Fused cast AZS blocks, as an indispensable key component in the structure of high-temperature industrial furnaces, play an important role. Its excellent high-temperature resistance, corrosion resistance, and good electrical conductivity are directly related to the operating efficiency of the furnace, the final quality of the product, and the maintenance cost of the overall system. However, in continuous high-temperature furnace operation, the fused cast AZS block will inevitably suffer from multiple adverse factors such as extremely high temperature, continuous erosion of chemical substances, and physical wear and tear. The combined action of these external factors will gradually weaken the original performance of the fused cast AZS block, leading to the shortening of its service life, and then affect the stable operation and production efficiency of the entire furnace.
Given the importance of the fused cast AZS block in the furnace system and the challenges it faces, it is particularly important to strengthen the daily maintenance and maintenance of the fused cast AZS block and adopt a scientific and reasonable maintenance strategy to maximize its service life. This is not only the key to ensuring that the furnace can continue to run stably and efficiently, but also an important means to effectively reduce production costs and improve economic benefits.
Therefore, this article will comprehensively and deeply explore how to strengthen the maintenance and care of fused cast AZS blocks, to help relevant industry practitioners better understand and cope with the complexity of fused cast AZS block maintenance and maintenance, so as to improve the overall performance and operating efficiency of the furnace.
First, a comprehensive and in-depth understanding of the basic characteristics of fused cast AZS blocks is an important cornerstone for developing and implementing an efficient care and maintenance strategy. Fused cast AZS block, a key high-temperature industrial material, generally has a high melting point, high hardness, excellent erosion resistance and excellent thermal stability, which together form the basis for its stable operation in high temperature furnace environments. However, it is worth noting that the performance of fused cast AZS blocks is not static, and its key indicators such as high temperature resistance, corrosion resistance and mechanical strength are deeply affected by its composition and production process, thus showing diverse characteristics.
Specifically, the different ratios of raw materials, melting temperature, molding process, and subsequent heat treatment process will profoundly affect the final performance of the fused cast AZS block. For example, certain components of fused cast AZS blocks may show more durable stability at high temperatures, while others may show greater resistance to erosion in certain chemical media. Therefore, when selecting the fused cast AZS block, the actual working conditions of the furnace must be fully considered, including but not limited to the chemical composition of the medium, the temperature distribution inside the furnace, and the expected service life.
On this basis, it is very important to choose the right type of fused cast AZS block. This not only means screening fused cast AZS blocks according to the specific needs of the furnace, such as long-term stability in high-temperature environments or erosion resistance in specific media, but also requires in-depth communication and cooperation with suppliers during the procurement process to ensure that the material, formulation, and production process of the selected fused cast AZS blocks can meet the actual operational needs of the furnace. Through such meticulous screening and matching, the performance advantages of the fused cast AZS block can be maximized, and a solid guarantee can be provided for the stable operation and efficient production of the furnace.
►Physical wear: The fused cast AZS block is washed by material, airflow, and friction of other moving parts in the furnace, causing the surface material to gradually fall off. This wear is usually manifested as scratches, dents, and peeling on the surface of the fused cast
AZS block.
►Chemical wear: The medium in the furnace (such as molten metal, glass liquid, etc.) will penetrate the block along the pores, cracks, and other capillary channels of the fused cast AZS block, and chemical reaction will occur with it to form a metamorphic layer. With the progress of the reaction, the metamorphic layer may crack and peel, thus accelerating the wear of the fused cast AZS block.
Aging mechanism:
►Thermal aging: Long-term high-temperature action will lead to phase change, sintering and other phenomena of the internal material of the fused cast AZS block, which will reduce the performance of the material. At the same time, the thermal stress caused by temperature fluctuations will also lead to cracks and spalling in the interior of the fused cast AZS blocks.
►Chemical aging: The medium in the furnace reacts chemically with the fused cast AZS block, resulting in a change in material composition and loose structure, thereby reducing its fire resistance. This kind of aging is usually manifested by the erosion of the surface of the fused cast AZS block, the spalling, and the destruction of the internal structure.
►Temperature: High temperature will accelerate the deterioration and loss of the fused cast AZS block, reducing its service life. At the same time, temperature fluctuations can also cause thermal stress, resulting in cracks, spalling, and other problems.
►Medium: The composition, concentration, and temperature of the medium in the furnace have an important effect on the wear and aging of the fused cast AZS block. For example, molten metal and glass will erode the surface of the fused cast AZS block, forming a metamorphic layer; Alkaline glass liquid containing Na2O will penetrate the block along the pores and cracks, and accelerate its wear.
►Physical factors: Physical factors such as material erosion, airflow erosion, and friction of other moving parts in the furnace will lead to the wear of the fused cast AZS block.
►Material factors: The material, composition, and process of the fused cast AZS block will also affect its wear resistance and aging resistance. For example, high-purity fused cast AZS blocks usually have better wear and aging resistance.
1. Preferably high-quality fused cast AZS block
♦High melting point characteristics: Select a high melting point of the fused cast AZS block, which is to ensure that it is not easy to melt, or deformation in the high temperature environment. The high melting point means that the fused cast AZS block can withstand the high temperature in the furnace for a long time, thus extending the service life.
♦Good corrosion resistance: There are usually a variety of corrosive media in the furnace, such as acid and alkali substances, high-temperature gases, etc. Therefore, the selected fused cast AZS block should have good erosion resistance to resist the erosion of these media and maintain the integrity and stability of the furnace structure.
♦Excellent thermal stability: Thermal stability is the ability of the fused cast AZS block to keep its physical and chemical properties stable when the temperature changes. The selection of electric melting blocks with excellent thermal stability can ensure that the furnace will not crack, deformation, and other problems during the heating and cooling process.
2. Consider furnace characteristics
♦Temperature environment: The working temperature of different furnaces is different, and some are as high as thousands of degrees. Therefore, when selecting the fused cast AZS block, the specific working temperature of the furnace must be considered, and the fused cast AZS block that can withstand the corresponding temperature must be selected.
♦Medium composition: The composition of the medium in the furnace has a great influence on the erosibility of the fused cast AZS block. For example, some media may be highly alkaline or reductive. Therefore, when selecting the fused cast AZS block, the special fused cast AZS block with corresponding corrosion resistance should be selected according to the medium composition.
♦Atmosphere conditions: The atmosphere conditions in the furnace (such as oxidation, reducibility, etc.) will also affect the performance of the fused cast AZS block. For example, in a reducing atmosphere, some fused cast AZS blocks may undergo a reduction reaction, resulting in a decline in performance. Therefore, when selecting the fused cast AZS block, the atmosphere conditions in the furnace must be considered.
1.Accurate measurement and cutting
Accurate measurement of furnace dimensions is a crucial first step before installing fused cast AZS blocks. This requires the use of high-precision measurement tools, such as laser rangefinders, vernier calipers, etc., to ensure the accuracy of the measurement. During the measurement process, every key part of the furnace should be taken into account, including length, width, height, and any details that may affect the installation of the fused cast AZS block. Once the measurements are completed, the fused cast AZS blocks are precisely cut based on the resulting data to ensure that their dimensions perfectly match the furnace structure. When cutting, professional cutting equipment and technology should be used to ensure the flatness and accuracy of the cutting surface, so as to minimize the installation error and lay a solid foundation for the subsequent installation work.
2.Rational distribution
The layout of the fused cast AZS blocks in the furnace is not only related to the structural stability of the furnace but also directly affects the heat field distribution and medium flow of the furnace. Therefore, in the layout, it is necessary to fully take into account the characteristics of the thermal field distribution of the furnace, such as the location of the hot spot, the gradient change of temperature, etc., and the flow path and speed of the medium in the furnace. Through reasonable layout, it can ensure that the fused cast AZS block forms a uniform and stable thermal field in the furnace to avoid local overheating or excessive erosion. At the same time, it is also necessary to pay attention to the relative position relationship between the fused cast AZS blocks to ensure that they can support each other and form a stable structural system.
3.Professional installation
The installation of fused cast AZS block is technical and demanding work. In order to ensure the quality of installation, it should be carried out by an experienced professional team. During the installation process, ensure that each fused cast AZS block is placed in a predetermined position and angle and that the gaps between the blocks are uniform and consistent.
1.Visual inspection
Regular appearance inspection of the fused cast AZS block is an important means to ensure its stable performance and detect potential problems in time. This step requires the operator to have a high degree of responsibility and careful observation, to be able to accurately identify and record any abnormal changes on the surface of the fused cast AZS block. The contents of the appearance inspection include but are not limited to cracks, peeling, signs of erosion, etc. Cracks may mean that the fused cast AZS block has been subjected to excessive thermal or mechanical stress during long-term use. Peeling may be due to chemical erosion or physical wear at high temperatures; The signs of erosion directly reflect the resistance of the fused cast AZS block to the medium in the furnace.
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2.Performance evaluation
The performance evaluation of the fused cast AZS block is an important step to ensure that it can meet the operation requirements of the furnace. This includes evaluating the high temperature resistance, erosion resistance and mechanical strength of the fused cast AZS block. High temperature resistance refers to the ability of the fused cast AZS block to maintain structural stability and not melt or deformation under high temperature environment; Corrosion resistance refers to the resistance of the fused cast AZS block to the chemical erosion of the medium in the furnace. The mechanical strength refers to the ability of the fused cast AZS block to maintain its structural integrity when subjected to external forces.
►Local repair: Local repair is an efficient and economical means of maintenance, especially for those who have suffered only minor damage to the fused cast AZS block. These injuries may include minor scratches on the surface, minor cracks, or minor wear in local areas. To accurately solve these problems and extend the service life of the fused cast AZS block, a series of professional and high-quality repair materials are used for local repair. First, the injury site is carefully examined and evaluated to determine the extent and extent of the injury. Then, according to the specific circumstances of the injury, the most appropriate repair material is selected. These materials usually have excellent wear resistance, high-temperature resistance, and chemical stability, which can ensure that the repaired part is consistent with the original material of the fused cast AZS block in performance and life. In the repair process, technicians should strictly follow the operating specifications to ensure that the repair material is evenly spread and fully cured. They will also use professional tools and equipment to ensure the flatness and accuracy of the repair parts to avoid adverse effects on the overall performance of the fused cast AZS blocks. After the repair is completed, the repaired part is inspected again to ensure that it meets the quality requirements. In short, local repair is a very effective means of maintenance, which can quickly solve the problem of minor damage to the fused cast AZS block and extend its service life. By using professional repair materials and strict operating specifications, it is possible to ensure that the repaired fused cast AZS blocks reach the best condition in terms of performance and life.
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►Integral replacement: Integral replacement is an essential part of ensuring stable operation and efficient output of the furnace, especially for those fused cast AZS blocks that are severely worn or significantly degraded due to long-term high-temperature operation, and frequent physical and chemical erosion. The damage of such fused cast AZS blocks will not only reduce the energy efficiency of the furnace but also may cause safety risks, so it is important to take measures to replace the whole promptly. When the wear degree of the fused cast AZS block is detected to reach or exceed the preset safety threshold, or its performance can no longer meet the production demand, the replacement process should be started immediately. This process involves the precise removal of old blocks and the precise installation of new blocks. To ensure the smooth progress of the replacement work, it is necessary to prepare new blocks that match the specifications and materials of the original melting blocks in advance, and these new blocks have undergone strict quality testing to ensure that they have excellent high-temperature resistance, good thermal stability and exceptional chemical inertia to adapt to the complex and changeable working environment in the furnace. When removing old blocks, professional tools and techniques are used to minimize damage to the furnace structure and ensure that the old blocks are completely removed without leaving any debris or residue, clearing the way for the installation of new blocks. Then, according to the specific design and production needs of the furnace, the installation position of the new block is precisely measured and positioned to ensure that each new block can be accurately embedded in the furnace structure, forming a tight and stable whole. After the new block is installed, a thorough inspection and testing are carried out to ensure that the replaced fused cast AZS block works perfectly with the rest of the furnace to bring out the best performance.
►Recording and tracking: recording and tracking a crucial link in the maintenance and management of fused cast AZS blocks, which can not only help us fully understand the use status and maintenance history of fused cast AZS blocks, but also provide a strong basis for developing more scientific and reasonable maintenance and maintenance plans in the future. To establish a sound maintenance and replacement record system for fused cast AZS blocks, a standardized record template is first developed to record in detail the specific information of each maintenance, inspection, and replacement. This information includes but is not limited to the installation location, specifications, models, production date, time of use, time and content of previous maintenance, the name and contact information of maintenance personnel, the date and batch number of replacement of new blocks, etc. Through these detailed data, the life cycle and maintenance trajectory of each fused cast AZS block can be clearly outlined.
♦Optimization of heating system: The design of the heating system is the basis of temperature control. In order to ensure a uniform temperature distribution in the furnace, it is necessary to rationally lay out heating elements, such as resistance wires, electric heat pipes, or electromagnetic induction heaters. The arrangement of these heating elements should not only take into account the structure and size of the furnace but also fully consider the material and process requirements of the fused cast AZS blocks.
♦Temperature monitoring: To grasp the temperature condition in the furnace in real time, the temperature sensor is installed in the key position of the furnace. These sensors can accurately measure and transmit temperature data inside the furnace, and timely understand the heating state and temperature distribution of the furnace. By comparing temperature data from different locations, potential heating irregularities can be identified and heating strategies can be adjusted in time to ensure that the temperature in the furnace is always maintained within a stable range.
♦Temperature control strategy: Developing a scientific temperature control strategy is the key to ensuring the stability of the furnace temperature. It is necessary to set a reasonable temperature control target and fluctuation range according to the production process of the fused cast AZS blocks and the heating characteristics of the furnace. At the same time, it is also necessary to adjust the heating power and heating time in time according to the real-time temperature data to avoid excessive temperature fluctuations in the furnace. By using the advanced temperature control system and algorithm, the furnace temperature can be accurately controlled and automatically adjusted, thus effectively reducing the risk of thermal fatigue and damage to the fused cast AZS block.
♦Medium management: During the operation of the furnace, the management of the medium is essential to protect the fused cast AZS block from chemical erosion. The medium in the furnace may include gas, liquid, or solid particles, and their composition and flow directly affect the chemical environment inside the furnace. Therefore, the composition of the medium must be strictly controlled to ensure that it meets the requirements of the use of the fused cast AZS block and to avoid containing chemicals harmful to the fused cast AZS block. At the same time, flow management is also important, too large flow may accelerate the erosion of the medium, and increase the wear and chemical erosion of the fused cast AZS block; However, too small a flow rate may cause the medium to stay in the furnace for too long, increasing the chance of chemical reaction. By precisely controlling the composition and flow of the medium, we can effectively reduce the chemical erosion of the fused cast AZS block and extend its service life.
♦Coating protection: To further improve the corrosion resistance of the fused cast AZS block, we can coat its surface with a layer of corrosion resistance coating. This coating usually has specific chemical properties, such as alkali resistance, acid resistance, etc., which can effectively resist the erosion of harmful chemicals in the medium to the fused cast AZS block. The choice of coating should be determined according to the composition and characteristics of the medium in the furnace to ensure the compatibility and effectiveness of the coating with the medium. The application of the coating should be uniform and dense to ensure that it can completely cover the surface of the fused cast AZS block to form an effective protective barrier. By applying the anti-erosion coating, we can significantly improve the corrosion resistance of the fused cast AZS block and extend its service life.
♦Regular cleaning: In addition to media management and coating protection, regular cleaning of the inside of the furnace is also an important measure to reduce the source of chemical erosion. During the operation of the furnace, impurities and sediments in the medium may gradually accumulate in the interior of the furnace, forming a thick layer of scale. This layer of scale will not only affect the thermal efficiency of the furnace but also may become the source of chemical erosion, accelerating the erosion of the fused cast AZS block. Therefore, we must regularly clean the furnace to remove these deposits and impurities. The cleaning method should be determined according to the structure and material of the furnace to ensure the thoroughness and safety of the cleaning. By regular cleaning, we can effectively reduce the source of chemical erosion inside the furnace and protect the fused cast AZS block from damage.
Strengthening the maintenance and care of fused cast AZS blocks is the key to extending the life of glass furnaces. Through scientific maintenance, advanced testing, timely repairs, and improved operating skills, not only can the furnace’s efficiency be improved, but the company’s commitment to sustainable development can be demonstrated. This is not only a technical requirement but also a strategic choice to help the glass industry move towards a more efficient and environmentally friendly future.
Henan SNR Refractory Co., Ltd (SNR) is a professional manufacturer of fused AZS refractory materials for glass furnaces for 25 years.If you have any needs, please contact us.
Web:www.snrefractory.com
Email:moon@snrefractory.com
