Application of polycrystalline mullite refractory fiber in bell jar kiln (2)

4. Application of polycrystalline mullite fiber in bell jar kiln

Our company BTK-05 type micro control bell jar kiln (hereinafter referred to as bell jar kiln) is made of fiber structure, lining is polycrystalline moushi fiber PMF-300 series, thickness 50 mm, lined with aluminum silicate fiber CF-300 The series has a thickness of 130 mm, the kiln wall and the kiln top are all 180 mm thick, and the furnace size is 1700 mm × 600 mm × 440 mm, and the volume is about 0.5 m 3 . The two fibers are glued with high-temperature glue, and the ceramic nails traverse the kiln wall or the top of the kiln. One of the ends is stuck with the outer casing by a gasket clamp, so that the kiln wall or the kiln roof forms a firm whole, as shown in Fig. 2. The inner layer is to be sprayed with refractory paint. At the same time, in order to prevent cracking of the coating, the drying kiln should be carried out slowly according to the drying curve.

The kiln is mainly used for SrTiO material pre-baking and electronic ceramics firing. Since the production was started in July 1990, the process temperature curve has good repeatability, the kiln car hydraulic lifting is stable, the furnace temperature stability is high, the product selection is good, and the operation is simple. The labor intensity is low and the energy saving is remarkable. On January 29, 1991, the Ministry of Electrical and Mechanical Services passed the ministerial appraisal. Appraisal opinion: The kiln reached the level of similar kiln in foreign countries in the early 1980s, filling the domestic gap.

In the past year, the bell jar kiln has a strong bond with the lining of the PMF. It has not fallen off yet and remains elastic, but only the inner wall coating has fine cracks, which is caused by the shrinkage of the fiber at high temperatures. After burning for a while, the fiber shrinkage joint is stabilized, and the crack can be repaired with new fibers.

5, energy saving effect analysis

Comparing the bell jar kiln with our 12-meter electric tunnel kiln and Japan CK-1-5 bell jar kiln, we can get the energy-saving effect.

Our company's 12-meter electric tunnel kiln has a rated power of 50 kW and a furnace size of 12,000 mm × 202 mm × 260 mm. The pre-fired SrTiO3 is now taken as an example. The tunnel kiln accommodates a total of 34 kiln cars, each loading 3.2 kg, the whole kiln is loaded with 3.2 × 34 = 108.8 kg, one car per hour, a total of 34 hours of pre-burning a kiln material, the pre-burning temperature is 1360, The average power consumption per kiln is 1190 kWh, and the consumption is 10.93 kWh/kg of qualified material.

The SrTiO material is pre-fired in a bell jar kiln, 40 每 per kiln, 2.5 kg per raft, 100 kg of kiln charge, 9 hours of heating and holding time, 24 hours of firing cycle, and pre-fired SrTiO3 for half a year. The average energy consumption per kiln is 207 kWh, and the unit consumption is 20.7 kWh/kg of qualified material. The above results are now listed in Table 4.

Table 4 Comparison of pre-burning conditions with 12-meter electric tunnel kiln

The energy saving efficiency of the bell jar kiln is: (10.93-2.07)/1.093*100%=81%

The bell kiln burns 1 190-207 = 983 kWh per burning kiln, and burns 10 kiln every month. The whole year is calculated by burning 120 kiln. The annual electricity saving is about 118,000 kWh, and the equivalent amount is more than 20,000 yuan.
See Table 5 for comparison with Japanese CK-1-5 bell jar kiln.
It can be seen from Table 5 that the bell jar of our company and the Japanese CK-1-5 bell jar kiln should be saved when the temperature of the pre-fired porcelain is close, and the power saving efficiency is: (1.63-1.20) / 1.63 * 100% =26.4%

Table 5 Comparison with Japanese CK-1-5 bell jar kiln

6. Suggestions for improvement

(1) Improve the structure of the kiln, such as adjusting the bulk density and installation thickness of high and low temperature fibers, so that their thermal insulation performance can be maximized. When installing, the fiber strips should be pressed tightly between each other, and the joints between them should be prevented from cracking due to heat shrinkage of the fibers. Preforms are placed at the four corners of the furnace to eliminate cracks in the corner joints.

(2) Adding polycrystalline mullite fiber to an appropriate amount of additives, and forming a felt, a board, a hard board, and various shaped products or mixed fiber products by a vacuum forming process to increase the strength and facilitate installation.

7, the conclusion

The application of polycrystalline mullite fiber in BTK-05 type micro-controlled bell jar kiln fills the blank of the all-fiber bell jar kiln in China's electronics industry. The energy saving is very remarkable, reaching more than 30%. The firing quality is stable and can meet each The requirements of the firing process. From the value creation created by energy conservation and product qualification, the investment of the Ministry can be recovered in two years.

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