JP7136148B2 - Coke oven construction method, module block manufacturing method, and module block template manufacturing method - Google Patents

Description

The present invention relates to a coke oven construction method, a module block manufacturing method, and a module block template manufacturing method.

Metallurgical coke used in iron making is produced by carbonizing coal in a chamber coke oven. The chamber-type coke oven is configured by alternately arranging a coking chamber and a combustion chamber for supplying heat to the coking chamber in the width direction of the furnace. Heat is supplied from the combustion chamber to the coking chamber through a shaped refractory. Some chamber-type coke ovens have a furnace chamber of 100 gates or more, and such a chamber-type coke oven can be said to be a huge brick structure with a total length of 100 m or more and a height of 10 m or more.

Refractory materials such as bricks that constitute coke ovens are gradually damaged due to exposure to high temperatures exceeding 1000° C. and friction during horizontal extrusion and extraction of coke obtained by carbonization of coal. Therefore, coke ovens are used while undergoing simple repairs such as thermal spraying, and partial reloading repairs mainly at the kiln mouth. It is necessary to renew or newly install coke ovens that have become

Construction of a coke oven (furnace building) is usually carried out by hand-loading standard refractories such as bricks by a furnace builder. Specifically, the work process is as described below.

Although the coke oven has a complicated structure, it is designed so that the connecting surfaces of the upper and lower standard refractories in the height direction are parallel to each other and the connecting surfaces are aligned at the same height throughout the coke oven. Standard refractories are counted as the first and second tiers from the bottom in the height direction. When renewing or installing a new coke oven, a total of several hundred furnace builders are placed in each fixed area, and 1 or 2 layers of standard refractory are piled up from the bottom of the furnace in order per day. To go.

The stacking of individual shaped refractories in the above work is carried out as follows. First, the standard refractories to be used are carried in advance to the working height position using a crane or the like, and placed near the construction position. Also, after the mortar is produced by a kneader, it is placed in a container, transported to the work site by a crane or the like, subdivided and placed near the construction position. Furnace workers apply mortar to the position where the standard refractories are to be stacked using a tool such as a trowel (Mukae Toro), and then remove the standard refractories placed nearby. , Stack the standard refractories on the mortar so that air does not enter. After adjusting the position of the piled standard refractories using a leveler or the like, move horizontally to the position where the next standard refractory is to be stacked. By repeating the above procedure, standard refractories for one stage are piled up. When the standard refractory stacking work for one stage is completed, it is confirmed whether the required accuracy is achieved, and if a problem is found, the part is restacked and then the stacking work for the next stage is started.

However, the above hand-built furnace has the following problems. First, since the standard refractories used in coke ovens weigh about 5 to 10 kg each, both placing them in advance at the work site and actually stacking them up are hard work, and a considerable burden on workers. Become.

In addition, coke ovens differ from ordinary building bricks in that they must be built by complexly combining standard refractories of various shapes, such as rectangular, trapezoidal, and L-shaped when viewed from above. In addition, the standard refractory structure of the coke oven requires extremely high precision. For example, the wall surface of the combustion chamber is required to have high smoothness such that unevenness is 1 mm or less. However, since refractory bricks, which are generally used as standard refractories for coke ovens, are made by firing, there is an error of about 1 to 2 mm in the dimensions of each refractory brick (for example, the diagonal distance in plan view or side view). There is For this reason, simply piling up refractory bricks does not meet the required accuracy, and after considering variations in brick dimensions, manual adjustments are made to obtain the final dimensional accuracy of the coke oven. , It is necessary to pile up bricks of complicated shapes. Therefore, the standard refractory stacking work of coke ovens requires a very high level of skill, and such skilled furnace builders are always in short supply.

For the above reasons, there is a demand for the development of a method for efficiently stacking standard refractories with less manpower.

On the other hand, for example, in Patent Document 1, a plurality of refractory bricks are stacked in advance via mortar outside the coke oven construction site to manufacture a module block, and the module block is transported/carried to the coke oven construction site. It has been proposed to construct a furnace structure by stacking the module blocks. According to this method, the work time can be shortened and the work load can be reduced as compared with the conventional construction process in which workers manually load the materials.

Patent No. 6008071

However, in the technique described in Patent Document 1, the outer dimensions of the module block are adjusted by changing the thickness of the mortar and the orientation of the bricks in order to suppress variations in the dimensions of the refractory bricks when manufacturing the module block. Since the adjustment of this variation is different for each module block, when installing the module block, it may interfere with the structure of the installation source, resulting in a construction defect that makes it impossible to load and unload. In the conventional construction process where workers lay by hand, the variation in the dimensions of the bricks is adjusted one by one, and the thickness of the mortar and the posture of the bricks are adjusted. By doing so, we were able to prevent construction defects and manufacture the furnace as a whole according to the design values. However, when stacking module blocks, the size of the module block is overwhelmingly large compared to the thickness of the mortar, and the dimensional adjustment allowance due to the thickness of the mortar and the posture of the module block is greater than when stacking a single brick. It is relatively small and cannot be adjusted sufficiently to prevent interference, which is likely to cause poor construction. Moreover, since the module block requires time and cost to manufacture, it is not easy to replace it. Problems such as a delay in the construction period and an increase in costs and work load for workers to recover from such construction failure troubles occur.

The present invention has been made in view of the above circumstances, and is a coke oven construction that can prevent construction defects and reduce the burden on workers while efficiently constructing a coke oven with high accuracy. It is an object of the present invention to provide a method and method for manufacturing a module block, as well as a method for manufacturing a module block template with which such a module block can be manufactured.

The gist and configuration of the present invention are as follows.
(1) The method for constructing a coke oven of the present invention comprises:
A coke oven construction method including a module block manufacturing process in which a plurality of standard refractories are stacked in advance to manufacture a module block at a location other than the coke oven construction site,
The module block manufacturing process includes:
a combined surface shape measuring step of measuring the combined surface shape of a module block arranged in a predetermined stage and a next-stage module block;
a module block template manufacturing step of manufacturing a module block template reproducing the shape based on the measured shape of the combination surface;
and a stacking step of manufacturing the next module block by stacking the plurality of standard refractories along the module block template.

(2) In (1) above, the module block manufacturing step includes:
It is preferable to repeat the combined surface shape measurement step, the module block template preparation step, and the stacking step from the combined surface shape measurement step at the start of repetition to the stacking step at the end of repetition.

(3) In (1) or (2) above, a module block transporting step of transporting the module blocks of the predetermined stage for which the measurement in the combined surface shape measuring step has been completed to a construction site of the coke oven;
It is preferable to further include a module block installation step of installing the transported module blocks of the predetermined stage.

(4) In (3) above, it is preferable that the module block transporting step transports the module blocks step by step.

(5) In the above (3), it is also preferable that the module block transporting step transports the module blocks by a plurality of stages.

(6) In any one of (3) to (5) above, after the module block transportation step and before the module block installation step,
It is preferable to include a mortar application step of applying mortar to the positions where the transported module blocks are to be installed.

(7) In any one of (1) to (6) above, in the stacking step,
Preferably, a mortar spacer having a height corresponding to a desired mortar thickness is arranged on the module block template, and the plurality of regular refractories are stacked on the mortar spacer.

(8) A method for manufacturing a module block of the present invention is a method for manufacturing a module block by stacking a plurality of standard refractories in advance at a place other than a coke oven construction site,
a combined surface shape measuring step of measuring the combined surface shape of a module block arranged in a predetermined stage and a next-stage module block;
a module block template manufacturing step of manufacturing a module block template reproducing the shape based on the measured shape of the combination surface;
and a stacking step of manufacturing the next module block by stacking the plurality of standard refractories along the module block template.

(9) The method for manufacturing a module block template of the present invention comprises:
Used for manufacturing module blocks by stacking multiple standard refractories in advance to manufacture module blocks at a location other than the coke oven construction site,
a combined surface shape measuring step of measuring the combined surface shape of a module block arranged in a predetermined stage and a next-stage module block;
and a module block template producing step of producing a module block template reproducing the shape based on the measured shape of the combination surface.

According to the present invention, a method for constructing a coke oven and a method for manufacturing a module block, which can prevent construction defects and reduce the burden on workers while efficiently constructing a coke oven with high accuracy, and It is possible to provide a module block template manufacturing method capable of manufacturing such module blocks.

1 is a schematic perspective view showing a module block manufactured by piling up shaped refractories and mortar used in a coke oven construction method according to an embodiment of the present invention. FIG. 1 is a schematic partial perspective view showing an example of a module block used in a coke oven construction method according to an embodiment of the present invention, and a combination structure of a plurality of module blocks; FIG. 1 is a flow chart of a coke oven construction method according to an embodiment of the present invention; 1 is a schematic perspective view showing a coke oven in which module blocks are stacked; FIG. It is a figure which shows an example of the measurement in a combined surface shape measurement process. FIG. 10 is a diagram showing how a module block template is produced; FIG. 10 is a diagram showing how a module block template is used to fabricate a module block in the next stage;

Embodiments of the present invention will be exemplified in detail below with reference to the drawings. It should be noted that the following description exemplifies the embodiments of the present invention, and the present invention is not limited to the following embodiments. Further, in the following description, unless otherwise specified, the standard refractory and the module block manufactured by stacking the standard refractory are based on the orientation in the state of being incorporated in the coke oven. The terms horizontal, vertical, longitudinal, depth, and height (direction) are used.

<Coke oven construction method>
FIG. 1 is a schematic perspective view showing a module block manufactured by piling up standard refractories and mortar, which is used in a coke oven construction method according to an embodiment of the present invention. In FIG. 1, the direction in which the module blocks 1 are stacked (height direction of the coke oven) is defined as the "wall height direction Z", and the direction of the block 1 that is the longitudinal direction of the coke oven when the module blocks 1 are stacked. is defined as "wall longitudinal direction X", and the direction orthogonal to "wall height direction Z" and "wall longitudinal direction X" is defined as "wall depth direction Y".

As shown in FIG. 1, a module block 1 is formed by piling up standard refractories 2 (bricks in this example) via mortar.

Here, the bricks used in the coke oven consist of bricks having various shapes, unlike bricks for ordinary buildings, as described above. In the illustrated example, the bricks 2 include wall bricks 2a, partition bricks 2b, and inter-wall bricks 2c.
The wall bricks 2a are bricks forming a wall surface in the longitudinal direction (X) of the wall. The partition bricks 2b are bricks that connect the wall bricks 2a in the wall longitudinal direction (X). The wall bricks 2 a and the partition bricks 2 b are connected via mortar 3 . The inter-wall bricks 2c are bricks that connect the partition bricks 2b in the wall depth direction (Y). The partition bricks 2 b and the inter-wall bricks 2 c are connected via mortar 3 .

As shown in FIG. 1, in this example, the partition brick 2b has fitting projections 4 called dowels on its lower surface and fitting recesses 5 called tenons on its upper surface. As a result, when the bricks are stacked, the fitting concave portion 5 on the upper surface of a predetermined step and the fitting convex portion 4 on the lower surface of the next step are fitted to each other, so that the strength of the structure can be increased. In the illustrated example, the partition brick 2b has the fitting protrusion 4 and the fitting recess 5, but the other bricks (the wall brick 2a and the inter-wall brick 2c) also have the fitting protrusion 4 and the fitting recess. It can have a joint recess 5 .
In the illustrated example, the inter-wall brick 2c has gas passage holes 6 through which gas can pass. In the illustrated example, the gas passage hole 6 is a hole extending in the wall height direction. As a result, combustion, exhaust gas, etc. can be recovered and flowed when the coke oven is in use.

Here, in the coke oven, in addition to requirements for the accuracy of the wall surface dimensions and flatness, strict quality is also required for the alignment of the gas passage holes 6 (not clogged). In addition, it is also necessary to pile up the fitting protrusions 4 and the fitting recesses 5 without interfering with each other.

On the other hand, as shown in an example in FIG. 1, the bricks constituting the module block 1 are of a plurality of types having various shapes. In some cases, it has a fitting recess 5 and in some cases it has a gas passage hole 6, and the shape of each brick is extremely complicated. Furthermore, the refractory bricks used for the module block 1 generally have dimensional variations of about 0.5% to 3% with respect to the designed dimensions due to shrinkage during firing. Therefore, it is generally difficult to combine these bricks and meet the above quality requirements.

Here, in the conventional coke oven construction method by manual work, a skilled worker adjusts the dimensional variation by adjusting the thickness of the mortar and the posture of the bricks, and stacks the bricks one by one. The dimensions and flatness of the wall surface were finished with high accuracy without causing the bricks to interfere with each other in the fitting recess 5, and the passage of gas was also ensured.

FIG. 2 is a schematic partial perspective view showing an example of a module block used in a coke oven construction method according to an embodiment of the present invention, and an example of a combination structure of a plurality of module blocks.
As shown in FIG. 2, when building a coke oven by stacking the module blocks 1, the module blocks are placed on the combination surface (upper surface) 7 on the already stacked module blocks 1 and combined to construct the coke oven. We will manufacture. Conventionally, the mating surfaces have protrusions and recesses due to the shapes of the fitting projections, fitting recesses, and gas passage holes. The shape and position of the mating protrusions, mating recesses, and gas passage holes of the module blocks on the next stage deviate from each other, causing the bricks to come into contact with each other and interfere with each other. , there was a risk that problems such as not being able to stack

FIG. 3 is a flow chart of a coke oven construction method according to an embodiment of the present invention. The coke oven construction method of the present embodiment includes a module block manufacturing step of stacking a plurality of standard refractories in advance to manufacture module blocks at a location other than the coke oven construction site.
FIG. 4 is a schematic perspective view showing a coke oven stacked with module blocks. The module blocks may be stacked manually by an operator, or may be automatically stacked by a robot or the like. Here, module blocks are alternately stacked in odd-numbered stages and even-numbered stages, thereby improving the strength of the structure. In the example shown in FIG. 4, the second module blocks 12 (12a to 12d) are arranged on the first module blocks 11 (11a to 11d) in a zigzag manner so as to be shifted from each other by half a pitch.
Returning to FIG. 3, the module block manufacturing process includes a combined surface shape measurement process (steps S102, S106, Step S110), a module block template manufacturing process (step S104, step S108) for manufacturing a module block template that reproduces the shape based on the measured shape of the combined surface, and a next stage module block as a module and a stacking step (step S105, step S109) of manufacturing by stacking a plurality of standard refractories along the block template.

In this embodiment, the above steps are performed at a location other than the coke oven construction site. "A place other than the construction site of the coke oven" is not particularly limited as long as it is a place different from the construction site of the coke oven and where the standard refractories can be piled up to manufacture module blocks, and any place can be used. can be used. For example, a place adjacent to a coke oven construction site such as land adjacent to a temporary shed provided at a site for constructing a coke oven, or if the coke oven is to be constructed within a steelworks, within the steelworks The module block manufacturing process can be performed at other locations such as In addition, although it is possible to manufacture the module blocks in a remote location away from the coke oven construction site, considering the time and cost required for transportation, it is preferable to manufacture the module blocks at a location adjacent to the coke oven construction site. It is desirable for efficiency that the module block manufacturing process be performed intensively at one place, but it is performed at multiple sites and the module blocks manufactured at each site are transported and carried to one coke oven construction site. can also be used.
Each step will be described below in order.

As shown in FIG. 3, in this embodiment, first, a module block that is the first stage is manufactured (step S101). The first module block can be manufactured by piling up standard refractories (bricks in this example) via mortar. When manufacturing the first-tier module block, for example, a template common to other first-tier module blocks is prepared, and standard refractories can be stacked along the common template.
Next, as shown in FIG. 3, the shape of the combined surface of the module block arranged in a predetermined stage (first stage) and the module block in the next stage (second stage) is measured (combined surface shape measuring step : step S102).

FIG. 5 is a diagram showing an example of measurement in the combined surface shape measurement process.
As shown in FIG. 5, the shape of the combination surface (upper surface) of the module blocks 14 (14a, 14b, 14c) arranged in a predetermined stage with the next module block is measured by a three-dimensional measuring device 15 in this example. Measure using In this example, the three-dimensional measuring device measures the shape of the combined surface using a pattern projection method using laser irradiation. As the measurement method, any known method with appropriate measurement accuracy and measurement time can be used. In addition, measurement is performed using a three-dimensional measurement device using, for example, the light section method, the time-of-flight method, etc. It can be carried out. Alternatively, a stereo camera may be installed, and images taken by the stereo camera may be analyzed and converted into data. As shown in FIG. 3, it is preferable to perform the combined surface shape measurement step after manufacturing the module block (to be measured) and before transporting it into the furnace. This is because there are many other bricks and module block structures in the furnace, which makes it difficult to stably measure the three-dimensional shape. Further, by advancing the measurement timing, the production of the module block template, which will be described later, is also accelerated, which leads to the shortening of the process as a whole.
In the example shown in FIG. 5, the shape data 16 of the combination surfaces of the individual module blocks are combined to obtain the shape data 17 of the combination surface of the module blocks of a predetermined stage.

Next, in the present embodiment, the first-tier module blocks for which measurements have been completed are transported to the construction site and stacked in the coke oven (step S103). In this way, a module block transporting step of transporting a predetermined stage of module blocks for which measurement in the combined surface shape measurement process has been completed to the construction site of the coke oven, and installing the transported predetermined stage of module blocks. , and a module block installation step. Furthermore, it is preferable to include a mortar application step of applying mortar to the positions where the transported module blocks are to be installed after the module block transportation step and before the module block installation step.

In the module block transportation step, the module blocks are transported to the coke oven construction site after drying. The method of transporting module blocks in the process of transporting module blocks is not particularly limited. Depending on the distance between the module block manufacturing site and the coke oven construction site, trucks, transporters (self-propelled trolleys), and cranes may be used. etc. can be used singly or in combination. For example, if there is a temporary shed at the coke oven construction site, transport from the module block manufacturing location to the temporary shed will be carried by a transporter, and in the temporary shed, overhead cranes and stage jacks will be used together to reach the construction location. can be transported. In the module block transportation process, the module blocks can be directly transported from the module block manufacturing site to the construction site of the coke oven construction site. Depending on the progress of the furnace, the module blocks may be transported from the module block storage location to the construction position at the coke oven construction location.

In the mortar application step, mortar is applied to the positions where the module blocks are to be installed. The method of applying mortar is not particularly limited, and mortar is applied to the positions where the bottoms and sides of the module blocks come into contact, in other words, the top and sides where the module blocks are installed, in the same way as when stacking standard refractories. do it.

In the module block installation process, the module blocks are installed at the positions where the mortar was applied in the mortar application process. The method of installing the module block is not particularly limited, but for example, the module block lifted by a crane or the like may be placed on the surface coated with mortar while adjusting the position. In this way, by constructing in module block units, the burden on workers can be reduced and the standard refractories can be piled up with high precision, compared to the case of manually stacking standard refractories one by one.

As shown in FIG. 3, next, in the present embodiment, based on the measured shape of the combined surfaces, a module block template is produced that reproduces the shape (module block template production step: step S104).
FIG. 6 is a diagram showing how a module block template is produced. In the example shown in FIG. 6, the point cloud data 17a and 17b of the shape of the first stage module block obtained in the combined surface shape measurement step (step S102) is converted into CAD/CAE data by the calculation unit of the computer 18. do. Using the obtained CAD/CAE data, the control unit of the computer 18 issues a processing instruction to, for example, the end milling machine 19, and the end milling machine 19 uses the end mill tool 20 to create a shape according to the CAD/CAE data. to produce a module block template 23a. As another example, using the obtained CAD/CAE data, the control unit of the computer 18 issues a processing instruction to the layered 3D printer 21 , and the layered 3D printer 21 outputs the A material is injected and processed into a shape according to CAD/CAE data to produce the module block template 23b. The module block template is not particularly limited as long as it has strength when stacking the module blocks, but it can be made of metal such as iron or resin, for example. As for the accuracy of processing, it is preferable to set the maximum error to 0.1 mm or less in consideration of the dimensional error of the bricks.

As shown in FIG. 3, in this embodiment, next module blocks are manufactured by stacking a plurality of standard refractories along the module block template (stacking step: step S105).
FIG. 7 is a diagram showing how the next-stage module block is produced using the module block template.
As shown in FIG. 7, the fabricated module block template 23 is placed, and a plurality of regular refractory materials (wall bricks 2a, partition bricks 2b, inter-wall bricks 2c) are piled up along the module block template 23. . Specifically, the standard refractories are piled up in accordance with the fitting protrusions, fitting recesses, and gas passage holes of the module block template 23 . As a result, the standard refractories can be piled up while ensuring gas passage while avoiding interference with the fitting projections and fitting recesses. In this case, it is preferable to stack the standard refractories while arranging a mortar spacer 24 having a height corresponding to the thickness of the mortar used when installing the module block in the furnace on the combination surface of the module block template 23 . These operations can be performed by an operator 25, as shown in FIG. 7, or by a brick-laying robot 26. FIG. It should be noted that the stacking process of the previous stage (n-1th stage) is performed during the module block template manufacturing process of a predetermined stage (nth stage), thereby effectively utilizing the waiting time for manufacturing the module block template. can be done.

Returning to FIG. 3, steps S106 to S111 are repetitions of steps S102 to S105. In this embodiment, when the number of the uppermost layer is N, this process is repeated until the Nth module block is stacked in the furnace (step S112). Then, when the N-th module block is piled up in the furnace, construction is completed (step S113).

According to the construction method of the coke oven of the present embodiment, before transporting the module blocks to the construction site, the module block template that reproduces the combination surface of the module blocks is used to pre-shape the next stage to match the combination surface of the previous stage. module blocks can be fabricated, the module blocks can be installed with high precision while eliminating or reducing rework at the construction site.
Therefore, according to the coke oven construction method of the present embodiment, construction defects can be prevented, and a coke oven can be efficiently constructed with high accuracy while reducing the burden on workers.

Here, in the module block manufacturing process, it is preferable to repeat the combined surface shape measurement process, the module block template preparation process, and the stacking process from the combination surface shape measurement process at the start of repetition to the stacking process at the end of repetition. .
Note that the repetition start stage does not have to be the first stage, and may be the second stage or later (for example, the fifth or sixth stage). Also, the repetition end stage does not have to be the top stage, and can be, for example, the second or third stage counting from the top stage.

Although FIG. 3 shows an example in which module blocks are conveyed one step at a time immediately after the combined surface shape measurement step in the module block conveying step, the module block conveying step may convey module blocks at a plurality of steps. can. In this case, the transportation of the module blocks of a certain stage is not performed immediately after the combined surface shape measurement process of the stage.
An appropriate transportation frequency can be determined in consideration of the number of times the module blocks are transported, the waiting time in the combined surface shape measurement process and the module block installation process, and the like.

In the stacking step, it is preferable to arrange a mortar spacer having a height corresponding to the desired mortar thickness on the module block template, and stack a plurality of standard refractories on the mortar spacer. This is because the coke oven can be constructed more accurately and efficiently by piling up the mortar in consideration of the thickness of the mortar in the process of installing the module blocks.

<Method for manufacturing module block>
A method for manufacturing a module block according to an embodiment of the present invention is a method for manufacturing a module block by stacking a plurality of standard refractories in advance at a place other than a coke oven construction site. The method comprises a combined surface shape measuring step of measuring the combined surface shape of a module block arranged in a predetermined stage and a next-stage module block, and based on the measured combined surface shape, the shape and a stacking step of manufacturing the next module block by stacking a plurality of regular refractories along the module block template.
The details of each step are the same as those described in the embodiment of the coke oven construction method, so the description is omitted.
According to the module block manufacturing method of the present embodiment, a coke oven can be efficiently constructed with high precision while preventing construction defects and reducing the burden on workers.

Preferred examples of the method for manufacturing the module block of the present invention are described below. The details are the same as those already explained in the embodiment of the coke oven construction method.
In the module block manufacturing process, it is preferable to repeat the combined surface shape measurement process, the module block template preparation process, and the build-up process from the repeated start stage combined surface shape measurement process to the repeated end stage build-up process.
In the stacking process, it is preferable to place a mortar spacer having a height corresponding to the desired mortar thickness on the module block template, and stack a plurality of standard refractories on the mortar spacer.

<Method for manufacturing module block template>
A method for manufacturing a module block template according to an embodiment of the present invention is used for manufacturing a module block by stacking a plurality of standard refractories in advance at a place other than a coke oven construction site. A step of measuring the shape of a combined surface of a module block arranged as a second stage and a next-stage module block, and a module block that reproduces the shape based on the measured shape of the combined surface. and a module block template making step for making a template.
The details of each step are the same as those described in the embodiment of the coke oven construction method, so the description is omitted.
According to the method for manufacturing the module block template of the present embodiment, the above-described module can be constructed such that a coke oven can be efficiently constructed with high accuracy while preventing construction defects and reducing the burden on workers. You can get blocks.

Examples of the present invention will be described below, but the present invention is not limited to the following examples.

In this example, the combustion chamber portion of the coke oven was manufactured by stacking module blocks. The module blocks were manufactured by piling up a plurality of standard refractories along the module block template for the second and subsequent stages. The structure of the combustion chamber consists of 8 odd-numbered stages and 9 even-numbered stages (two of which are for half-pitch size ends). It has a structure that stacks up. The structure of each module block is a structure in which five layers of bricks having two flues at the locations corresponding to the combustion chambers of the coke oven are piled up.
First, eight bricks were piled up to form the first module block at a building site different from the coke oven construction site. The manufacture of modular blocks was carried out by bricklayers. A three-dimensional laser scanner was used to measure the shape of the assembly surface of the manufactured module block with the subsequent module block.
The shape point cloud data of the measured surface of each module block combined with the next module block was converted into three-dimensional CAD data using commercially available analysis software. On the CAD software, reproduce the CAD data of each module block in a combined state, select the place where the next module block is stacked on top of them, and create CAE data for machining as template data for the next stage. did. Based on the created CAE data, a 2m long, 1m wide, and 30mm thick plate was cut using a general-purpose NC milling machine to reproduce the shape of the surface where the module block is combined with the next module block. Then, nine module block templates for the next stage were produced.
Spacers corresponding to mortar between module blocks were placed on the prepared module block template, and bricks were piled up thereon by a bricklaying worker to build the next module block. When stacking each brick, the wall surface of the module block template and the wall surface of the bricks constituting the module block are aligned, and the module block template and the bricks constituting the module block are fitted to each other by dowels and tenons. By stacking them on top of each other, we were able to prevent interference between module blocks.
In the above method, it is necessary to measure the shape of the combination surface of the module block with the next module block and to prepare a module block template. In this embodiment, while a certain module block is being stacked, each work such as measuring the shape of the combined surface of another module block and making a module block template is performed in parallel, thereby shortening the overall work time. We were able to suppress the increase. Furthermore, in the conventional method, spare module blocks were prepared for reloading when module blocks interfered. The working time was almost the same as the conventional method.

In the conventional examples using the conventional method, construction defects such as interference between module blocks occurred at a frequency of about 30%. On the other hand, in the example, construction defects such as interference between module blocks could be reduced to about 5%. As a result, we were able to reduce process delays due to remaking module blocks and reloading, and reduce the burden on workers.

1: module block,
2: Regular refractories (bricks),
2a: wall bricks, 2b: partition bricks 2b, 2c: inter-wall bricks,
3: mortar,
4: fitting projection,
5: fitting recess,
6: gas passage hole,
7: combination surfaces 11, 11a, 11b, 11c, 11d, 11e: module blocks,
12, 12a, 12b, 12c, 12d, 12e: module blocks,
14, 14a, 14b, 14c: module blocks,
15: three-dimensional measuring device,
16: data,
17: data,
17a, 17b: point cloud data,
18: computer,
19: end milling machine,
20: end mill tool,
21: Layered 3D printer,
22: modeling material injection head,
23a, 23b: module block template;
24: mortar spacer,
25: worker,
26: Brick-laying robot

Claims (9)

A coke oven construction method including a module block manufacturing process in which a plurality of standard refractories are stacked in advance to manufacture a module block at a location other than the coke oven construction site,
The module block manufacturing process includes:
a combined surface shape measuring step of measuring the combined surface shape of a module block arranged in a predetermined stage and a next-stage module block;
a module block template manufacturing step of manufacturing a module block template reproducing the shape based on the measured shape of the combination surface;
and a stacking step of manufacturing the next module block by stacking the plurality of standard refractories along the module block template. The module block manufacturing process includes:
2. The method according to claim 1, wherein the combined surface shape measurement step, the module block template preparation step, and the stacking step are repeated from the combined surface shape measurement step at the start of repetition to the stacking step at the end of repetition. How to build a coke oven. a module block transporting step of transporting the module blocks of the predetermined stage that have been measured in the combined surface shape measuring step to a construction site of the coke oven;
3. The coke oven construction method according to claim 1 or 2, further comprising a module block installation step of installing the transported module blocks of the predetermined stage. 4. The coke oven construction method according to claim 3, wherein the module block transporting step transports the module blocks step by step. 4. The coke oven construction method according to claim 3, wherein the module block transporting step transports the module blocks by a plurality of stages. After the module block transportation step and before the module block installation step,
The coke oven construction method according to any one of claims 3 to 5, comprising a mortar application step of applying mortar to positions where the transported module blocks are to be installed. In the stacking step,
A mortar spacer having a height corresponding to a desired mortar thickness is placed on the module block template, and the plurality of regular refractories are stacked on the mortar spacer. Construction method of the coke oven according to. A module block manufacturing method for manufacturing a module block by stacking a plurality of standard refractories in advance at a location other than a coke oven construction site,
a combined surface shape measuring step of measuring the combined surface shape of a module block arranged in a predetermined stage and a next-stage module block;
a module block template manufacturing step of manufacturing a module block template reproducing the shape based on the measured shape of the combination surface;
and a stacking step of stacking the plurality of standard refractories along the module block template to manufacture the next module block. A method for manufacturing a module block template for use in manufacturing a module block, wherein the module block is manufactured by stacking a plurality of standard refractories in advance at a location other than the construction site of the coke oven, the method comprising:
a combined surface shape measuring step of measuring the combined surface shape of a module block arranged in a predetermined stage and a next-stage module block;
and a module block template manufacturing step of manufacturing a module block template reproducing the shape based on the measured shape of the combination surface.

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