Method for renovating ring chamber furnaces

Abstract: A method for the renovation of a ring section furnace comprising several sections connected in series, each section consisting of a number of parallel walls (3) extending between the interconnecting section walls (9), so forming a number of pits (1) therebetween, whereby a complete renovation of the funcace is accomplished according to a continuous program where one or more, preferably three sections at a time and when needed, are demolished and rebuilt while the remaining sections are still in operation.

Description: The present invention relates to a method for the renovation of ring section furnaces, of the kind comprising several sections connected in series, each section consisting of a number of parallel walls extending between the interconnecting section walls, so forming a number of pits therebetween. For baking carbon bodies for cells for the electrolytic reduction of aluminia or for other electrometallurgical processes, special furnaces are used for the heat treatment (baking or calcining) of such carbon bodies. The carbon bodies are made in the required shape from a mixture of crushed coke or anthracite and a binding agent which, for example, contains coals, tar and pitch. At room temperature, the mixture of coke and binder is stiff, but it becomes soft at temperatures over about 120°C, giving off low-volatile components from the binder. When subjected to further heating over a period of time, to a maximum of 1300°C, the paste hardens and its physical properties, such as electrical conductivity and resistance against oxidation, change. Carbon bodies awaiting baking are usually referred to as "green carbons". These green carbons may weigh several tons and have a length of 2 metres or more. To prevent their becoming deformed when passing through a temperature range in which they become soft, special precautions have to be taken. The green carbons are placed in deep pits in a furnace which is made of refractory bricks. The space between the carbons and pit walls are filled with coke to support the carbons. Coke breeze also serves to protect the carbon against air combustion. Several pits are built adjacent to one another, thereby forming a so-called section. In the walls between the pits there are channels, or ducts, for the flue gases. Heat is supplied to the carbons by passing the flue gases through these ducts. The flue gases pass from one section, through ducts, to the adjacent section. In this manner, the flue gasses can pass through several sections connected in series in a so-called firing zone. The usual fuels are oil or gas. The flue gas vent and the burner manifold can be moved from section to section. In a large ring furnace, there may well be two rows of sections built along side one another, thus forming parallel rows. At the end of a section row, the flue gas ducts are connected to the ducts in the parallel section row. In this way, the sections are joined together forming a ring. It is for this reason that such a furnace for baking carbon bodies is known as a ring section furnace. In a ring section furnace there may be several firing zones in which the temperature is regulated according to a given program. The first sections in a firing zone have low temperature. These are followed by sections with higher temperature, while the final stage in a firing zone consists of those sections in which the carbons are cooled. In a furnace of conventional design, each sections is closed at the top by means of a section cover and this has to be removed when green carbons are to be charged or baked carbons removed. On account of the special properties of carbon bodies it is necessary to avoid excessive temperature gradients during baking, as these would result in cracks in the final product. Each section must therefore follow an exact time and temperature program. In the first part of the zone, the sections are heated up to 600°C by the heat in the flue gases from the last part of the firing zone. Later, for the temperature range from 600°C to the required top temperature 1200°C - 1300°C), the heat must be supplied by the above mentioned combustion of gas and oil. In the cooling zone, the pit walls are cooled by air until the carbons can be removed without danger of oxidation. Steps are taken to make the best possible use of the heat absorbed by the cooling air, by using this air for combustion. The firing zone is moved by moving the oil or gas burners from one section to the next. The frequency of this operation is referred to as the heating cycle, and determines the capacity of the firing zone. As already mentioned, it must also be possible to connect a gas exhaust system to a section to be converted to the firing zone. This is usually achieved by connecting a fan between this section and a pipe connection on an exhaust duct around the furnace. This exhaust duct is referred to as the main flue ring and is kept under negative pressure by a main fan. In connection with the renovation of the furnaces, damage occurs in the form of cracks or the like due to thermal and mechanical strain and stress. Minor damage is continuously taken care of during regular maintenance of the furnace. However, after some time, the damage is so extensive that a complete renovation has to be accomplished. Depending on the use and quality of the furnace, complete renovation is necessary after 8-10 years. On account of the extensive work to be done, the furnaces have to be closed down for a long period of time, and this will result in production losses which may amount to large economical losses. Also when such extensive renovations are carried out, several workers and expensive equipment are needed to shorten the renovation period, and this can sometimes be difficult to provide. The condition of an individual section (pit wall, section wall etc.) determines when a complete renovation should take place. Thus, the renovation is determined by the so-called "weakest link in the chain" principle. This implies that the furnaces are completely renovated before all the sections have lasted their full life. Hence, another disadvantage with a total renovation is that the average life of the sections is reduced. In accordance with the present invention a method for the renovation of a ring section furnace, of the kind comprising several sections connected in series, each section comprising a number of parallel walls extending transversely between the interconnecting section walls so forming a number of pits, wherein at least two moving firing zones are created by applying heat for a predetermined cycle to a fixed number of sections, each zone moving around the ring and being spaced from the other zone(s), the method comprises prolonging the heating cycle in at least one firing zone so as to reduce the distance between at least two successive firing zones in the ring and to produce an increased distance between at least two successive firing zones in the ring, prolonging the heating cycle of the remaining firing zones(s), renovating one or more sections in the said increased distance(s) between successive firing zones whilst operating the furnace continuously, and successively shortening the heating cycle for each firing zone so that the distances between successive firing zones are substantially equal. This allows for a complete renovation by a continuous program and so production losses may be eliminated or vastly reduced. Less personnel and equipment are required than before and also, since each individual section is renovated only when necessary, the average life of the sections is prolonged. During renovation it is also possible to rebuild an old type ring section furnace as a new type one. The invention will now be further described by way of example with reference to the accompanying drawings in which: Figure 1 shows in perspective a cross-sectional view of the section in a ring section furnace according to an older ring furnace principle. Figure 2 shows in perspective a cross-sectional view of sections in a ring section furnace according to a new principle. Figure 3 shows a firing zone scheme for a ring section furnace according to the invention with two firing zones. Figure 4 illustrates the flue gas flow in a firing zone. Figure 5 shows simplified firing zone schemes for a ring section furnace with two firing zones, wherein each scheme illustrates the firing zone situation for different steps of the method according to the invention. Figure 6 shows similar schemes for a ring section furnace with three firing zones. The present invention can be employed both on the older type ring section furnace, the so-called Riedhammer furnace (Fig.1), as well as the new type of ring section fumace (Fig.2) which has been designed by the applicant and which is further described in the Norwegian patent specification No. 152,029. The constructional design and operation of these furnaces will now be described. Figure 1 is a partially cut-away illustration of a section of earlier design with five pits 1. In the pit walls 2 there are flue gases flowing downwards from the space under the section cover (not shown) into a space 4 under the bottom of the pits 1. The upward flow of the flue gases from below is through combustion chamber 5. Figure 2 shows a similar section from which the combusion chambers have been removed. Under the bottom of the pits there is provided a partition wall 6 which divides the space under the pits into two. In this manner, the flue gases flow upwardly through one group 7 of gas ducts 3 and downwardly through another group 8 thereof. In operation, a cover plate rests on secion walls 9. This cover plate is not shown , but will, in Figure 1 as in Figure 2, ensure that the gas flow is through the appropriate ducts. From the space under the pits there is a duct (not shown) to pipe connector points 9a on the top of the furnace. These are used for connecting the individual section to the main flue ring 10. Firing can, as previously mentioned, be performed in several ways. The fuel can be fed, in whole or in part, into the space over each pit wall. Combustion can also be achieved with insufficient air being fed to the space or spaces into which the fuel is injected, more being added in one or several space(s) downstream. By feeding the air to point 4, heating can also be localized to the bottom of the pits without the fuel carbonizing. Figure 3 is a view looking downwardly onto a ring section furnace with two firing zones. In each of the firing zones there are combustion chambers at different stages. 11 denotes a section from which the section cover has been removed. Air is drawn in through the one half in the direction in which firing takes place. The carbons in section 11 are cooled by means of air which is drawn in by exhaust fan 12, and this air is thus preheated before it reaches the burners. 13 represents sections, the top of which are sealed with cover plates so that the cooling air from 11 is drawn through the ducts in the pit walls, upwards through the first half and downwards through the second half, up to the next sections 14 which have oil or gas burners 15. 16 indicates the section in the firing zone from which the flue gases are exhausted by means of connecting pipes 17 to the main flue ring 10. 19 indicates the section with covered gas ducts in the one half so that air cannot be drawn in in the direction opposite to the heating cycle. 20 denotes open sections from which the baked carbons are removed and the green carbons inserted. The gas scrubber and stack are not shown. Figure 4 shows, in diagram form, the gas flow in a firing zone in a ring section furnace according to the illustrated embodiment of the invention. Air 21 enters the section at the left and is drawn through group 8 of gas ducts 3 down into space 4 under the bottom of the pits 1 of each section and is led through ducts in wall 9 to the next section with cover plate 22 which closes off space 24. Here, the flue gases are drawn up through the ducts 3 in the first half 7 of the section and down through the ducts 3 in the pit walls in the other half 8, and then onto the next section. The above describes how an older type (Fig.1) and a new type of ring section furnace (Fig. 2) are designed and how the furnaces are operated. It has also been described how such furnaces , after some time in operation, need to be completely renovated. This is achieved by stopping the operation of the furnaces, cooling to room temperature, and thereafter demolishing and rebuilding them. The present invention allows for a complete renovation of ring section furnaces while the furnaces are still in operation. The complete maintenance or renovation of a ring section furnace is carried out by a continuous maintenance program where one or more, preferably three sections at a time and when needed, are demolished and thereafter rebuilt while the furnace is still running. To enable such renovation, the firing zones have to be asymmetrically operated relative to one another which will be further described in the following by means of an example. As previously mentioned, the present invention can be applied to both the older and the new type of ring section furnaces. Also, the method according to the invention can be applied to the rebuilding of the older type into the new type of such furnaces, and the example refers to such rebuilding. Example After several years of operation of a furnace damage occurs in the form of severe cracks in the refractory material form which a ring secton furnace is made, and a complete renovation of the furnace is necessary. The furnace is of the traditional Riedhammer type with vertical flue gas ducts, and it is therefore decided that the furnace should be rebuilt to the new furnace concept. Such rebuilding implies that a partition wall has to be built at the bottom underneath the pits; that the lids are provided with a sluice for horizontal firing; that the combustion chambers are removed and that a channel is built in the section wall (Fig. 2, pos. 9a). As part of the regular maintenance, all of the pits, bottom plates and pillars are exchanged. The reasons for rebuilding the furnace to the new concept, is that the heat conduction to the carbon will be improved and the space utilization is increased by about 33.3% without having to alter the outer measurements of the furnace. Also an increased productivity is achieved by running the furnace at a higher pace compared to the older type. The furnace is divided into units of three sections and the rebuilding starts with sections 1, 2 and 3 with adjacent section walls, i.e. the section wall for section 2 and the section wall between sections 1-2 and 2-3. The rebuilding as such will now be described step by step with reference to Figure 5. However, it should be stressed that the dates mentioned are casually chosen and are only used to improve the clarification of the invention. 1. The furnace comprises 30 sections and has two firing zones α and β. The zone α comprises sections 1-5 and 27-30, whereas the zone β comprises sections 12-15 and 16-20 (Fig. 5a). It is decided that the asymmetrical running of the furnace should start on February 10 at 6 o'clock pm. This is done by setting the zone β with section 20 in front on a 48 hour heating cycle, whereas zone α is running on a 30 hour heating cycle, as is common. 2. After 10 days, i.e. February 20 at 6 o'clock pm, the zones have moved as is revealed in Figure 5b, where zone α now comprises the sections 5-13, whereas zone β comprises the sections 17-25 (the zones are moving in the direction of the arrows). On account of the difference in the heating cycles, the distances between the front section 13 of the zone α and the end section 17 of the zone β is reduced to three sections, 14-16. This is the shortest possible distance being necessary to remove the baked carbon bodies from the pits of zone β (section 15) and to insert new green carbon bodies into the pits of zone α (section 14) which is now the front section of zone α. To maintain a constant distance between the zones, zone α from now on has to be run on a 48 hour heating cycle. At the other end of the zones, where section 25 is the front section of zone β and section 5 is the end section of zone α, the distance is correspondingly prolonged, i.e. there is a distance of about 9 sections (sections 1-4 and 26-30).As the zone α has moved through sections 1, 2, 3 and 4, the baked carbon bodies have been removed from the pits of these sections and the tearing down of the sections 1-3 with adjacent section walls can start (it is still February 20).The sections contain a large amount of refractory material, and due to the short cooling period, the temperature is still high when the tearing work is started. It is therefore necessary to use mechanical devices for this work which will not be further described here. 3. The rebuilding of section 1 is already started 1 day after the demolition was started, i.e. on February 21. The rebuilding is time consuming and section 1 will therefore not be included as front secton of zone β before 3 March, i.e. 12 days after the demolition of this section was started. 4. The renovation work has to be finished by 5 March when section 2 is entering zone β. The zone relationship at this point of time is shown in Figure 5C, where zone β comprises the sections 1-2 and 24-30, and zone α comprises the sections 12-20. It is now 5 March, 6 o'clock pm, and zone β with section 2 in front is set to 42 hours heating cycle. The other zone, α, is run with the same heating cycle, 48 hours. The rerunning of the zones to normal operation has now started. This rerunning is for simplicity sake shown in the table below. It shows the day and time the individual section enters the firing zones, as well as the altering of the heating cycle. Section entering zone α : Date Time Section Heating cycle March 5. 1800 20 48 hours March 7. 1800 21 March 9. 1800 22 March 11. 1800 23 March 13. 1800 24 42 hours March 15. 1200 25 March 17. 0600 26 March 18. 2400 27 37 hours March 20. 1200 28 March 21. 2400 29 March 23. 1200 30 March 24. 2400 01 March 26. 1200 02 30 hours Section entering zone β: Date Time Section Heating cycle March 5. 1800 02 42 hours March 7. 1200 03 March 9. 0600 04 March 10. 2400 05 36 hours March 12. 1200 06 March 13. 2400 07 30 hours March 15. 0600 08 March 16. 1200 09 March 17. 1800 10 March 18. 2400 11 March 20. 0600 12 March 21. 1200 13 March 22. 1800 14 March 23. 2400 15 March 25. 0600 16 March 26. 1200 17 5. As will appear from the above tables, the heating cycle is gradually set back to regular running. Regarding zone β, the heating cycle is returned to normal operation, i.e. 30 hours heating cycle, on 13 March. Zone α is also returned to normal operation on 26 March and the distance between the zones is the same at both ends, i.e. six sections with open lids between the zones as shown in Figure 5D. In the above example the method according to the invention is applied on a ring section furnace comprising 30 sections with two firing zones. However, the method can obviously be applied on ring secton furnaces with fewer or more sections and with more than two firing zones, for instance 48 sections and three firing zones.Referring to Figure 6 which illustrates this example, the method according to the invention can be performed in two ways; a) The zones can be run asymmetrically and the renovation can be accomplished after the sections of the last zone has passed (sections 1, 2, 3 and 4) as shown in figure 6A, or b) Two zones are run asymmetrically with three sections in between, whereby the renovation can be accomplished on two places of the furnace, i.e. after the singular zone (sections 5, 6 and 7), and after the two zones (sections 23, 24 and 25), see Figure 6B. In a similar way, ring section furnaces with more sections and more firing zones can successively be renovated.

Claims: A method for the renovation of ring section fumaces of the kind comprising several sections connected in series, each section comprising a number of parallel walls extending between the interconnecting section walls, so forming a number of pits, wherein at least two moving firing zones are created by applying heat for a predetermined cycle to a fixed number of sections, each zone moving around the ring and being spaced from the other zone(s), the method comprising prolonging the heating cycle in at least one firing zone so as to reduce the distance between at least two successive firing zones in the ring and to produce an increased distance between at least two successive firing zones in the ring, prolonging the heating cycle of the remaining firing zone(s), renovating one or more sections in the said increased distance(s) between successive firing zones whilst operating the furnace continuously, and successively shortening the heating cycle for each firing zone so that the distances between successive firing zones are substantially equal. A method according to Claim 1 where two firing zones are created, characterised in that the heating cycle for the first zone (β) is prolonged, that the heating cycle for the second zone (α) is similarly prolonged when a maximum distance is achieved between the front end of the first zone (β) and the rear end of the second zone (α) while limited by a minimum distance between the rear end of the first zone (β) and the front end of the second zone (α) and which makes it possible to operate the furnace continuously, in that the heating cycle for the second zone (α) is prolonged to the same heating cycle as said first zone (β) when the second firing zone (α) has passed the section or sections to be renovated, in that the renovation of the section(s) is performed before the section(s) enter the first zone (β), and in that the heating cycle of both firing zones is successively shortened so that both firing zones return to normally symmetrical firing operations. A method according to any preceding claim wherein three sections at a time are renovated.

Inventors: ELIASSEN CARLO, LINGA HOGNE, ELIASSEN, CARLO, LINGA, HOGNE
Applicants: NORSK HYDRO AS, NORSK HYDRO A/S
Application year: 1989
Main classification: F27D1
IPC codes: F27D1, F27B13