CS261176B1 - Reactor's brickwork for technical black production and method of its realization - Google Patents

Abstract

In the reactor in which they were made insulating layers of linings, made in the bottom part of the reactor creates a monolithic segment cast-concrete layer, this segment it can also be made of mulitocorundum of corundum mortar. On this segment is always always in length 1,000 to 1,500 mm settle corundum rings and combining them with corundum mortar forming a corundum layer. Then the remaining space between this section corundum layers and insulating layers watered with pre-prepared potting beads that pass through the reactor shell also with individual insulating layers, refractory.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lining for an industrial carbon black reactor, and more particularly to a lining of a carbon black forming zone of a horizontal reactor operating in a pressurized mode, and to a method of making the lining.

Technical carbon black is produced in reactors of various types. They are generally cylindrical horizontal bodies of various designs and with stepped diameters, divided into mixing, cooling and soot-forming zones. A carbonaceous feedstock is injected into the reactor by one or more burners, which is controlled to form a solid carbon aerosol in the gaseous reaction products. The actual carbon black forming process is terminated by injecting cooling water into the reactor. The working temperature in the carbon black-forming part of the reactor is between 1,100 and 1,700 ° C, depending on the type of carbon black produced, and the working overpressure for reactors operating in the pressurized mode is between 2 and 4 kPa. The reactor jacket is made of aluminum metallized steel sheet. An integral part of the reactor is a lining that protects the reactor jacket against excessive thermal stress, but in particular minimizes heat losses from the carbon black forming zone of the reactor and thus increases the utilization of the feedstock by increasing the carbon black yield. The lining consists of several layers, in the inner layers, which are usually two in the carbon black-forming zone, the emphasis is mainly on the heat resistance, in the outer layers (1 to 3 depending on the zone and the type of reactor). To improve thermal insulation, an asbestos plate is inserted between the reactor jacket and the last outer layer of the lining. The individual refractory or insulating material fittings used for the individual layers are still used, lining is carried out with mortar corresponding to the type of the material of the fittings. For the inner refractory layer, corundum is used in the most stressed zone of the reactor, for less stressed zones, and for the second refractory layer, mulitocorundum or fireclay. Corundum mortar is used for masonry, the main part of which is corundum meal. Fireclay is used for the individual insulating layers, preferably fireclay for the outer insulating layers, the masonry is made with fireclay mortar or alporite sealant, in some cases the outer insulating layers are assembled dry. An example of a lining according to the prior art is a lining assembled in accordance with the art. No. 246 110, the way this lining protects MS. No. 227 279. The linings of the present invention are made of corundum shaped bricks (80 to 100% AljOj) in the base of the refractory layer and bricked with corundum mortar in the refractory layers and dry-refined refractory refractory bricks. In the case of lining of carbon black reactors, the emphasis is generally placed on the perfect tightness of the mortar joints of all prefabricated layers of the individual layers, in particular the basic refractory layer made of corundum components. The requirement for perfect tightness of the refractory layer is doubled for pressurized-mode reactors. Nevertheless, due to thermal and mechanical stresses, the existing types of linings gradually break down the joints and beat the reaction flame into the insulating layers, which leads to their degradation and possibly even damage to the metal shell of the reactor. The main disadvantage of the prior art is the low lifetime of the lining, which on average for reactors operating in pressurized mode is about 3,500 operating hours. Overhauling the reactor involves considerable material and labor costs, and requires the reactor to be shut down for at least twenty days, reducing the plant's production capacity.

These drawbacks considerably reduce the lining of the reactors and the process according to the invention. The essence of these linings is that the base refractory layer, which immediately delimits the carbon black forming zone, consists of a corundum layer with a thickness of 100 to 150 mm. The second refractory layer with a thickness of 80 to 160 mm consists of a monolithic layer of cast refractory concrete. This second refractory layer can also be designed such that its lower segment is formed by a mulitocorundum layer in the range of 25-35% of the reactor circumference and again by a monolithic cast refractory layer for the remainder of the circumference. The actual embodiment of the lining according to the invention is based on the fact that in the reactor in which the lining insulation layers were made, a segment of a monolithic cast refractory layer is formed in the lower part of the reactor, this segment can also be formed by lining with mulitocorundum. The corundum rings are deposited successively on this segment over a length of 1000 to 1500 mm and a corundum layer section is formed by joining them with corundum mortar. Subsequently, the remaining space between this corundum layer section and the insulating layers is sealed with pre-prepared potting beads, which pass through the reactor jacket and the individual insulating layers, with refractory concrete while compacting with an electro vibrator. This creates a monolithic layer of cast refractory concrete over the entire perimeter of the reactor or over the entire remaining perimeter above the mulitocorundum layer segment.

Where appropriate for the design of the reactor, dilatation of the cast-in-situ castable cast-in-situ casting can be compensated by transversely casting the cast-in-cast castable cast-in-place casting asbestos board with a thickness of 5 to 10 mm after each lining step.

The use of the lining and process according to the invention guarantees the perfect gas tightness of the carbon black forming zone of the carbon black reactor. Gas-tightness is achieved by a monolithic layer of cast refractory concrete, which is created by casting corundum rings. In addition, the method used will ensure a reliable sealing of the joints between the corundum rings due to the imperfections of the lining technology, as well as the solid perfect bonding of the monolithic cast castable layer with the corundum layer. In this way, the insulating layers of the lining are virtually perfectly secured against overheating or even smelting through the flaming reaction flame, damage to the reactor jacket by the reaction flame is avoided. The thickness of the cast castable monolithic layer, in particular when applied over the entire circumference, can be selected operatively as required by the reactor design and method of operating the reactor. In operational practice, the application of the invention means a multiple prolongation of the lining life and a reduction of heat losses from the carbon black forming zone of the reactor to the surroundings. This stabilizes the production process with positive effects on the yield and quality of soot, increases labor productivity by increasing overall production capacity while reducing material costs and saving labor.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a longitudinal section through a reactor in which a corundum base refractory base layer was clad with corundum mortar and a second refractory layer as a monolithic cast refractory layer around the perimeter; FIG. 2 represents section AA of this reactor. Fig. 3 shows a longitudinal section through a reactor whose base refractory layer was made of corundum bricks lined with corundum mortar and whose second refractory layer was formed in the lower third of the perimeter by a corundum-lined mullite-corundum segment; . Section 4 of this reactor is shown in Fig. 4. In these drawings, position 2 shows corundum layer, 2 monolithic cast refractory layer, 3 insulating layers, reaction space, 5 mulitocorundum layer, 16 pot chimney, 2 reactor shells and 2 transversal asbestos board . The following examples show a comparison of the lining used with the lining according to the invention and their practical implementation.

He did

The pressurized horizontal carbon black reactor was equipped with a prior art lining technology in such a way that four layers of lining were formed in the first section of the carbon black forming zone with a reaction space diameter of 2,200 mm and a length of 535 mm:

150 mm thick inner layer - corundum shaped pieces,

I. 114 mm thick middle layer - mulitocorundum shaped pieces,

II. middle layer with thickness of 114 mm - fire clay tiles, outer layer with thickness of 114 mm - shaped fire clay.

In the second section of the carbon black forming zone with a reaction space diameter of 2300 mm and a length of 1415 mm, the individual layers of the lining were made as follows:

100 mm thick inner layer - corundum shaped pieces

I. middle layer 114 mm thick - mulitocorundum shaped pieces

II. 114 mm thick middle layer - fireclay bricks outer layer 114 mm thick - light fireclay bricks

Finally, in the third section of the carbon black forming zone with a reaction space diameter 4400 mm and a length of 2060 mm, the same material was used for each layer as follows:

inner layer 100 mm thick I. middle layer 114 mm thick IX. middle layer 114 mm thick outer layer 65 mm thick

- corundum fittings,

- mulitocorundum fittings,

- fireclay fittings,

- shaped chamotte blocks.

For corundum and mulitocorundum layers, corundum mortar was used for masonry, for other layers fireclay mortar. After 3,550 operating hours, the lining with partial deformation of the reactor jacket 11 collapsed as a result of the melting of the layers formed from the chamotte and expanded chamotte blocks. The reactor was shut down and handed over for overhaul.

Example 2

A horizontal reactor for the production of technical carbon black of the same basic construction as in Example 1 was provided with a lining according to the invention as follows: In all sections, insulation layers 3, i.e. II. middle layer and outer layer, made of fireclay or foamed clay by bricklaying with fireclay mortar similar to Example 1. The corundum layer 2 ° with a thickness of 130 mm in the first section, with a thickness of 110 mm in the first section, was used as the base refractory layer. the second section and with a thickness of 1Ό0 mm in the third section. The second refractory layer was formed as a monolithic layer of cast castable 2 over the entire circumference and was selected to be 150 mm in the first section, 120 mm in the second section and 90 mm in the third section. The lining itself was realized by first lining the insulating layers 2 · Subsequently, a segment of a monolithic cast casting 2 layer was created in the lower part of the first section of the carbon black zone ZO 1 600. · ^After compaction and partial solidification of the segment corundum rings were placed on it · The remaining space between this corundum layer 2 ^{and the} insulating layers 2 was filled with refractory concrete ZO 1 600 using a pre-prepared potting chimney 2 »which passed through the reactor jacket 2 and the individual insulating layers. The concrete was compacted with an electro vibrator, the pot chimney 16 was filled completely up to the reactor jacket 7, thus forming a corresponding section of the cast-in-situ castable refractory 2 over the entire perimeter of the reactor. Similarly, a corundum layer 2 ^{and a} monolithic layer of cast castable 2 were formed in the second and third sections of the carbon black forming zone of the reactor, except that the third section was lined in two lining steps. After 9,000 reactor operating hours, the lining was free of any disturbance.

Example 3

The horizontal reactor for the production of technical carbon black according to Example 1 was provided with insulating layers 2 > ¹¹ ' with a middle layer and an outer layer, lined with fireclay mortar of fireclay or foam fireclay fittings similar to the previous examples. As a basic refractory layer directly bounding the reaction space 4 using alumina layer 2 ^{», and} in the first section of the carbon black yielding zone of 150 mm in the second and in the third section of 100 mm.

The second refractory layer was formed as a segment of mulitocorundum layer 5, bricked at the bottom of each section of the carbon black-forming zone of mulitocorundum shaped pieces with corundum mortar, in the range of 33% perimeter and 115 mm thickness and as monolithic cast castable 2 . In the reactor, the insulating layers 3 were first lined, then the mulitocorundum segment 5 was lined with corundum and mulitocorundum fitting at the bottom of the first section of the carbon black forming zone. This section of corundum layer 2 ^and insulation layers 2 were filled with refractory concrete 1600 by a pre-prepared potting chimney 6, which passed through the reactor jacket 7 and through the individual insulation layers 2. cast lining 2 completed the lining of the first section of the carbon black forming zone of the reactor. Similarly, lining was created in the second and third sections, while the third section was bricked in two lining steps. After each lining step, a transversal interleaving 8 of the monolithic layer of cast castable 2 with asbestos board was made, asbestos board with a thickness of 10 mm, asbestos board with a thickness of 5 mm, was used between the first and second sections. Visual inspection of the lining thus performed was performed after 7,000 reactor operating hours, the lining showed no signs of failure.

Claims (5)

OBJECT OF THE INVENTION 1. The lining of an industrial carbon black reactor, in particular a lining of the carbon black forming zone of a horizontal reactor operating in a pressurized mode, characterized in that the base refractory layer which immediately delimits the reaction space (4) consists of a corundum layer (1) of 100 to 150 mm and a second refractory layer having a thickness of 80 to 160 mm by a monolithic layer of cast refractory concrete (2). Lining according to claim 1, characterized in that the lower segment of the second refractory layer is formed by a mulitocorundum layer (5) in the range of 25 to 35% of the circumference of the reactor and by a monolithic layer of cast refractory concrete (2). 3. Method of lining according to claim 1, characterized in that a segment of a monolithic layer of cast refractory concrete (2) is formed in the lower part of the reactor, in which the lining insulation layers (3) were made, successively in each case a length of 1000 up to 1 500 mm the corundum rings settle and by joining them with corundum mortar a corundum layer section (1) is formed, after which the remaining space between this corundum layer section (1) and the insulating layers (3) is sealed with pre-prepared potting chimneys (6) the reactor jacket (7) as well as the individual insulating layers (3), the refractory concrete while compacting with an electro vibrator, to form a monolithic layer of cast refractory concrete (2) along the entire perimeter of the reactor. 4. A method according to claim 2, characterized in that in the lower part of the reactor with the insulating layers (3) formed there are lined mulitocorundum shaped pieces and a corundum mortar segment of the mulitocorundum layer (5), to which The 500 mm corundum rings settle and join them together with corundum mortar to form a corundum layer (1), and the remaining space between this corundum layer section (1) and the insulating layers (3) is sealed with pre-prepared potting chimneys (6) passing through the jacket. (7) of the reactor and the individual insulating layers (3), refractory concrete, while compacting with an electro vibrator, to form a monolithic layer of cast refractory concrete (2) over the remaining reactor perimeter. 5. A method according to claim 3 or 4, characterized in that after each lining step a transverse insertion (8) of the monolithic layer of cast castable (2) is carried out with an asbestos board with a thickness of 5 to 10 mm.