Prototype chimney system with a new type of joint for W3G chimney systems

The prototype of a chimney system with a new type of joint is the result of the joint know-how of the Czech Technical University in Prague, the Faculty of Mechanical Engineering and the world's leading manufacturer of refractory materials RHI Magnesita Czech Republic a.s. (formerly P-D Refractories CZ a.s.). Research and development activities have created a chimney system using a new principle of joining ceramic chimney liners (or pipes) and an optimized method of building the chimney system. Thanks to the combination of a unique method of constructing the entire chimney system, low acquisition costs of the system and high utility properties, it was possible to create a new, very durable chimney system for all types of operations while meeting strict certification tests, which, among other things, meets the highest standard for chimney operation, namely T400 N1 W3 G50.

The new joint of the prototype is implemented through a new structural and material solution of the joint. The structural solution of the joint, consisting in increasing the height of the joint and adjusting its geometry, minimizes the possibility of capillary elevation and prevents moisture from wicking up from the inner space of the insert to the outer surface and further into other structures. To further increase the tightness of the joint, it is possible to supplement the joint with a graphite seal. The technical solution using the inserted graphite seal is described in the attached drawing on a specific example of a design with a pipe with a new type of joint (1 and 2) and with an inserted graphite-based seal with a diameter of 4 mm (3) into a semicircular groove with a radius R of 2.5 mm. The detail of the joint is described in a section along the axis of two connected chimney pipes. In addition to the resulting product, a method of manufacturing individual parts of the chimney system was also developed.

The material solution is implemented using a developed sealant, which has both excellent workability in the construction of the chimney system and excellent properties during chimney operation. Together, the design and material solution ensures maximum tightness of the chimney system using cheaper extruded ceramic chimney pipes. The resulting products based on the prototype chimney system are unique in their ratio of useful properties and price on the current market. The useful properties of the new chimney system are comparable only to systems using isostatically pressed neck liners - these systems are an order of magnitude more expensive than the developed chimney system.

Figure 1: Design of optional graphite sealant ring for the new seal/joint prototype
 

Figure 2 (left): Assembly of the chimney system for experiments and evaluation 
Figure 3 (right): Chimney pipes in the of tunnel kiln
 

The development and research of the prototype of the chimney liner was possible mainly thanks to previous research activities, which, through the project "FV10151 - Development of technology for production of ceramic chimney pipes to improve their utility properties and reduce production costs ", laid the foundations for obtaining the necessary shared know-how for the design and development of both new products and new and productive approaches and technologies for the production of ceramic chimney liners. The main output of the FV10151 project in 2019/2020 was an automatic line for the production of ceramic chimney liners, with achieved degree of automation, digitalization and data collection which is entirely based on the principles of Industry 4.0. As part of the development and optimization of the production line, a digital twin was created to facilitate and accelerate the intended optimizations. Such a result was only possible thanks to the close and long-term cooperation of a group of researchers from the Department of Machining, Process Planning and Metrology and company employees. In 2023, the automatic line won the Industry 4.0 award from The Confederation of Industry and Transport of the Czech Republic. Advanced production control elements are constantly being improved on the line and in adjacent technologies with the aim of maximum autonomy of the production equipment. Which is pretty tough goal, due to the constantly changing physical properties of the material and its natural plasticity and softness. The current state of knowledge, know-how and technology for the production of chimney liners is among the best in the world, surely in Europe.

Figure 4: Automatic production line for ceramic chimney pipes
 

Figure 5: Price for Industry 4.0 from The Confederation of Industry of Czech Republic for year 2023
 

Through the new product, especially chimney liners with a new type of joint, the position of RHI Magnesita Czech Republic a.s. on world markets as a major player in terms of the achieved product quality and their utility properties is significantly strengthened. Already in the first year after the end of the project (2023), the project results (based on the prototype) were used in the company's business activities. Sales using the project results for the year were EUR 680,000, with a profit of EUR 80,000. A full 100% of this volume was exported abroad. The share of sales using the project outputs in the company's total sales in 2023 was 1%.
Based on the project results, the Faculty of Mechanical Engineering of the Czech Technical University concluded a license agreement with the company P-D Refractories CZ a.s. The license agreement is valid for 2023-2025. The amount of the license agreement is approximately 12 000 EUR per year for the Faculty of Mechanical Engineering, taking into account the number of products.

Figure 6: Some of the results of colaboration
 

The result was created within the framework of the project FW01010048, where the Faculty of Mechanical Engineering was another beneficiary. The solution of the joint project created shared know-how, which moved both the main beneficiary and the CTU Faculty of Mechanical Engineering to the world's top in the field of current knowledge of ceramic products and their efficient and economical production and assembly. Team members from the Faculty of Mechanical Engineering can further develop this knowledge within their research activities. Both parties have committed themselves in the project and the Agreement on the Use of Results to the subsequent distribution of intellectual property rights to the result "Prototype chimney system with a new type of joint for W3G chimney systems": Intellectual property: P-D Refractories CZ a.s. 90% (now RHI Magnesita Czech Republic a.s.), CTU in Prague, Faculty of Mechanical Engineering 10%.

Cooperation between individual institutions and team members still continues - current research and development tasks are being addressed not only in the field of ceramic chimney liner production, but also, for example, in the areas of decarbonization of ceramic and refractory production, research and development of new progressive recyclable materials, and sustainability of production.

Contact:

Ing. Libor Beránek, Ph.D.

Department of Machining, Process Planning and Metrology FME CTU in Prague

E-mail: libor.beranek@fs.cvut.cz

Phone: +420 608 231 531