RU2018445C1 - Flow line for production of building ceramics - Google Patents

Abstract

FIELD: industry of building materials. SUBSTANCE: flow line comprises excavating, molding, transport and load-gripping systems, water and fuel containers with their distribution systems, addition delivery and heat-treatment equipment, and control instruments. Besides, the line has a working deck with stone-separating grate, clay storage with entrance and exit, molding equipment in the form of a bulldozer with a vibratory blade and a hydraulic control cylinder, and shock-absorbing molding plate with cassette molds, equipment for delivery of additions in the form of a spreader secured in the rear end of the bulldozer, and a water-distributing system mounted on working deck. Heat-treating equipment comprises continuous conveyor-type drying-and-burning oven with gravity drive and movement equalizer with generator-motor. Loading and unloading parts of the conveyor are arranged at different levels in the oven while their connecting parts are inclined. Load-gripping equipment is made as a hydraulic manipulator grip. EFFECT: improved design. 2 cl, 6 dwg

Description

 The invention relates to the construction materials industry, in particular the production of building ceramics.

 Closest to the invention is a technological line for the production of building ceramics, containing excavating, molding, transport and lifting equipment, water and fuel tanks with distribution systems, equipment for supplying additives, heat treatment and monitoring and control devices [1].

 The known line is complex and cumbersome, which leads to increased unit costs for its construction and use.

 The purpose of the invention is to simplify the design, ensuring the continuity of the process, expanding the scope of use.

 The goal is achieved by the fact that the technological line for the production of building ceramics, containing excavating, molding, transport and cargo gripping equipment, water and fuel tanks with distribution systems, equipment for supplying additives, heat treatment and monitoring and control devices, is equipped with a work platform with a grill - stone separator, clay accumulator with entry and exit, molding equipment is made in the form of a bulldozer with a vibrating blade and a control hydraulic cylinder and a shock-absorbed mold a slab with technological equipment in the form of cassette flask molds, while the equipment for supplying additives is made in the form of a spreader and mounted on the bulldozer at the back, and the water distribution system is located on the working platform.

 In the described technological line, it is advisable to perform the equipment for heat treatment in the form of a continuous conveyor drying and calcining furnace with a gravity drive and a motion equalizer with an electric motor-generator, while loading and unloading sections of the conveyor should be located at different levels connected by sections of the conveyor made inclined at this load-lifting equipment to perform in the form of a hydraulic gripper-manipulator.

 In FIG. Figure 1-3 shows the plant-plant diagrams for the production of raw products: a quarry with an excavator in a profile projection, material handling equipment, a mass processing and molding unit, a work platform, a water supply system and a platform for support molds in a horizontal projection; in FIG. 4 - molding platform, motor transport, processing and molding unit, molding plate with flasks in profile projection, section; in FIG. 5 - conveyor oven for drying and firing products with a conveyor, profile projection; in FIG. 6 - the same horizontal projection.

 The line contains: a unit 1 for processing and molding the mass, a dump truck 2, a forklift 3 with hydraulic grips, a conveyor furnace 4, a multi-tiered platform - a canopy 5 for storing reverse flask molds, capacity 6, system 7 for technological and drinking water supply, excavator equipment 8 , industrial equipment - flask molds 9, as well as the molding platform 10.

 The mass processing and molding unit 1 consists of a tractor on which a blade 11 is mounted in front, having a vibrator 12 and a working control hydraulic cylinder 13, as well as rear additives spreader 14 (for example, a type of mounted fertilizer spreader NRU-05) having a hopper for containing additives, a disk or other spreader 15 additives driven by the shaft 16 of the tractor power take-off, as well as the control body 17, dispensing the consumption of additives of known designs.

 Dump truck 2, forklift trucks 3, water tank, excavator 8 known designs. Forklift trucks 3 are additionally equipped with hydraulic grippers-manipulators 18 of known designs.

 The conveyor furnace 4 has a tunnel or trench type housing, an annular conveyor conveyor 19, a storage site 20 of fuels and lubricants with capacities 21 and 22 for solid and liquid fuels, a gaseous fuel supply system with a main valve 23, liquid fuel with a valve 24, a blocking valve 25 and gas-liquid burners 26 on the furnace body in the firing zone and the tube 27 for supplying solid fuel to the firing zone.

The furnace also has a loading platform-zone 28, zones of the beginning of intensive drying and dehydration of raw 29, preparation and firing 30, quenching and cooling, unloading products 31 of the site and zones. In this case, the loading and starting drying, gas exhaust zones are located at a higher level of H ₂ than the firing, quenching, cooling and unloading zones of H ₁ , forming at the same time the inclined part of other zones and the conveyor with the optimal angle α, taking into account the reliable self-movement of the conveyor bogies 32 under the influence of the difference of gravitational forces acting on the loaded and idle branches of the conveyor.

 To ensure uniform movement of the conveyor on its idle branch in the unloading zone, a leveling device 33 is installed with rollers or other braking devices in contact with the bodies of the trolleys using pneumatic cylinders or springs with an organ 34 that controls the force of contact and braking, as well as an electromechanical brake - the motor-generator 35 well-known designs to ensure the movement of the conveyor when it is loaded at the beginning of work or repair - with work in motor mode and braking mode, stopping when loaded conveyor - generator operating mode of the electric generator-engine with the release of electricity to the external circuit.

 This design of the furnace creates natural draft and improves the circulation of working gases in the furnace. The arrangement of such a furnace is most suitable for zones of the piedmont region, since it uses irregularities in the natural topography of the area. At the same time, it is acceptable for other areas, taking into account the creation of artificial irregularities in the base of the furnace.

Additionally, to create a draft of gases and release them into the atmosphere, a chimney 36 is mounted in the loading zone at a height of H ₂ , installed on the foundation with fasteners and additionally fixed with braces 37.

 The exhaust pipe and the cavity of the furnace are connected by a chimney with a gate valve 38 regulating its cross section.

 To increase the resistance of gas suction through the inlet cavity, it has a prechamber with curtains 39 made of cord fabric.

 On the side walls or arch (with the trench design of the furnace) there are inspection hatches 40 with dampers and entrances with doors 41 for monitoring the cavity of the furnace and performing maintenance and repair of the conveyor. During operation, hatches and entrances must be carefully closed, preventing air suction through them in order to avoid violation of the aerodynamic mode of operation of the furnace. Sensors for indicating and recording instruments for measuring vacuum, traction and temperature in the zones are installed in the working areas. The devices themselves are located on the control panel of the furnace.

 The conveyor carts are interconnected by hinges in a single chain and mounted on rail tracks 42. Their working platform has a refractory lining. For thermal insulation of the lower part of the carts and the track, they have at the joints and sides heat-reflectors 43 made of heat-resistant material, such as asbotten or sheet. The rail track is additionally insulated in dehydration, firing and quenching zones with refractory sand backfill 44. The indicated zones of the furnace body are also made of refractory-durable materials (for example, refractory bricks, stone, clay or concrete). The rest of the furnace body is made of ordinary building materials.

 The length of the working zones of the furnace, as well as the speed of the conveyor are determined by the calculations of thermal and technological modes of operation.

 Raw materials are loaded and products are unloaded in zones 28 and 31 using hoisting-and-transport equipment with hydraulic grips-manipulators 18 of known designs (for example, forklifts 3). The molding platform 10 is a plane raised above the surrounding level with a fence or a shallow pit of a circular or trench type with a hard coating of the working surfaces and entrance, exit routes (Fig. 1-4). The platform has clay filler 45 with a stone separator 46, a molding section with a molding plate 47 located on it in the recess, shock-absorbed by elastic buffers 48, as well as entering along arrow A and leaving the molding section. The molding plate is used to place cassette flask forms 9 on it. The plate has flask clamps and sockets for installing hollow core formers 52. Products of a given shape are molded in flasks.

 Cassette flask molds are used to give the product the desired shape, transport it and place it on the carts of the conveyor belt of the furnace, as well as unload it from the furnace. The flasks are made of refractory, durable material (for example, heat-resistant cast iron or steel) taking into account shrinkage of products, molding slopes within tolerances on product dimensions and surface cleanliness and product fixation in nests due to molding slopes and friction. The number of sockets in the flask is determined on the basis of the optimality of the plant’s productivity, for example, 500-1000 pcs.

 The dimensions of the molding plate are also set based on the optimality of the installation performance, for example, on brick - to accommodate 2-4 flasks at the same time.

 To moisten the mass, the working platform along the circuit has an irrigation system 7 with spray nozzles 50. The system is connected to an external water supply or water tank 6 through a valve 51, through which the water flow is regulated.

In the drawings, the arrows show the directions of movement of the units, the supply of liquid T _g , solid T _t and gaseous T _{g of} fuels, as well as exhaust emissions into the atmosphere. β is the angle of inclination of the bottom of the drive, entry, molding area, exit and the walls of the working platform (10-60 ^about ).

 The installation is as follows.

 During the operation of the plant, using the excavator 8 and the dump truck 2, the cultural layer is removed - the soil I is above the clay layer II and transported to the storage site for subsequent reclamation of the selected quarry.

 After that, the quarry is leveled and the clay pit is selected by the excavator 8 with a bulldozer, the clay is loaded onto a dump truck 2, which transports it to the work platform 10, and pours it onto the stone separator 46 into the storage unit 45.

 With the help of the grating, possible stones are prevented from entering the drive and the working mass. Next, using the unit 1, the mass is leveled, the chassis and the blade 11 are crushed, mixed with additives scattered by the spreader 14 additives using a disk rotating by means of a drive from the tractor power take-off shaft 16. In this case, the unit makes a circular motion (with a round platform) or reciprocating (with a straight platform). In this case, the mass is moistened to the required condition (18-20% humidity) with water using the irrigation system 7 and spray nozzles 50, adjusting the flow rate by the valve 51.

 As additives, use: sand, coal and brick dust, flooring, straw section, sawdust and other components, depending on the composition of the clay.

 After preparing the mass, installing the flask molds 9 onto the molding plate 47 using the forklift 3, the aggregate 1 dumps the flask molds with mass 11, runs into the flasks and with its chassis and blade (mass and vibrating blade) levels, thrombs (compresses) the mass and products in flask cells. In this case, the blade is controlled using a hydraulic cylinder 13 and a vibrator 12. After sufficient compaction of the mass in the flasks, which is checked by a soil densitometer of known design and experience, the unit moves back from the flasks in the rear movement and dumps excess weight from the flasks with the trailing edge of the blade, levels the contact surfaces of the products in cell flasks.

 Next, the forklift 3 molded flasks are selected from the molding plate 47 and transported to the drying-kiln 4, are installed on the working carts 42 of the conveyor conveyor 19 in the loading zone 28.

 In this case, the flasks are captured by hydraulic grippers-manipulators 18, are oriented in space according to the scheme of laying them on carts. The spatial orientation of the flask is obtained by articulating grips and changing the gripping point relative to the center of gravity of the flask or in another way based on the design of the manipulator.

 When molding full-bodied products, hollow core rods 52 are removed from the forming plate. When forming hollow products, these rods are left or installed on the forming plate and provide strict fixation of the flasks relative to the rods using the clips on the plate.

 Next, the processing and molding unit continues to prepare the mass and the process of molding raw. At the same time, the flasks are selected from the working capital at the canopy site 5 using a forklift 3.

 In the drying-kiln 4, the raw material is conveyed sequentially through the conveyor belt 19 to the zones: loading and starting drying 28, intensive drying and dehydration 29, preparation and firing 30, quenching, cooling and unloading 31, where it is unloaded. The movement of the conveyor is carried out at the beginning of the launch using the generator-engine 35 when operating in the motor mode, and then due to the difference in the gravitational forces of the loaded and unloaded branches of the conveyor-generator (main) mode of operation. The uniformity of movement, change in speed and stopping the conveyor are provided by leveling device 33 due to generator or mechanical braking, as well as by changing the location and speed of unloading products and loading raw.

In the process, the fuel supply to the burners 26 is provided depending on the source of fuel: through the valve 23 from the gaseous fuel supply system T _t or valve 24 from the tank 22 liquid fuel T _g . At the same time using a two-way valve 25 provide blocking of gaseous or liquid fuels, at the same time control the operation of the burners, changing the amount of fuel supplied.

 When using solid fuel, it is fed in portions through tubes 27, the openings of which are closed by hinged covers after the fuel is fed.

The working process in the furnace occurs by a predetermined continuous function sequence in accordance with the technology of drying and calcining the product from performing the following operations and heating modes of operation: loading the raw and the start of drying - the mass temperature rise from the initial value to 50 ^C, the intensity (velocity) heating 50- 80 ^about C / h; raw intensive drying and heating it to 50 to 100 ^C, heating rate ^of 50-80 C / h; drying the end and beginning with raw dehydration by heating it from 100 ^to 200 ° C, heating rate ^of 50-80 C / h; raw dehydration with heating it from 200 ^to 400 ^° C, heating rate ^of 100-200 C / hr; raw dehydration with heating it from 400 to 600 ^C, heating rate ^of 100-200 C / hr; end of the dehydration, beginning with raw firing heating it from 600 to 800 ^C, heating rate ^of 100-200 C / hr; roasting raw with heating from 800 to 950-1000 ^о С, heating rate of 100-150 ^о С / h; tempering and cooling of products from the beginning temperature of 950 ^{° C} to 800 ^{° C,} the cooling rate ^of 100-150 C / hr, the beginning of intensive cooling from 800 to 600 ^{° C,} the cooling rate ^of 150-200 C / hr; intensive cooling with product 600 ^to 40 ° C, the cooling rate ^of 200-300 C / hr; unloading products, unloading flasks, sorting products, delivering them to the finished goods warehouse or selling them to the consumer after posting, returning flasks to site 5 of the flasks fund.

 Raw heat in preparatory operations is due to the heat of the contacted working gases from the cooling and firing zones. In the firing zone, heating occurs due to the combustion of fuel.

 The thermal regime and the heating and cooling rates in the zones are controlled by changing the fuel supply, gas flow, and also the conveyor speed. The mode of operation of the furnace is monitored using control devices, as well as using work experience.

 The cavity of the furnace is observed through inspection hatches 40 and openings 41, which are maintained in a closed state.

The circulation of gases in the furnace is due to the difference in atmospheric pressure at the levels of discharge H ₁ and load H ₂ , as well as the height of the chimney 36.

 At the same time, to ensure the correct aerodynamic circulation of gases, the inlet of the furnace in the loading zone is hung with curtains 39, and the chimney to the pipe has a damper 38. This ensures a counter flow of gases and products, which gives an economical mode of operation of the furnace.

 When the leveling device 33 and the generator-motor 35 are operating in the generator braking mode (main operating mode), electric energy is released into the external circuit, which additionally saves energy resources during installation operation and reduces the cost of production.

 Unloading of products is also carried out by hoisting vehicles using a hydraulic gripper-manipulator 18, for example, a forklift 3 with a manipulator.

 The flasks returned to site 5 undergo a technical audit and repair, after which they are launched for a second cycle of the installation.

 After sampling, the quarry is subjected to reclamation using a previously stored topsoil or in another way.

Claims (2)

 1. Technological line for the production of building ceramics, containing excavating, molding, transport and cargo gripping equipment, water and fuel tanks with distribution systems, equipment for the supply of additives, heat treatment and monitoring and control devices, characterized in that it is equipped with a working platform with a stone separator grate, a clay drive with entry and exit, the molding equipment is made in the form of a bulldozer with a vibrating blade and a control hydraulic cylinder and a shock-absorbing shape ovochnoy plate with industrial equipment in the form of cluster flasks forms, with equipment for supplying additives is designed as a spreader and strengthened rear dozer, and the water distribution system is placed on the platform.  2. The production line according to claim 1, characterized in that the equipment for heat treatment is made in the form of a continuous conveyor drying and kiln with a gravity drive and a motion equalizer with an electric motor-generator, while the loading and unloading sections of the conveyor in the furnace body are located in different levels, and the sections of the conveyor connecting them are made inclined, while the load-gripping equipment is made in the form of a hydraulic gripper-manipulator.

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