Introduction:
The furnace is the heart of glass production. After years of continuous high-temperature operation, its refractory lining gradually erodes and ages, leading to increased energy consumption, more glass defects, and ultimately compromising safe production. Regular cold repairs are crucial for ensuring the furnace operates safely, stably, and efficiently. Recently, a major cold repair project for a float glass production line, undertaken by Zhengzhou Chaoyu Refractories Co., Ltd. as the general contractor, has been fully completed and successfully relit. This marks the rebirth of the production line, laying a solid foundation for the client's future continuous production.
Project Background: Severe Challenges and Clear Objectives
The original furnace of this float line had operated continuously for over eight years. Prior to shutdown, the client observed declining insulation performance, localized fire leakage, and fluctuating glass melt quality. Following meticulous online inspections by our technical team and post-shutdown internal surveys, the primary issues identified included:
Major Arch Erosion: Severe erosion at critical points of the silica major arch, with thinning of the arch top posing safety hazards.
Thinning of Pool Walls: The thickness of the electrically fused AZS pool wall bricks, particularly around the feed inlet and hot spots, had approached the safety limit.
Storm Chamber Blockage: Insufficient flow rate through the checkerwork severely impacted heat exchange efficiency and furnace pressure stability.
Aging of Steel Structures: Deformation and oxidation were observed in parts of the furnace's steel framework.
The objective of this cold repair is not merely “repair” but “upgrade.” Through systematic maintenance, we aim to comprehensively enhance the kiln's overall performance and extend its next firing cycle.
Zhengzhou Chaoyu's Comprehensive Solution
As the general contractor for this cold repair, we provide a one-stop solution covering the entire process from diagnosis, dismantling, and material supply to new construction.
1. Precise Inspection and Design: Immediately after furnace shutdown and cooling, our engineering team entered the kiln to conduct precise measurements and damage assessments of every component. Based on this data, we developed a detailed, customized Cold Repair Construction Plan.
2. Systematic Demolition and Cleaning: Organized specialized teams to safely and efficiently remove obsolete refractories according to a predetermined sequence. Conducted comprehensive inspections and reinforcement of the kiln's steel structure, preparing a solid “foundation” for the new construction.
3. Core Material Supply and Upgrades:
Arch: Utilized premium silica bricks, precisely laid according to the designed curvature to ensure structural stability.
Melting Pool: Critical sections utilized 41# chromium-free AZS bricks with superior erosion resistance, replacing traditional oxidized AZS bricks. This not only extended service life but also aligned with environmental sustainability trends.
Heat Storage Chamber: High-purity magnesia bricks were used for the middle layer, while premium magnesia-alumina spinel bricks were employed for the top layer. The checkerboard structure design was optimized to enhance heat transfer efficiency and erosion resistance.
4. Precision Construction and Full-Process Supervision: Experienced project managers and skilled workers were deployed on-site to strictly adhere to masonry specifications, ensuring all critical metrics—including joint width, flatness, and verticality—met standards. Round-the-clock quality oversight was maintained throughout construction.
Project Outcomes and Customer Value
Following 7 days of intensive construction, this cold repair project achieved complete success:
Quality Acceptance: All masonry metrics exceeded design standards, with the client granting approval upon initial inspection.
Performance Restoration: The new kiln structure is robust, with sealing and insulation performance restored to design levels.
Successful Ignition: The kiln ignited as scheduled, completed firing, and entered stable production.
Client Feedback: “The Zhengzhou Chaoyou team demonstrated exceptional project management and technical execution. This cold repair not only resolved our existing issues, but the upgraded materials and processes have given us full confidence in the stable operation of the next kiln cycle.”
Conclusion
The success of this major cold repair project marks another significant milestone in Zhengzhou Chaoyu's transformation from a single-material supplier to a comprehensive kiln service provider. We not only supply premium refractory materials but also deliver technical diagnostics, project management, and construction services grounded in extensive experience. Choosing Zhengzhou Chaoyu means selecting a full-lifecycle kiln partner.