耐酸轻质浇注料的：先砌筑耐火耐酸砖，后施工轻质浇注料。Fortheinsulatinglayerinstalledbyacid-prooflightweightcastable:refractoryacid-proofbricksarelaidfirstandthenmasonryoflightweightcastableiscarriedout.c、焙烧炉灰缝设计：2mm;施工灰缝偏差：2mm1.Designsformortarjointsofbakingfurnace:2mm;errorofmortarjointsduringinstallation:2mm2、锥体部位砌筑Masonryforcone（1）使用材料：锥体用耐火耐酸砖、耐酸火泥、耐酸重质浇注料、Refractorymaterialsrequired:refractoryacid-proofbricks,acid-proofmortar,acid-proofheavyweightcastable,acid-prooflightweightcastable(oraluminumsilicatefiberboardandhightemperatureadhesives)andaluminumsilicatefiberblanket.（上下口径尺寸与设计尺寸误差不得大于2mm.(模具最好做成整体圆锥体)，CUNSE10模具表面做成光滑面，有利于整体脱模，表面最好加上白铁皮或油毡。按照图纸设计位置将模具固定好，确保模具的中心点与炉体的中心点在同一直线上，然后浇注，浇注层与炉底的结合处用耐火纤维板做垫层，其厚度一般在15-30mm。浇注料的搅拌方法及浇注遵循《施工说明书中》的要求进行。Mouldsforcastinglayeroflowerpartofconeshallbemadeinaccordancewithdesignrequirements,theerrorbetweendimensionofitsheight,upperandlowercaliberanddesignsizearenotgreaterthan2mm(itisexpedientthatthemouldismadeintomonolithiccone).Theconesurfaceshallbesmoothforfacilitatingmonolithicdemoulding,coveredwithgalvanizedsheetortreatedfeltpreferably.Fixthemouldinaccordancewithplacesdesignedindrawingstoensurethatthecenterofthemouldandthatoffurnacebodyshallbeinthesameline,andthencastingcanbecarriedout.Refractoryfiberboardisusedasinthejunctionsbetweencastinglayerandfurnacebottomwithdepthisfrom15to30mm.Themixingandcastingmethodsofcastableshallfollowrequirementsof<<InstallationInstructions>>.（3）锥体的砌筑方法Installationmethodofcone在砌筑前，先根据炉体的中心点，把整个炉体平均分成36等分。平分后，将每个平分点挂线，按线砌筑，根据需要可制作弧面测量工具在砌筑过程中进行测量。Thefurnacebodyshallbedividedinto36equaldivisionsinthelightofthecenteroffurnacebeforeinstallation.Then,hangalineateverybisectingpointonwhichtheinstallationisbased.Measuringtoolsforcamberedsurfacecanbemadeandusedduringinstallationaccordingtoneeds.在椎体砌筑过程中，以分层砌筑法，即每一圆周为一层。砌筑时所用砖的型号与数量以配砖表为主，并结合现场实际情况确定所用的量。砌筑的内径尺寸应以炉体中心线为准进行测量。砖体背面与炉体结合处，用轻即工作面不能出现高低不平和倒台现象，用弧面测量工具，测量砌体，在整个内圆的同一测定面上，不允许出现二处与弧度不符的点，否则，返工CUNSE11重新砌筑。Duringinstallationofcone,thelayeredinstallationmethodisadopted,i.e.eaamodlesanddeterminetheusageactualduringinstallation.Theinternaldiameterofinstallationshallbesubjecttomeasuringonthebasisoftthethetampedbyisfilledwithacid-proofmortar).Ruggedandcollapsephenomenonshallbeunavailableiarenotallowed.Otherwise,itshouldbereinstalled.锥体与燃烧室的结合部位所留的膨胀缝，必须根据设计所需用耐火纤维毯填实。Expansionjointsrequiredbyjunctionsbetweenconeandcombustionchambershalltampedbyrefractoryfiberblanketaccordingtothedesign.3、燃烧室部位砌筑Installationofcombustionchamber（1）需用材料：耐火耐酸砖、耐酸火泥、耐酸轻质浇注料，刚玉质结剂等。Refratorymaterialsrequired:refractoryacid-proofbricks,acid-proofmortar,alightweightcastable,corundumacid-prooframmingmix(orcorundumbricks),lightweandhightemperatureadhesives.（2）燃烧室部位砌筑有：燃烧室、人孔、回料（风）孔和测温孔等。combustionchamberare:combustionchamber,manhole,charge(blast)returnholeandtemperaturemeasuringhole.（3）若烧嘴不采用刚玉砖时，则需要先制作模具，根据烧嘴长度，将模具做成3-5节，以便施工和脱模，模具表面应作光滑处理。Mouldsmadenotcombustionchamber.CUNSE12Mouldscanbemade3-5sectionsforfacilitatinginstallationanddemouldinginthelightofthelengthofburners.Mouldsurfaceshallbesmoothhandling.（4）整个燃烧室结构复杂，在施工时应认真核对设计图，严格按照设计施工，认真操作。所用耐火耐酸砖的型号与数量以设计为准，分层砌筑，层层测量，确保内部尺寸。Reviewandcheckthedrawingscarefully,strictlyconformtothedesignandoperateseriouslyduringinstallationduetothecomplicatedcombustionchamber.Allmodelsandquantitiesofrefractoryacid-proofbricksshallcomplywiththedesign.Layeredinstallationmethodsareadoptedandeachlayermustbemeasuredtoensuretheinternaldimension.（5）烧嘴的砌筑Installationofburners首先测量烧嘴的中心点，每个烧嘴的中心线都要保持水平与设计要求相一致。First,thecenterofburnersshallbemeasured.Thecenterlineofeachburnershallkeephorizontal,complyingwithdesignrequirements.a、采用纤维板和刚玉砖的，首先在烧嘴的桶壁上粘贴耐火纤维板，粘贴完毕后砌筑第一块刚玉砖（刚玉砖的中心必须与烧嘴的中心保持一泥把子母口接好，其灰缝应符合设计要求。Burnerswithinstallationbyadoptionoffiberboardandcorundumbricks:sticktherefractoryfiberboardontheburnerside.Thefirstcorundumbrickcanbelaidaftersticking(thecenterofcorundumbrickmustkeepconsistentwiththatofburner),thenitcanbetampedbyrammingmix.Thefollowinginstallationforeachsectioniscarriedoutinthisway.Fortheconnectionofcorundumbrick,maleandfemaleareconnectedbycorundummortarandmortarjointbetweenthemshallconformtodesignrequirements.b、采用轻质浇注料和刚玉捣打料的，先固定第一节模具（模具的中心必须与烧嘴的中心保持一致）,然后砌筑一段轻质浇注料和轻质隔热砖，隔热砖的材质及型号和数量按设计要求进行砌筑，砌筑时按环形砌筑，灰浆必须饱满。砌筑长度达到200-500mm后，将环形隔热砖内的火泥和杂物清理干净，然后进行捣打料的施工，捣打料是按分节进行，每节的接头处必须作拉毛处理，以便结合。脱模后做工作面的处理。按圆的内径平均分成434mmCUNSE13在整个捣打过程中，捣打料的水分不宜过大，应根据施工环境和施工进度调整。捣打法采用分层捣打，其捣打厚度应小于200cm。这样节节进行。Burnerswithinstallationbyadoptionoflightweightcastableandcorundumrammingmix.Fixthefirstsectionofmould(thecenterofmouldmustkeepconsistentwiththatofburner),thentheinstallationoflightweightcastableandlightweightinsulatingbricksinasectioncanbecarriedout.Allqualities,modelsandquantitiesshallconformtodrawingdesign.Installationshallbering-shapedandmortarmustbeoverflowing.Aftertheinstallationlengthisupto200-500mm,mortarandinclusionintheinsulatingbrickslaidintheringmustbecleanedup.Theninstallationoframmingmixcanbecarriedoutbysub-sectionmethod.Jointsofeachsectionshallbenappingtreatmentforfacilitatingcombining.Afterdemoulding,theworkingfaceshallbeprocessed.Accordingtotheinternaldiameterofacircle,itcanbedividedinto4equaldivisionsand3~4mmexpansionjointisrequiredinthepositionofeachbisectrixforthepurposeofeliminatingsurfacestress.Duringthewholerammingprocess,waterinrammingmixshallnotbetoomuchandmaybeadjustedaccordingtoinstallationenvironmentandschedule.Layeredrammingmethodsareappliedandrammingdepthshallbelessthan200cm.Thenthefollowinginstallationforeachsectioniscarriedoutinthisway(6)人孔的砌筑Installationformanhole人孔施工分两步Installationformanholeconsistsoftwosteps：a、人孔耐酸砖的砌筑：其尺寸应根据图纸设计进行砌筑，尺寸误差不能大于3mm。Installationofacid-proofformanhole:theinstallationdimensionshallconformtothedrawingdesignandthedimensionerrorshallnotbegreaterthan3mm.b、过梁施工,先固定模具然后使用耐酸重质浇注料浇注，其尺寸应根据图纸设计进行浇注，尺寸误差不能大于5mm.Installationoflintel:fixthemouldfirstandthencastitbyacid-proofheavyweightcastable.Thecastingdimensionshallconformtothedrawingdesignandthedimensionerrorshallnotbegreaterthan5mm.整个燃烧室与炉体上部结合处用耐火纤维毯填实，填充厚度按设计要求。Thejunctionbetweenthecombustionchamberandtheupperpartoffurnaceshallbefilledwiththerefractoryfiberblanketwiththethicknessaccordingtodesignrequirements.CUNSE144、炉体上部砌筑Installationofupperpartoffurnace（1Refractorymaterialsrequired:refractoryacid-proofbricks,acid-proofmortar,lightweightcastable(orfiberboard).（2）砌筑方法：分层砌筑，层层测量，所用耐火耐酸砖的型号与数量以设计为准。Installationmethods:layeredinstallationmethodsareappliedandeachlayershallbemeasured.Allmodelsandquantitiesofrefractoryacid-proofbricksshallcomplywiththoseofthedesign.整个炉体砌筑完毕后，要进行炉壁表面的处理工作。Aftertheinstallationfortheoverallfurnacebodyisfinished,thehandlinginthesurfaceoffurnacewallshallbecarriedout.三、烘炉Heating-upfurnace根据焙烧炉的大小，气候环境，通风时间制定出适应客观条件的烘炉曲线，之后严格按照烘炉曲线进行烘炉操作。Acurveofheating-upfurnace,adaptingtotheobjectiveconditions,shallbemadeaccordingtotheroastingfurnacesize,climateandenvironmentaswellasventilationtime.Thenoperationofheating-upshallbecarriedoutinstrictaccordancewiththecurve.CUNSE文丘里砌筑施工15InstallationforventuriA：施工前的准备工作Preparationbeforeinstallation1）检查文丘里砌筑用各种材料是否全部运抵现场。Checkthevariousmaterialsforventuriinstallationavailableininstallationsite.2）对照图纸认真核对文丘里防腐后的各个内部尺寸是否符合设计要求。Checkeveryinternaldimensionofcorrosion-proofventuriinaccordancewithdesignrequirements.3）清扫文丘里内部的杂物，为砌筑做好准备。Cleanuptheinternalinclusionsinventuristoprepareforinstallation.4）查看是否具备施工条件；Checkwhetherornotinstallationconditionsaresatisfied.a)现场的水电供应情况是否通畅。Whetherornotwaterandelectricitysupplyareeasyandsmooth.b)砌筑时所用的工具是否能正常运行。Whetherornottoolsforinstallationcanworknormally.c)的检查每个管道连接口及斜插口的位置是否完好无损。Inquireabouttheinternalcorrosion-prooflayerhaspassedtheacceptanceofownerandsupervisorornot.Checkeverypipeconnectorandpositionofinclinedinsertingmouthareintactornot.具备以上条件方可施工。Installationscannotbecarriedoutuntiltheabovementionedconditionsaresatisf