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Converter Debricking Machine CB120

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Converter Debricking Machine: A Critical Equipment for Steelmaking Efficiency and Safety

In the modern steelmaking industry, the converter stands as the core equipment for molten iron smelting, where high-temperature chemical reactions transform raw materials into qualified steel. However, during the long-term smelting process, molten slag and metal oxides inevitably adhere to the inner lining of the converter, forming a hard "brick deposit" layer. This layer not only reduces the effective volume of the converter, lowers smelting efficiency, but also poses potential safety hazards such as lining erosion and even converter leakage. Against this background, the Converter Debricking Machine emerges as a key equipment to solve this problem, playing an irreplaceable role in ensuring the stable operation of the steelmaking process.

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LB130

1. Overview of Converter Debricking Machine

The Converter Debricking Machine is a specialized mechanical equipment designed to remove the residual slag and brick deposits on the inner lining of the steelmaking converter. Unlike traditional manual debricking methods, this equipment realizes automated, efficient and safe debricking operations through precise mechanical structure and intelligent control system. According to the structural form and working mode, it can be divided into several types such as gantry type, cantilever type and crawler type. Among them, the gantry type debricking machine is widely used in large and medium-sized steel plants due to its stable operation and strong load-bearing capacity; the cantilever type is suitable for small converters or occasions with limited workshop space due to its flexible movement.

The core design concept of the debricking machine is to balance "efficiency" and "protection". On the one hand, it needs to quickly and completely remove the hard brick deposit layer; on the other hand, it must avoid excessive impact on the converter lining to extend the service life of the lining. With the development of steelmaking technology, modern debricking machines have gradually developed towards high integration, intelligence and environmental protection, becoming an important part of the intelligent upgrade of steel plants.

2. Core Structure and Working Principle

2.1 Core Structural Components

A mature Converter Debricking Machine is composed of multiple functional modules, and each component cooperates closely to ensure the smooth progress of debricking operations. The main structural components include:

Mechanical Execution System: It is the core part of the debricking machine, including the debricking hammer, lifting mechanism and traversing mechanism. The debricking hammer is usually made of high-strength alloy steel, which has strong wear resistance and impact resistance; the lifting mechanism and traversing mechanism drive the hammer to move in multiple directions (up and down, left and right, front and back), so as to cover the entire inner lining of the converter.
Hydraulic Control System: Provides power for the mechanical execution system, and controls the impact force, frequency and movement speed of the debricking hammer through hydraulic valves and oil cylinders. The hydraulic system has the characteristics of stable power output and adjustable parameters, which can adapt to different thicknesses and hardness of brick deposits.
Intelligent Control System: Composed of PLC controller, touch screen and sensor, it realizes automatic control and monitoring of debricking operations. The system can preset debricking parameters according to the converter model and brick deposit condition, and real-time monitor the working status of the equipment (such as hammer position, impact force, hydraulic oil temperature, etc.). When an abnormality occurs, it can automatically alarm and stop the machine to ensure operational safety.
Safety Protection System: Includes safety guards, emergency stop buttons, overload protectors and other components. The safety guard prevents splashing slag from harming operators; the overload protector avoids equipment damage caused by excessive impact force; the emergency stop button can quickly cut off the power supply in case of emergency to avoid accidents.

2.2 Working Principle

The working process of the Converter Debricking Machine is mainly divided into four stages: preparation, positioning, debricking and inspection, and its specific working principle is as follows:

Preparation Stage: Before starting the debricking operation, the operator first checks the working status of the equipment (such as the integrity of the debricking hammer, the pressure of the hydraulic system, the normal operation of the control system, etc.), and cleans up the sundries around the converter to ensure a safe working environment. At the same time, according to the detection results of the brick deposit layer (such as thickness, distribution area, hardness), the debricking parameters (impact force, hammering frequency, movement path) are set in the control system.
Positioning Stage: The converter is tilted to a preset angle (usually 30°~60°) to expose the brick deposit area. The debricking machine moves to the working position through the traversing mechanism, and the lifting mechanism adjusts the height of the debricking hammer to align it with the brick deposit layer. The sensor in the control system real-time feeds back the position information of the hammer to ensure accurate positioning.
Debricking Stage: The hydraulic system drives the debricking hammer to reciprocate, and impacts the brick deposit layer with a preset impact force. While hammering, the traversing mechanism and lifting mechanism drive the hammer to move according to the preset path, so as to remove the brick deposit layer layer by layer. During the process, the control system monitors the impact force and hammering frequency in real time. If the brick deposit is too hard, the system will automatically increase the impact force or adjust the hammering frequency to avoid incomplete debricking; if the impact force exceeds the safety threshold, the system will automatically reduce the force to protect the converter lining.
Inspection Stage: After the debricking operation is completed, the operator uses the visual inspection or ultrasonic detection equipment to check the inner lining of the converter. If there is residual brick deposit, the local debricking operation is carried out by adjusting the parameters of the debricking machine until the inner lining meets the smelting requirements. Finally, the debricking machine is reset, and the waste slag is cleaned up to complete the entire debricking process.

3. Technical Advantages Compared with Traditional Methods

Before the popularization of the Converter Debricking Machine, steel plants mainly relied on manual debricking or simple mechanical debricking. Manual debricking requires operators to enter the converter or stand on the side of the converter to knock the brick deposit layer with tools, which has the problems of low efficiency, high labor intensity and great safety risks (such as high-temperature scalding, slag splashing). Simple mechanical debricking has poor parameter adjustability, which is easy to cause incomplete debricking or lining damage. Compared with these traditional methods, the modern Converter Debricking Machine has obvious technical advantages:

3.1 High Efficiency and High Quality

The debricking machine can realize continuous and high-frequency hammering operations, and the debricking efficiency is 5~10 times that of manual debricking. At the same time, under the control of the intelligent system, the impact force and movement path of the hammer can be accurately controlled, which can ensure that the brick deposit layer is completely removed, and the damage rate of the converter lining is reduced to less than 1%, which effectively improves the quality of debricking.

3.2 Safe and Reliable

The debricking machine adopts remote automatic control mode, and operators can complete the operation in the control room without direct contact with the high-temperature converter, which fundamentally avoids the safety risks of manual operation. In addition, the safety protection system of the equipment can monitor the working status in real time and deal with abnormalities in time, and the equipment failure rate is less than 3%, ensuring the reliability of the operation process.

3.3 Cost Saving

On the one hand, the debricking machine reduces the labor cost by replacing manual operation; on the other hand, it reduces the damage to the converter lining, extends the service life of the lining by 15%~20%, and reduces the frequency of lining replacement. At the same time, efficient debricking shortens the downtime of the converter, increases the annual smelting output of the converter by 5%~8%, and brings significant economic benefits to steel plants.

3.4 Environmental Protection and Energy Saving

Modern debricking machines are usually equipped with dust collection devices, which can collect more than 90% of the dust generated during the debricking process, reducing air pollution. In addition, the hydraulic system of the equipment adopts energy-saving technology, which reduces the energy consumption by 20%~30% compared with the traditional mechanical system, in line with the development concept of green steelmaking.

4. Application Scenarios and Industry Development Trends

4.1 Main Application Scenarios

The Converter Debricking Machine is mainly applied to the debricking operation of various types of steelmaking converters, including oxygen converters, electric converters, etc. It is suitable for different scales of steel plants, from small steel plants with a single converter to large integrated steel plants with multiple converters. In addition, with the expansion of application fields, the debricking machine is also gradually applied to the debricking of other high-temperature containers, such as ladles and tundishes, showing a wide application prospect.

4.2 Industry Development Trends

With the continuous progress of steelmaking technology and the increasing requirements for efficiency, safety and environmental protection, the Converter Debricking Machine is developing in the following directions:

Intelligent Upgrading: Integrate technologies such as machine vision and artificial intelligence to realize automatic detection of brick deposit layers. The machine vision system can automatically identify the thickness and distribution of brick deposits through cameras and image processing algorithms, and the AI system can automatically optimize debricking parameters according to historical data, realizing "detection-decision-execution" integrated intelligent operation.
High-Performance Material Application: Adopt new high-strength, wear-resistant materials (such as ceramic composite materials, high-speed steel) to manufacture debricking hammers, which can extend the service life of the hammer by 30%~50% and reduce the frequency of replacement parts.
Modular Design: Adopt modular design concept to divide the debricking machine into multiple independent modules (such as execution module, control module, safety module). This design not only facilitates the maintenance and replacement of equipment, but also can be customized according to the needs of different steel plants, improving the adaptability of the equipment.
Digital Management: Connect the debricking machine to the digital management platform of the steel plant, realize real-time monitoring and data analysis of the equipment working status, predict equipment failures in advance, and formulate scientific maintenance plans to improve the management level of the equipment.

LBS120

5. Conclusion

As a key equipment to solve the problem of converter brick deposit, the Converter Debricking Machine has fundamentally changed the traditional debricking mode with its advantages of high efficiency, safety, reliability and cost saving, and has become an indispensable part of the modern steelmaking process. With the continuous development of intelligent, high-performance and green technologies, the debricking machine will be further upgraded, and its application scope will be more extensive, which will provide stronger support for the high-quality development of the steelmaking industry.

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