Glass Kiln Full Tracking Solution

1. Kiln Masonry

1. Thickness of brick joints in masonry

AZS The supplier has pre-laid the masonry in advance. During formal masonry work, dry laying should be carried out according to the assembly numbers provided by the supplier. Inspection with a gauge should meet the requirements of the following table:

2. Ramming material

When using two types of ramming materials, the lower layer uses ( ZrO2  60% ）Zirconia ramming material, and the upper layer uses ( ZrO2  33% ） AZS ramming material. When using only one type, it should be selected AZS ramming material. It can be divided into three types according to particle size: BEN-50 The maximum particle size of the aggregate is 5mm，BEN-06 The maximum particle size of the aggregate is 0.6mm，BEN-04 The maximum particle size of the aggregate is 0.4mm . Ramming material construction is extremely important; it directly affects the quality of the masonry and the service life of the kiln. The construction procedure is described with reference to the standards of Zhongqing International Engineering Co., Ltd.:

a. Wipe the brick surface clean with a damp cloth to give the brick surface a moist feel.

b. Lay BEN-50 ramming material, first use a wooden mallet to level the laid material. It should be as high as the wooden frame (determined by the ramming area, which should be ⅓ higher than the ramming thickness), and there should be no unevenness. Then, tap it once with a wooden mallet.

c. Based on the leveled surface, use a ramming hammer to tamp back and forth three to five times using a method of pressing half a hammer at a time until it cannot be tamped any further.

d. When the ramming hammer has tamped the mud to a glossy finish and eliminated air bubbles, the ramming can be considered to have basically met the requirements. Then, tap it once with a wooden mallet, followed by polishing with a mud trowel. When polishing, you must press down firmly and polish to a smooth, flat finish.

e. The paving thickness is 5mm of BEN-06 mud, scrape it flat, and then immediately pave AZS the surface bricks to prevent 06 the mud from oozing out or remaining in the brick joints.

f. Use BEN-04 material to fill (using a watering can) vertical brick joints. To prevent leakage into the expansion joints, the surrounding expansion joints should be pre-filled with expandable polystyrene.

3. Steel structure

The selected steel structure must ensure that the kiln has sufficient strength and firmness under conditions of heating, cooling, and high temperatures. Many manufacturers use AZS bricks for many parts of small kilns, or use silicon bricks for the heads of the tongues, often resulting in AZS brick detachment due to different coefficients of expansion. Therefore, it is required that during steel structure design, the AZS bricks should be individually reinforced.

4. Kiln cooling

Kiln cooling areas are generally the pool walls, liquid flow holes, charging port corner bricks, bubble bricks, etc. Their layout and size play an important role in improving the service life of the kiln. The following table lists the relevant indicators:

Before laying the ramming material, inspect the brick joints, steel structure, and cooling air on site, put forward reasonable suggestions, and communicate with the construction unit on ramming material construction, etc.

1. Kiln firing

Kiln firing is the initial stage of glass kiln operation and is an important link. When formulating the heating curve, the AZS expansion properties of the bricks should be fully considered, AZS bricks heat up around 1200°C, and ZrO₂ transforms from monoclinic to tetragonal at this time AZS The bricks contract violently, then begin to expand again as the temperature gradually increases. This temperature transition point is usually after the fire is amplified, considering AZS the temperature difference between the inside and outside of the bricks, it is generally required to be 1100-1350°C range, the heating rate does not exceed 4 °C/ hour, if necessary, at 1200 °C or so, appropriate insulation should be carried out. This process is actually a continuation of the kiln firing work.

For newly built kilns, the bottom ramming material is newly laid. Therefore, kiln firing also includes the sintering of the bottom ramming material. Generally, the overall temperature of the ramming material reaches 1200°C, before sintering. Because there is another layer of AZS paving bricks on top of the ramming material, and the pool depth varies from kiln to kiln, so generally when the kiln's high flame temperature reaches 1450 °C insulation for 24 hours, allowing the bottom ramming material to be completely sintered before adding material.

Before firing the kiln, go to the site to discuss with the staff AZS the characteristics of bricks and ramming materials in depth to reach a consensus, to prevent AZS brick cracking, ensuring the sintering of the ramming material lays a good foundation for improving the service life of the kiln.

1. Glass composition and raw materials

The glass composition should meet the requirements stipulated in "Basic Unified Standard for the Chemical Composition Range of Daily-use Glass" and "Allowable Glass Values for the Chemical Composition of Daily-use Glass Products". Regarding glass raw materials, the main control is the particle size of crushed glass ≤ 25mm , when the particle size is smaller, the AZS mechanical wear is smaller. Before the crushed glass enters the batching, the metal impurities in it must be thoroughly picked and removed. If conditions permit, install an iron removal device on the raw material conveyor belt to prevent the kiln bottom from drilling holes during kiln production.

Basic Unified Standard for the Chemical Composition Range of Daily-use Glass

Chemical Composition (Analysis Value)

Kiln Operation and Management . Daily operation and management of the kiln are the key to ensuring the normal operation of the kiln and the production of high-quality products.

Kiln Atmosphere

1. Except for the production of carbon-sulfur colored brown glass, the flame is an oxidizing atmosphere, which is manifested by the bright and clear flame, preventing insufficient secondary air.

The flame has a certain rigidity, and the flame outlet is close to the liquid surface. For horseshoe flame pool furnaces, the flame length reaches

2. 2/3 turns at the place. The maximum operating temperature of the kiln, in terms of flame temperature, is not greater than

3. º, the temperature fluctuation range is within ± 1600C º. 7 C The kiln pressure is controlled in a slightly positive pressure state, avoiding negative pressure operation, and adjusted through the damper.

4. Implement automatic liquid level control to achieve thin-layer feeding, accelerate melting, and reduce material accumulation on

5. the mechanical wear of bricks. AZS Gas sources and cooling water pipes are equipped around the kiln for temporary cooling of the brick body.

6. According to the kiln situation, prepare

7. bricks for tiling. AZS Record the kiln operating parameters and maintenance log.

8. Regarding the work of glass composition, batching, and kiln operation management, every quarter, go to the site and make reasonable suggestions to the customer based on the kiln situation.

关于玻璃组成、配料及窑炉的运行管理工作，每季度到现场，根据窑炉情况向客户提出合理化建议。