Emergency control plan for central control operation of firing system

The kiln system includes preheater, decomposition furnace, rotary kiln, grate cooler and connecting equipment and auxiliary equipment. Problems in the raw material grinding system and coal grinding system also directly affect the operation of the kiln. When an emergency occurs, the operation should first consider the safety of the on-site personnel and equipment, and then notify the inspection workers, electricians, and dispatchers to deal with them immediately. At the same time, take effective measures to minimize downtime and gain time for on-site repairs.

1 equipment trip

1.1 high temperature fan trip

Stop the kiln head coal, prevent the kiln head from tempering and burning the high temperature lens, and hurt the kiln head personnel.

Close the coal mill hot air valve to prevent the coal mill system from exploding.

The central control closes the air damper and informs the on-site inspection of the air damper, stopping the material, stopping the kiln tail coal, greatly reducing the kiln speed and preventing serious material diversion.

Reduce the speed of the 篦 cooling fan, reduce the speed of the exhaust fan, and adjust the negative pressure of the kiln head;

Inform the site personnel to stay away from the kiln head, the slant chain bucket and other places.

The waste heat power generation adjustment valve is notified. After the valve is adjusted, if the electric dust collection temperature of the kiln head is high, the cold air valve is opened in time and the spray gun is adjusted according to the outlet temperature of the humidification tower, and the booster pump and the overflow reamer are opened. When the moisture in the humidification tower is too high, it shall not be stored in the warehouse. When the ash is caught by hand, it should be taken outside. After the material is stopped, the outlet temperature of the humidification tower is lower than 180 °C, and the water spray should be stopped to prevent the wet bottom.

After the system is adjusted normally, the kiln head rotor scale is turned on.

Inform the electrician and the post worker to inspect; notify the dispatcher that if the fault can be eliminated for a short time, the kiln head small coal volume, the kiln low speed continuous operation, keep the kiln tail temperature about 800 °C, the c1 outlet temperature can not be too high, the high temperature fan inlet temperature is not More than 350 ° C.

If the fault cannot be eliminated in a short time, other operations are stopped in the normal parking sequence.

special attention items:

The high-temperature fan should stop in time to inform the raw material vertical grinding operator to prevent the material layer from being unstable due to the change of raw material grinding speed, which causes the vibration amplitude of the grinding machine to be large and problems occur.

There was a distress, and the kiln head, the surrounding area of ​​the grate cooler, and the trench were notified to leave the scene to prevent personal accidents.

After the occurrence of dips, the clinker should be promptly changed into the center library for use.

When the temperature in the kiln is high and then ignited, the coal should be turned before the kiln is turned, and the personnel in front of the kiln door cover are not stopped to prevent the pulverized coal from blasting and damaging.

When the moisture in the humidification tower is too high, it shall not be stored in the warehouse. When the ash is caught by hand, it should be taken outside. After the material is stopped, the outlet temperature of the humidification tower is lower than 180 °C, and the water spray should be stopped to prevent the wet bottom.

1.2 rear exhaust fan trip

Stop material, stop kiln tail coal, reduce kiln speed, reduce high temperature fan speed, adjust the fan speed of the chiller to ensure the negative pressure of the kiln head. Temporarily close the air-extinguishing valve on the kiln chute in order to prevent the tarpaulin and tape from burning out.

Stop the raw material grinding system, open the high temperature fan into the humidification tower valve, close the hot air valve into the raw material vertical mill, and perform the downwind operation.

Inform the site personnel to stay away from the kiln head, slant chain bucket and other places.

Gradually reduce the amount of coal fed to the kiln head and reduce the air volume of the primary fan.

The waste heat power generation adjustment valve is notified. After the valve is adjusted, if the temperature of the kiln head is high, the cold air valve is opened in time and the spray gun is adjusted according to the outlet temperature of the humidification tower, and the booster pump and the overflow reamer are opened. When the moisture in the humidification tower is too high, it shall not be stored in the warehouse. When the ash is caught by hand, it should be discharged. After the material is stopped, the outlet temperature of the humidification tower is lower than 180 °C, and the water spray should be stopped to prevent the wet bottom.

Inform the electrician and the post worker to inspect; notify the dispatcher that if the fault can be eliminated for a short time, the kiln head small coal volume, the kiln low speed continuous operation, keep the kiln tail temperature about 800 °C, the c1 level outlet temperature can not be too high, the high temperature fan inlet temperature Not more than 350 ° C.

If the fault cannot be eliminated in a short time, the other operations are all stopped in the normal parking sequence.

1.3 Kiln head coal feeding system failure

Appropriate material reduction, slow kiln, low temperature fan pull air, low load production, prevent kiln material.

Inform the post and the electrician to quickly find the cause of the malfunction and notify the dispatcher.

Inform the site personnel to stay away from the kiln head, slant chain bucket and other places.

Strictly control the temperature of the decomposition furnace to prevent blockage of the preheater crust due to excessive temperature.

At the same time, pay attention to the coal mill temperature and adjust the hot and cold air valve in time.

If the fault can not be eliminated within 5 minutes, notify the post to close the air damper, stop material, stop kiln tail coal, reduce kiln speed, reduce the speed of the high temperature fan, reduce the speed of the exhaust fan, adjust the fan speed of the chiller to ensure the negative pressure of the kiln head.

The waste heat power generation adjustment valve is notified. After the valve is adjusted, if the temperature of the kiln head is high, the cold air valve is opened in time and the spray gun is adjusted according to the outlet temperature of the humidification tower, and the booster pump and the overflow reamer are opened. When the moisture in the humidification tower is too high, it should not be put into storage. When the ash is caught by hand, it should be discharged. After the material is stopped, the outlet temperature of the humidification tower is lower than 180 °C, and the water spray should be stopped to visit the wet bottom.

If the fault cannot be eliminated in a short time, the other operations are all stopped in the normal parking sequence.

Inform the coal vertical mill controller to pay attention to the temperature changes of each measuring point of the system.

1.4 Kiln tail coal feeding system failure

Appropriate material reduction, slow kiln, low-temperature fan to pull the wind, appropriate increase of kiln coal, low-load production, to prevent kiln material.

Inform the post and the electrician to quickly find out the cause of the malfunction. Notify the dispatcher.

Inform the site personnel to stay away from the kiln head, slant chain bucket and other places.

At the same time, pay attention to the coal mill temperature and adjust the hot and cold air valve in time.

If the fault can not be eliminated within 5 minutes, notify the post to close the air damper, stop material, reduce the speed of the kiln, reduce the speed of the high temperature fan, reduce the speed of the exhaust fan, adjust the fan speed of the chiller, and ensure the negative pressure of the kiln head.

The waste heat power generation adjustment valve is notified. After the valve is adjusted, if the temperature of the kiln head is high, the cold air valve is opened in time and the spray gun is adjusted according to the outlet temperature of the humidification tower, and the booster pump and the overflow reamer are opened. When the moisture in the humidification tower is too high, it should not be put into storage. When the ash is caught by hand, it should be discharged. After the material is stopped, the outlet temperature of the humidification tower is lower than 180 °C, and the water spray should be stopped to prevent the wet bottom.

If the fault can be eliminated in a short time, the kiln head small coal volume, the kiln low speed continuous operation, keep the kiln tail temperature about 800 °C, the c1 level outlet temperature can not be too high, the high temperature fan inlet temperature does not exceed 350 °C.

If the fault cannot be eliminated in a short time, the other operations are all stopped in the normal parking sequence.

Inform the coal vertical mill controller to pay attention to the temperature changes of each measuring point of the system.

1.5 Kiln main motor failure

Immediately after the main motor trips, contact the electrician and the post worker to check, and stop the material after the restart fails.

Inform the patrol worker in the kiln to hang the auxiliary transfer kiln, notify the post to close the air damper, stop the material, stop the kiln tail coal, reduce the speed of the kiln, reduce the speed of the high temperature fan, reduce the speed of the exhaust fan, adjust the fan speed of the chiller to ensure the speed The kiln head is under negative pressure.

Gradually reduce the amount of coal fed to the kiln head and reduce the air volume of the primary fan.

The waste heat power generation adjustment valve is notified. After the valve is adjusted, if the temperature of the kiln head is high, the cold air valve is opened in time and the spray gun is adjusted according to the outlet temperature of the humidification tower, and the booster pump and the overflow reamer are opened. When the moisture in the humidification tower is too high, it should not be put into storage. When the ash is caught by hand, it should be discharged. After the material is stopped, the outlet temperature of the humidification tower is lower than 180 °C, and the water spray should be stopped to prevent the wet bottom.

Inform the post and the electrician to quickly find out the cause of the malfunction. Notify the dispatcher. If the fault can be eliminated in a short time, the kiln head small coal volume, the kiln low speed continuous operation, keep the kiln tail temperature about 800 °C, the c1 level outlet temperature can not be too high, the high temperature fan inlet temperature does not exceed 350 °C.

If the fault cannot be eliminated in a short time, the other operations are all stopped in the normal parking sequence.

1.6 篦 cooler one section, two sections, three sections, crusher, oblique chain bucket failure

When a trampoline fails, the material is greatly reduced, the slow kiln is lowered, and the high-temperature fan is pulled; when the second trampoline and the oblique chain bucket are faulty, the material is appropriately reduced, the slow kiln is lowered, and the high-temperature fan is pulled.

The notice frame worker pays special attention to the fluctuation of the flapping valve of the unloading pipe due to the adjustment of the feeding amount to ensure the safety of the frame.

Inform the kiln patrolman to smash the cold air gun and increase the air volume of the chiller.

Strictly control the temperature of the decomposition furnace to prevent the crust blockage of the preheater due to excessive temperature, and appropriately reduce the kiln head coal so that the kiln current and the kiln tail temperature are not too high.

Inform the maintenance worker, the post worker to check, such as a trampoline failure, the hydraulic pressure of the trampoline reaches 12mpa can not be ruled out, close the air damper, notify the post work stop material, reduce the kiln speed, reduce the high temperature fan speed, adjust the rear fan speed, adjust The chiller fan and excess fan speed ensure the kiln head negative pressure.

The waste heat power generation adjustment valve is notified. After the valve is adjusted, if the temperature of the kiln head is high, the cold air valve is opened in time and the spray gun is adjusted according to the outlet temperature of the humidification tower, and the booster pump and the overflow reamer are opened. When the moisture in the humidification tower is too high, it should not be put into storage. When the ash is caught by hand, it should be discharged. After the material is stopped, the outlet temperature of the humidification tower is lower than 180 °C, and the water spray should be stopped to prevent the wet bottom.

If the fault can be eliminated in a short time, the kiln head small coal volume, the kiln low speed continuous operation, keep the kiln tail temperature about 800 °C, the c1 level outlet temperature can not be too high, the high temperature fan inlet temperature does not exceed 350 °C.

If the fault cannot be eliminated in a short time, the other operations are all stopped in the normal parking sequence.

Two trampoline failure: If the hydraulic pressure of a trampoline reaches 12mpa, the failure cannot be ruled out and the material is processed.

Three boring machine, crusher, slant chain bucket failure: If a boring machine hydraulic pressure reaches 12mpa failure can not be ruled out, do the material processing.

1.7 Kiln system suddenly power off

First, the kiln will be assisted to slow down and prevent the cylinder from deforming. If there is no electricity in the auxiliary transmission, use a manual rotary kiln to prevent deformation of the kiln.

Inform the site personnel to stay away from the kiln head, slant chain bucket and other places.

Inform the post and the electrician to quickly find out the cause of the malfunction.

Notify the frameworker to close the air damper.

The high temperature fan of the boring machine of the boring machine should also be manually rotated to maintain the boring activity and the ventilation of the high temperature fan to prevent the deformation of the shovel and the deformation of the blade.

1.8篦cooler fan trip

Fan full jump: stop material, stop tail coal, stop the main motor of the kiln, open the auxiliary transmission, properly adjust the speed of the high temperature fan, notify the inspection workers, electricians, dispatch immediately.

Jumping a fan: Notifying the inspector, electrician. The schedule is processed immediately. The thickness control of the material layer is slightly thinner, and the large fan inlet valve is opened to notify the dispatch.

1.9 one blower stop

Start the accident fan, the outlet valve is fully open, reduce the material, slow kiln, notify the patrolman, electrician, dispatch immediately; if it can not be opened for a long time, stop the material, stop the tail coal, stop the kiln main motor, open the auxiliary transmission, reduce the system Air volume.

1.11 Preheater front swinging feeder skipping

Stop the material, stop the tail coal, adjust the high temperature fan speed and adjust the kiln speed according to the actual situation, appropriately reduce the head coal, notify the patrolman, electrician, and dispatch immediately.

2 Blocking and cutting

2.1 preheater block

phenomenon:

The cone pressure suddenly shows zero;

At the same time, the inlet and the next-level outlet temperature rise sharply;

If c5 is blocked, the temperature of the smoke chamber, the decomposition furnace and the c5 outlet will rise sharply.

Reason judgment:

The calcination temperature is too high to cause skinning;

The inner crust is collapsed, and the high-temperature material is too late to be discharged and blocked at the constriction of the taper;

Insufficient amount of air is drawn, the air is not smooth or the wind changes, causing the airway to collapse;

The refractory material or the inner cylinder of the preheater is detached from the part;

Flap valve failure;

Leakage caused severe agglomeration;

Pulverized coal is not well burned, and there is still coal powder in c5 to continue burning;

The raw meal feed rate fluctuated too much.

Treatment measures:

Inform the post worker to close the air damper and immediately stop the material and stop the decomposition of the coal. Slowly turn the kiln, kiln head small fire insulation or stop coal, seize the time to block.

According to the framework, it is necessary to reduce the speed of the high temperature fan, reduce the speed of the exhaust fan, and adjust the fan speed of the grate cooler to ensure that the kiln system is in a negative pressure state.

Pay attention to the coal mill temperature and adjust the cold air valve in time.

Inform the site personnel to stay away from the kiln head, the slant chain bucket and other places.

The waste heat power generation adjustment valve is notified. After the valve is adjusted, if the temperature of the kiln head is high, the cold air valve is opened in time and the spray gun is adjusted according to the outlet temperature of the humidification tower, and the booster pump and the overflow reamer are opened. When the moisture in the humidification tower is too high, it should not be put into storage. When the ash is caught by hand, it should be discharged. After the material is stopped, the outlet temperature of the humidification tower is lower than 180 °C, and the water spray should be stopped to prevent the wet bottom.

Other operations are stopped in the normal parking sequence.

special attention items:

When the cone pressure is gradually changed, it should be purged and strengthened in time, and the operating parameters should be reduced and adjusted. When the cone pressure is zero, the kiln should be stopped immediately and the kiln should not be used for 4 hours. Pulling the wind method to deal with the blockage, manual blockage.

Remind the post worker, before you can figure out the internal situation, you must not open the larger manhole door. Step by step from a smaller viewing hole. And before cleaning, all the manhole doors below the boring hole should be closed.

In the process of clearing the plug, the high temperature fan must work normally to ensure that the preheater is in a certain negative pressure state. However, it should not be too large to avoid a significant drop in temperature in the kiln. When diverting materials, remind the post workers to stay away from the kiln head and the oblique chain ditch to ensure personal safety.

2.2 running raw materials

phenomenon:

Watching the fire TV shows that the kiln head is sanding and dim. Even no image;

The third wind temperature rises sharply;

The kiln system increases resistance and the negative pressure rises;

The pressure of the grate cooler is lowered;

Kiln power drops sharply;

The kiln head coal powder has a "deflagration" phenomenon.

Reason judgment:

Raw materials kh, sm high, difficult to burn;

The kiln head appears to break coal immediately;

There is a ring behind the kiln;

The feed amount is too large;

The decomposition rate is low and the pre-burning is not good;

Coal does not burn completely.

Treatment measures:

When sanding, the speed of the kiln should be reduced in time and slowly burned up;

Improve the decomposition rate of the kiln and strengthen the ventilation in the kiln;

When the raw materials are severe, the kiln should be stopped in time, but not only the kiln coal, but the kiln will be turned 1/2 every 3~5 minutes until it is re-charged.

2.3 preheater collapse

Phenomenon and cause judgment:

The total amount of exhaust air suddenly drops;

The cone negative pressure suddenly decreases;

The kiln tail temperature drops a lot;

The vacuum pressure of the kiln head is reduced and it is positive pressure.

Treatment measures: the collapsed material is treated according to the failure of the raw material; the material is reduced and the speed of the kiln is reduced; if the material is less, the kiln head can be appropriately fed to the coal, or it can be processed.

3 parameter abnormality, device alarm

3.1 pulverized coal warehouse temperature rise alarm

It may be that the accumulated pulverized coal is self-igniting. At this time, the system adopts emergency stop. It is strictly forbidden to draw air and close the warehouse. At the same time, liquid nitrogen is injected to confirm that when the fire is fired, co2 gas is injected to extinguish the fire.

3.2 bag dust collection inside the co content alarm

At this time, emergency stop should be taken, and the electric dust collector should be powered off. Turn off the pneumatic valve of the electric dust-removing inlet motor and spray it into co2 to extinguish the fire.

3.3 support roller temperature is too high

Reduced material, slow kiln. Notify the scene to find out the cause and deal with it. Continue to raise, stop the tail coal, stop the main motor of the kiln. See Table 1 for specific measures.

Roller fever

the reason

Judging criteria

Treatment

Main issues in processing

Circulating water blockage

Inlet pipe temperature is higher than return pipe temperature

Unblock the blocked pipe

Pay attention to the temperature of the tile, not higher than 65 degrees

Torque

The oil with the oil spoon is less than 1/2, the oil on the oil plate is less or no oil.

Replenishing oil to the roller base oil window 1/2 or more

Oil can't exceed the upper limit of oil window, otherwise it can leak oil

Roller oil is uneven

Oil distribution board is uneven in oil distribution along the axial direction

Slow kiln adjustment oil board

The adjustment range should be small, pay attention to the oil spoon can not touch the oil board

The side of the roller has a small clearance and it is difficult to enter the oil.

The roller shaft has no oil film or thin oil film, and the shaft temperature and tile temperature continue to rise.

After changing the oil, if the temperature of the tile continues to rise to 65 degrees, the kiln should be stopped.

Contact angle is 30 degrees, every 15*15mm, 1-2 contact points

The roller is too skewed along the centerline

The roller and the wheel have uneven contact

The roller can be adjusted according to the contact situation

The adjustment range should be small, and each adjustment should not exceed 15 degrees. After confirming that the temperature of the tile is no longer rising, adjust it according to the actual situation.

The axial clearance of the thrust surface of the roller is too small or no clearance

The axial gap installation clearance is generally reserved 2-5mm, if there is no gap at one end or the thrust surface temperature is higher than the shaft temperature, and the temperature rises too fast.

When the kiln is up, the low-end support wheel thrust surface is heated. It is necessary to immediately adjust the hydraulic gear wheel travel switch to change the upward direction to the downward direction, and notify the central control slow kiln to change the oil, and pay close attention to whether the temperature of the tile is decreasing. If the temperature is decreasing, There is no need to stagnate the kiln.

Down the kiln, the high-end support wheel thrust surface heat, need to immediately go down through the hydraulic gear wheel down, and notify the central control slow kiln, change the oil, smear on the surface of the roller and the wheel and pay close attention to whether the temperature of the tile is falling, if The temperature is declining and there is no need to stagnate the kiln.

The kiln is up, the high-end tow wheel thrust surface is heated, and it is necessary to immediately apply oil on the surface of the supporting wheel and the wheel belt, and notify the central control slow kiln to change the oil, and observe whether there is any change in the axial clearance of the supporting wheel. If the temperature is decreasing, no stagnation is required. Stop the kiln.

If the above adjustment of the temperature of the tile does not decrease and the axial clearance does not change, it is necessary to report the abnormal equipment process and adjust the position of the roller seat. The adjustment should follow the following principles. The kiln should go up, the roller should go down, and the high-end clearance should be compared. Large, kiln down, the supporting wheel should be up, the low end gap is large, the adjustment roller can be used to squat, stand in the kiln head to the end of the kiln, the kiln is turned down towards the person, the top high-end top wire, the kiln down, the top The low end top wire is up.

The up and down time is generally adjusted to 4-6 hours. If the bearing temperature exceeds 65 degrees, the kiln should be decisively stopped to avoid the tile accident.

Table 1

Rotary kiln support wheel heat treatment method

4 The local temperature of the rotary kiln is too high

It should be determined that the kiln skin is dropped or the brick is dropped.

The kiln skin is generally characterized by local overheating, and the slightly reddish temperature is not very high. The method of reducing the material, reducing the kiln speed, reducing the speed of the high temperature fan, and reducing the kiln head coal calcination and filling the kiln skin can be adopted.

Burning bricks generally shows a local temperature of more than 400 degrees, and the edges of the high temperature zone are clear.

After the brick is dropped, the kiln head stops coal, so as not to burn out the cylinder, and stop the material at the same time, the site can take water to prevent the barrel from being sharply deformed.

5 Raw material bottom material flow out of control

The central controller should reduce the kiln speed, add kiln coal in time, strengthen the calcination according to the size and length of the material, and prevent the dip.

Pay attention to the coal mill temperature and adjust the hot and cold air valve in time.

Inform the post worker to check the blanking of the framework and pay attention to the safety of the framework.

Inform the post and the electrician to quickly find out the cause of the malfunction.

Inform the post worker to quickly close the electric brake or turn off a part to adjust the feed amount.

6 Conclusion

In the operation of the kiln system, our principle is: first consider the safety of the on-site personnel and equipment, and then inform the patrolman, electrician, and dispatcher to deal with it immediately, and take effective measures to minimize downtime and gain time for on-site repair. The formulation and implementation of the above plans have adhered to the application of this principle. Only in this way can the kiln system achieve safe, efficient, low-cost, high-yield operation.

1 2 3 4 5