Gas kiln quality appraisal

gas kiln takes the synergy of gas combustion and thermal control as its core principle. By optimizing combustion efficiency, temperature uniformity and atmosphere stability, it achieves efficient firing and quality consistency of ceramics, refractory materials and other products. It is widely used in the fields of ceramic manufacturing, refractory materials and precision casting. In high-temperature ceramic sintering, it is used for precise control of oxidation/reduction atmosphere; in special material sintering, it meets the process requirements of low residual ash and low deformation. Compared with electric kilns, gas kilns have the characteristics of high calorific value, suitable for large-scale firing, and intelligent temperature control (multi-zone independent adjustment). They are the core equipment of high-temperature firing process.

As an authoritative organization for judicial filing, Zhongke Testing provides gas kiln quality appraisal services. Relying on a team of thermal engineering and material science experts and CMA/CNAS certified laboratories, Zhongke Testing issues legally binding technical reports on issues such as firing defects, abnormal energy consumption and equipment corrosion.

With the refinement of the firing process, there has been a significant increase in related quality disputes. The focus of judicial disputes is:

1. Disputes over performance indicators: the product's firing pass rate does not meet the standard and the unit gas consumption exceeds the standard;

2. Material defects: insufficient thermal shock stability of the refractory lining and high-temperature resistant alloy composition of the burner Deviation;

3, process problems: temperature field uniformity is too poor, atmosphere control fluctuations lead to product color difference;

4, contract performance dispute: core modules (such as imported combustion control systems, high-precision thermocouples) are not consistent with the technical agreement.

Gas kiln quality appraisal requires systematic technical means:

1. Appearance inspection: observe cracks in the refractory bricks of the kiln body, carbon deposits on the burners and leaks in the sealing structure;

2. Performance testing: infrared thermal imaging cameras detect temperature field distribution, and flue gas analyzers calculate combustion efficiency;

3, material analysis: direct reading spectrometer detects burner alloy composition, scanning electron microscope observes grain boundary oxidation of refractory materials;

4, dynamic verification: full load firing monitors temperature stability and product qualification rate;

A ceramic factory of the applicant signed a "High Temperature Daily Use Porcelain Gas Kiln Purchase Contract" with an equipment manufacturer of the respondent, and it was agreed that the product deformation rate should be ≤3%. After being put into production, the measured deformation rate reached 8%. The manufacturer argued that it was caused by a problem with the raw material formula.

Identification and analysis results:

The expert group found that: the burner air distribution parameters were set incorrectly, the number of thermal shock cycles of the refractory lining did not meet the agreed requirements, and the temperature control system lagged, resulting in local overburning.

The appraisal conclusion determined that equipment process control and material defects were the main causes of out-of-control quality.

Gas kiln quality appraisal report should include:

1, appraisal purpose and cited standards;

2, equipment model involved, technical agreement and firing records;

3, testing methods and equipment

4, correlation analysis of test data and failure;