Beruflich Dokumente
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PROJECT IN CAMBODIA
L61-COAL GRINDING
操作说明书
Operation Specification
中信重工工程技术有限责任公司
二零一七年三月
March 2017
5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
目 录
Catalog
第一章 总 论 ....................................................................................................................... 1
Chapter 1. General instructions ............................................................................................. 1
第二章 工艺流程及工艺设备介绍 ........................................................................................ 2
Chapter 2 Introduction for process and quipment ..................................................................... 2
一、工艺流程简介 Introduction for process.................................................................... 2
二、工艺设备 Equipment ............................................................................................... 3
第三章 启动前的准备工作 .................................................................................................... 4
Chapter 3 Preparation Work prior to Startup ............................................................................ 4
第四章 启动与停车操作........................................................................................................ 8
Chapter 4 startup and shutdown operation................................................................................ 8
一、系统启动操作顺序 System startup sequence .......................................................... 8
二、运转中检查调整项目 Inspection and adjustment items during operation .............. 14
三、系统停车操作顺序 System shut-down operating sequence .................................... 16
四、设备紧急停车时的处理方法 Treatment when emergency stop of equipment ........ 19
第五章 试生产 ..................................................................................................................... 24
Chapter 5 Trial Production..................................................................................................... 24
一、试生产的日程安排及其目的 Trial-production schedule and purpose .................... 24
二、试生产的准备 Preparation for trial-production ...................................................... 25
三、试生产要领 Trial production essentials.................................................................. 25
四、安全措施 Safety measures ..................................................................................... 27
五、安全注意事项 Safety Precautions .......................................................................... 31
5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
第一章 总 论
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
第二章 工艺流程及工艺设备介绍
Chapter 2 Introduction for process and quipment
本系统的工艺流程见流程图。
Process for this department refers to flowsheet.
原煤仓下设有棒条阀(L61-NG1),经棒阀由链板喂煤秤(L61-CV1)取出定量的原煤,
送入立式磨煤机(L61-RM1)进行原煤的烘干和粉磨,合格的煤粉随气流进入袋收尘器
(L61-BF1)进行净化收尘,得到满足要求的煤粉成品。处理后的气体经风机(L61-FN1)排
入大气,部分气体经循环风管重新返回磨机。袋收尘器收集的煤粉经螺旋输送机(L61-SC1、
L61-SC2、L61-SC3、L61-SC4、L61-SC5)、螺旋泵(L61-PP1)进入窑头及窑尾煤粉仓,然
后供窑及分解炉煅烧。
Under the raw coal bin is bar gate(L61-NG1); through the bar gate, the drag chain conveyor
(L61-CV1)takes out quantitative raw coal and sends into the vertical mill (L61-RM1)for coal
drying and grinding. Satisfactory pulverized coal enters the bag filter (L61-BF1) with air flow for
purifying and dust collecting to obtain the pulverized coal product that meets the requirements. The
processed gas is exhausted into the air through the fan(L61-FN1)and some of the gas returns to the
mill through the circulation duct again. The pulverized coal collected by the bag collector through
the screw conveyors (L61-SC1、L61-SC2、L61-SC3、L61-SC4、L61-SC5), and screw pump
(L61-PP1)into the pulverized coal bin for the calcination of the kiln and the calciner.
用于原煤水分烘干的热源:来自独立设置的热风炉及窑尾预热器废气,热气体入煤磨前
与循环风混合调整风温,使进磨的热风温度调整为 200oC 左右。
Teat sources for drying raw coal: the waste gas from independent hot-blast stove and the
preheater of the kiln inlet, the hot gas mixes with the circulation air before entering the coal mill to
adjust the air temperature, making the hot air temperature into the mill adjust to around 200℃.
为防止煤磨、原煤仓、煤粉仓、袋收尘器发生火灾,本系统设置了一套 CO2 喷吹灭火装
置,需要时可喷出 CO2 气体。另外,在煤粉仓、除尘器、煤粉输送的垂直管道上均设有防爆
阀。
In order to prevent the outbreak of the fire into the coal mill, raw coal bin, pulverized coal bin
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and bag collector, the system is equipped with a set of CO2 injection extinguishing device which
can blow out CO2 gas. In addition, the vertical pipelines of the raw coal bin, pulverized coal bin,
dust collector, and pulverized coal conveying are all equipped with explosion-proof valves.
二、工艺设备 Equipment
本系统所有工艺设备主要技术参数见设备表。
Equipment technical please see the equipment list.
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第三章 启动前的准备工作
Chapter 3 Preparation Work prior to Startup
煤粉制备系统的全部设备在启动前都应作认真的检查调整工作,不仅在开始试生产时要
做到这一点,还必须作为一条制度在以后运转启动前,也要作同样的检查工作。
A serious check and adjustment work should be done on all equipment of the pulverized coal
preparation system before startup, which shall not only be conducted at the beginning of the trial
production, but also be regarded as a rule to follow in the future operation.
检查项目
序号 设备名称及编号 检查调整项目
Inspection
No. Equipment name and number Check and adjustment items
items
1 油量检查 ①煤磨减速机的润滑站 Lubrication station
Oil quantity of the reducer of the coal mill
check ② 风 机 的 轴 承 , 联 轴 器 Fan
bearing,coupling
③磨辊液压站 roll hydraulic station
④各电动机的轴承 all motor bearings
⑤回转下料器的轴承,管道中各阀门的轴
承 rotary feeder bearing ; all valve bearings
of pipeline
⑦皮带输送机的轴承 belt conveyor
bearings
⑧磨机选粉机干油润滑站 grease
lubrication station of mill separator
2 人孔及保 ① 确认人孔,捅料孔,检查门,保
护 盖 护盖是否完全密封 Confirm manhole,
manhole poke hole, inspection door, and
and protective cover are completely sealed
protective ② 确认有无异物在设备内 Confirm
cover there is no foreign body in the
equipment
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5 阀 门 的 开 ① 煤磨循环风阀门 ①确认采用摇控方式操作时现场的
闭方向及 ②煤磨热风阀门 开度指示与中央控制室的开度方向
开度确认 ③风机进口阀门 是否一致。②确认开闭方向是否正确
The ④袋收尘器进出口阀门 a、Confirm whether site opening
opening and ⑤热风旁路阀门 indication is in accordance with the
closing (1)Coal mill cycle wind valve opening direction of the central
direction as (2) Coal mill hot blast valve control room when using remote
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9 保 养 ① 主要设备(停机三日以上): 确认设备内部无块煤,煤粉及其它杂
Maintenanc 煤磨 、袋收尘器、原煤仓、煤粉仓、计量 物
e 秤、风机、罗茨风机、螺旋泵 ① 确认没有块煤,煤粉堆积堵塞,可
② 输送设备:胶带输送机、螺旋输送机、 用仪表或锤打听音确认
三通阀 ②确认是否清扫整洁
③其它:所有工艺过程管道、所有收尘管 (1) Confirm there is no coal,
(1) Main equipment (stopping for more than inside the equipment
Coal mill, bag collector, raw coal bin, and pulverized coal, use the
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第四章 启动与停车操作
Chapter 4 startup and shutdown operation
下面叙述的内容是正常生产时的启动操作顺序
在操作中,应特别注意磨机出口的气体温度不能超过 85oC。
The following content is the startup operation sequence in normal production
In the operation, it shall be noted that the mill outlet gas temperature should not exceed 85℃。
序号 设备操作 检查部位
1 做好系统启动前的所有准备工作 ① 确认原煤及煤粉输送系统能正
① 确认原煤仓进料 常运行
② 确认需水冷的设备已通入冷却水 ②确认仓内料位满足要求
③ 确认煤粉仓能接收煤粉 (1)Confirm the conveying system
Well conduct all preparation work before the can run normally
start of the system (2) confirm material level in the bin
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5 煤粉输送组启动 ①确认煤粉输送至窑头还是窑尾
罗茨风机(L61-BL1)→螺旋泵(L61-PP1) 煤粉仓,分别打开进各仓管道上的
→螺旋输送机(L61-SC5、L61-SC1、L61-SC2、 阀门
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L61-SC3、L61-SC4)启动 ②电动换向三通阀(L61-MW2)
Startup of pulverized coal transportation group 打到指定位置
Roots blower ( L61-BL1 ) - screw pump (1) Confirm the pulverized coal is
(L61-PP1) - screw conveyor (L61-SC5、 conveyed to the bin on the kiln
L61-SC1、L61-SC2、L61-SC3、L61-SC4)starts outler or inlet and respectively open
the valves on the pipe of each bin
(2) Electric reversing 3-way valve
( L61-MW2 ) turned to the
specified location
6 煤磨排风机(L61-FN1)准备起动 进口阀门关闭
煤磨排风机(L61-FN1)起动 Close inlet valves
增压风机(L61-FN2)准备起动
增压风机(L61-FN2)起动
Coal mill bag filter fan(L61-FN1) ready to start
Coal mill bag filter fan(L61-FN1)ready to start
Booster fan (L61-FN2)ready to start
Booster fan (L61-FN2)starts
7 袋收尘器(L61-BF1)启动
Start of coal mill bag filter(L61-BF1)
8 暖机 ① 用下述温度计测温
Heater 煤磨进口温度计
慢慢操作各阀门,在缓慢增加进入煤磨的热风 煤磨出口温度计
量的同时,缓慢升高煤磨排风机进口气体温度 排风机进口处温度计
和煤磨进口的气体温度,各阀门的操作方向如 袋收尘器进口处温度计
下: 增压风机入口热风管道温度计
Operate the valve slowly, slowly add hot air 罗茨风机出口管道温度计
volume into the coal mill, at the same time, Use the following thermometer for
slowly increase inlet gas temperature of the temperature measurement
coal mill exhaust fan inlet and gas temperature at Coal mill inlet thermometer
the inlet of coal mill inlet. The operation
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(5) Gradually decrease the opening degree of Bag collector inlet and outlet
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After the normal operation of the kiln system, system has been running
the drying heat source of the coal mill adopts the
waste gas of kiln inlet and specific startup
sequence is as follows:
chain conveyor(421-CV8) starts -chain
conveyor (421-CV6、421-CV7) start→ electric
dust collector J1P01 starts → open the inlet
valve(441-SD2) of EP(441-SD2)
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2 气压 调节阀门的开度使磨机进口压力在
①磨机进口气体压力 煤磨 coal mill 设定值-500Pa.
②磨机出口气体压力
Air pressure
(1) mill inlet gas
pressure
(2) mill outlet gas
pressure
3 溜子是否堵塞
①定量喂煤机出口溜子 定量给料机 检查清扫
②胶带输送机下料溜子 胶带输送机 Check and cleaning
Whether the trough is Constant feeder
blocked Belt conveyor
(1) constant feeder
trough
(2) belt conveyor
discharge trough
4 煤磨系统操作 ①根据煤粉仓的煤粉重量调节喂料
①喂煤量 量
Operation of coal mill ②正常操作后要掌握煤的品种及水
system 份的变化与粉磨能力的关系,使设
(1)feeding quantity 备的操作更加稳定。
(1) according to the weight of
pulverized coal in the bin, adjust the
feeding quantity.
(2) grasp the relationship of the
variety of coal and moisture changes
with the grinding ability after normal
operation to make the equipment
operation more stable.
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以下叙述的内容为系统正常停车时的操作内容,当设备紧急停车时,其操作方法见第四
部分“设备紧急停车时的处理方法”。
The following content is operation content for the normal operation of the system. In case of
emergency shutdown, see part 4 "processing methods inc case of emergency stopping of the
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序号 设备操作 检查部位
No. Equipment operation Inspection part
1 做好系统停车前的准备工作 ①注意各温度计所指示的温度值
将各控制位置置于“手动”位 ②注意使煤磨进口负压保持在
停止链板喂煤机的喂料 -500Pa 左右
热风炉停止加油 (1) pay attention to the temperature
逐渐减小热风量,增加冷风量,使磨机出 value indicated by the thermometer
口气体温度下降到 65oC,各阀门操作如下: (2) pay attention to keep the inlet
Do all preparation work before system negative pressure of the coal mill
shutdown around - 500 Pa
Each control position in "manual" position
Stop the feeding of the constant feeder
Stop oiling to hot- blast stove
Gradually reduce the hot-air volume, and
increase the cold- air volume, making the
mill outlet gas temperature down to 65℃。
The operation of each valve is as follows:
①慢慢减小增压风机进口阀门(L61-LD4)
的开度
②慢慢减小排风机进口阀门(L61-LD3)
的开度。
③慢慢减小电收尘器进口阀门(441-SD2)
的开度。
④慢慢加大入磨循环风阀门(L61-LD2)
的开度。
(1) slowly decrease the opening of booster
fan inlet valve (L61-LD4)
(2) slowly reduce the opening of bag filter
fan inlet valve (L61-LD3).
(3) slowly reduce the opening of electric bag
filter inlet valve (441-SD2).
(4) slowly increase the opening of inlet
circulation gas valve(L61-LD2)
2 喂煤系统停车 ①磨内无残留煤块及煤粉
①链板喂煤机(L61-CV1)停车 ②注意热风温度的调节(磨机出口气
②关闭棒阀(L61-NG1) 温不超过 65oC)
经过一定时间准备煤磨停车 ③ 注意热风量的调节
Shutdown of coal- feeding system (1) no residual coal and pulverized
(1) constant feeder (L61-CV1)stops coal in the mill
(2) electric flap valve (L61-NG1)closes (2) pay attention to the regulation of
after a certain time , be prepared to stop the hot air temperature (mill outlet gas
coal mill temperature does not exceed 65℃)
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3 电收尘器 441-EP1 停车
立即关闭电收尘器进口阀门 441-SD2
The EP (441-EP1) stops
Immediately shut off the inlet valve of
electric dust collector (441-SD2)
4 高温风机(L61-FN2)立即停车
立即关闭风机进口阀门
Immediately stop Booster fan (L61-FN2)
Immediately close the inlet valve of the fan
5 煤磨(L61-RM1)停车
Coal mill(L61-RM1)stops
6 袋收尘器(L61-BF1)停车
立即关闭袋收尘器进出口阀门(L61SD1、
L61-SD2)
Bag collector(L61-BF1)stops
Immediately shut off the inlet and outlet
valves of bag filter (L61SD1、L61-SD2)
7 排风机(L61-FN1)立即停车
立即关闭排风机进口阀门
Bag filter fan (L61-FN1)immediately stops
Immediately shut off the exhaust fan inlet
valve
8 间隔一定时间后,煤粉输送系统螺旋输送
机(L61-SC1、L61-SC2、L61-SC3、L61-SC4、
L61-SC5)、螺旋泵(L61-PP1)、罗茨风
机(L61-BL1)、三通阀(L61-MW2)停
车
After a certain interval, pulverized coal
conveying system:screw conveyors
(L61-SC1、L61-SC2、L61-SC3、L61-SC4、
L61-SC5), screw pump(L61-PP1)Roots
blower (L61-BL1), and two-way gate
(L61-MW2) stops.
9 确认管道内各阀门的位置
①使进磨热风阀门全关
②使入磨循环风阀门全开
Confirm the position of each valve in the
pipeline
(1) inlet hot blast valve is fully closed
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在生产中,当出现紧急情况如电机突然跳闸,原煤供应突然中断、堵塞及煤粉仓的温度
过高时,请按下述处理方法进行处理。
In the production, when there is an emergency situation, such as sudden motor trip, coal supply
disruption, blockage and too high temperature of pulverized coal bin, please handle it as the
following approaches.
设备名称 现象 Phenomenon 处理方法 Treatment
Name of equip
喂煤设备 电机跳闸 ①棒阀(L61-NG1)全部关闭
Coal feeder ②系统中喂煤设备以外的设备继续运转
① 链板喂煤秤 ③逐渐减少进磨热风量,慢慢打开磨头循环
(L61-CV1) 风阀门,使煤磨出口气体温度保持在 85oC 以
Drag Chain 下
Conveyor ④以下按正常停车时,喂煤系统设备停车后
(L61-CV1) 的操作顺序使系统停车。
① Valve(L61-NG1)all closed
② The system equipment except coal feeder
continue running
③ Gradually reduce the amount of hot air into
the mill, slowly open the circulating air valve
at mill head, make the coal mill outlet gas
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b.入磨溜子堵塞 使磨机入口气体温度降低或启动磨内喷水系
②磨机堵塞 统
a.原煤水份过高,喂料过 ① Rapid stop feeding
多 ② Maintain normal air flow
① Sudden coal disruption When the mill outlet gas temperature tends to
Causes: be over 85℃, lower down the inlet gas
a. Coal storage blockage temperature or start the water spraying system
b. Trough conveyor into in the mill
the mill blockage
② Mill blockage
⑦ Too much moisture
of the coal, too much feed
③磨机内部着火
③ Mill inside on fire
现象 Phenomenon:
a.磨机出口气体温度突 ①迅速查明着火点
然高于 85oC。 ②立即停磨,关闭磨机进口热风阀门
b.气体中 CO 含量上升 ③立即向磨内喷入 CO2 气体或启动磨内喷水
c.磨壳体上的油漆剥落 系统
a. The mill outlet gas
① Rapidly identify the fire point
temperature suddenly
② Immediately stop the mill, close the mill
higher than 85℃.
inlet hot air valve
b. CO content increased
c. Paint peeling on mill ③ Immediately inject CO2 gas into the mill or
housing start the water spraying system in the mill
原煤仓 ①原煤仓内温度上升报 ①喂煤系统紧急停车。
Coal bunker 警。 ②原煤输送系统紧急停车。
原因: ③确认着火时喷入 CO2 气体进行灭火。
堆积的煤粉自燃。 ① Coal feeding system emergency stop.
① Coal bunker ② Raw coal conveyor system emergency stop.
temperature rising and ③ If being sure of fire, inject CO2 gas for
alarm. extinguishing fire.
Cause:
Spontaneous combustion ①检查仓上部收尘管道是否堵塞,可用锤打
of accumulated pulverized 听音等方法检查。
coal.
②检查仓顶防爆阀片是否损坏。
②仓内煤粉外逸
① Check if the upper bunker dust collecting
原因:
pipe is blocked, by the method of peening
a.原煤仓在正压下进料 sound or the others.
b.局部煤粉爆炸使法兰 ② Check if the bunker top explosion-proof
等变形。 valve damaged.
② Bunker coal powder
escaping
Causes:
a. Coal bunker feeding
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第五章 试生产
Chapter 5 Trial Production
1. 日程 Schedule
当所有设备安装完毕,同时经过单机试车和联动无负荷试车,各设备经过全面检查,确
认没有隐患之后,就必须进行煤磨的试生产阶段的试车,如在试车期间中有的设备出现故障,
则必须把用于检查维修的时间剔除出。
When all the equipment are installed, after single machine test run and linkage no-load test,
each equipment is completely inspected, and confirming there is no hidden trouble, then it must be
the coal mill test of trial-production stage. If there is any fault occurring during the test, the time for
the inspection, maintenance must be removed.
2. 目的 Purpose
为了使轴承,齿轮等设备的运转部件适应运转的需要,进行无负荷试车是必要的,同时
为了避免投料试车中的以下几点出现故障,必须给予充分的检查:各设备的润滑油供应情况、
运动部件与固定部件之间有无不正常接触、组装时的精度等。
No load test is necessary for the moving parts, such as bearings, gears and others to adapt to
the operation requirements, and in order to avoid the following faults in the commissioning, fully
check: lubricating oil supply condition of each device, if there is any unusual contact between
moving parts and fixed parts, the assembling accuracy and others.
为了检查各设备的运转情况,为满负荷试车作好准备。必须进行 30%负荷的试车,经过
这一阶段的试车,能使各轴承,齿轮更好的跑合,增加齿轮表面的硬度。同时经过这一阶段
的试车,可以看出各计量仪表的工作性能,以及让操作人员学会如何实际地去操作,去调整,
为满负荷试车做好准备。
In order to check the operating condition of each device, and prepare for the full load test, 30%
load test must be done; after this, all bearings, gears can be better running-in, increase the hardness
of gear surface. At the same time, after this test, we can see the work performance of all measuring
instruments, and allow the operator to actually learn how to operate, how to adjust, and prepare for
the full load test.
100%负荷试车,主要是为了根据控制各个参数来选择最佳的设定值,从而找到最好的运
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
行条件和效果。
100% load test is mainly for choosing the best setting values according to the control of
various parameters, thus determining the best operating conditions and results.
在充分细致地检查完煤磨及其它所有设备之后,必须进行下述试运转的准备。
After fully and carefully check the coal mill and all other devices, we must make the following
preparation for the commissioning.
1. 润滑油的注入 Filling of lubricating oil
在加入润滑油之前,要对润滑装置进行仔细地清洗及内部检查,然后,按各设备的《说
明书》要求,加入合适的润滑油,达到油位计标准线为止。
Before filling the lubricating oil, carefully clean the lubrication system and make the internal
inspection, then, according to the "instructions" requirement of each device, add the appropriate
lubricant up to the oil level gauge marking.
2. 磨机密封部位检查 Mill sealing parts inspection
要保证煤磨系统的正常工作,必须严格控制漏入系统的冷风量。因此必须对容易漏风的
部位----出入磨各接口进行检查。
To ensure the normal operation of coal mill system, we must strictly control the amount of
cold air leaking into the system. Therefore, we must check each joint of mill inlet and outlet, which
is easy to leak.
煤粉制备系统的试生产必须按时间要求,慎重实施。该系统试生产期间运转的好坏,将
直接影响整条生产线能否尽快投入正常生产,因此,必须认真对待。
The trial production of coal preparation system must be carefully implemented as the time
requirements. The operation of the system during the trial production is good or bad, will directly
affect the whole production line and determining whether it can be put into normal production as
soon as possible, therefore, it must be treated seriously.
3.1 无负荷试车 No-load test run
各设备在不加物料的情况下,系统设备运转 8 小时,检查系统运行是否正常,轴承温度,
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
润滑油温度、压力是否正常。若无异常情况,无负荷试车阶段结束;否则,应进行检查、调
整,然后再次运行,直至确认异常消除。
The system equipment running for 8 hours without adding material, check if the system is
operating properly, if the bearing temperature, oil temperature, pressure is normal. If there is no
abnormal conditions, finish the no-load test; otherwise, make the inspection, adjustment, and then
running again until confirming abnormality eliminated.
在无负荷试车阶段,要定时检查、测定、记录各设备的声音、振动、润滑状态、温度、
压力等情况。
During the no-load test, regularly check, determine, record the sound, vibration, lubrication,
temperature, pressure and other conditions of each equipment.
3.2 带负荷试车 Load test
3.2.1 在设备无负荷试车中发现的问题,得以彻底解决并确认后,即可进行带负荷试车。
After completely solve the problems in the no-load test and make sure of it, proceed the
load test.
3.2.2 各阶段带负荷试车时,各设备、各部位的检查,应严格地进行,并做好有关的测量、
记录。
At each stage of the load test, strictly make the inspection of each equipment, each parts,
and make the relevant measurements, records.
3.2.3 在各试车阶段,要特别注意对基础螺栓、连接螺栓的紧固,发现松动时,随时紧固
处理。如不及时紧固,有可能导致设备振动。在各阶段要做到发现问题,及时处理。
In each test phase, pay particular attention to the tightening of foundation bolts,
connection bolts, if finding loosening, fasten it at any time. If not, it may cause the vibration of
equipment. If finding any problem at each stage, handle it at once.
3.2.4 由于煤粉易燃、易爆、易产生外泄有害气体 CO,为了防止煤粉在系统内积滞时间过
长而引起自燃,在生产煤粉前,需先粉磨一定量的石灰石填充管道、溜子、设备的积灰区。
可加入 2~3t,粒度<50mm 的干燥石灰石(避免加入粘性物料),整个系统运转 30min 左右停
磨,稍后停系统各设备,将进入煤粉仓的石灰石粉做为喂煤粉系统试车之用。
As the pulverized coal is flammable, explosive, easy to produce harmful gas CO leaking,
in order to prevent the pulverized coal accumulated too long in the system and cause spontaneous
combustion, before producing the pulverized coal, first grind a certain amount of limestone to fill
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
the pipeline, trough conveyor, ash deposit area of the equipment. We can add 2 ~ 3t dry limestone
with the size <50mm (in avoidance of sticky material added), the entire system running about
30min and stop the mill, later stop the system equipment, and use the limestone powder entering the
pulverized coal bin for the test run of coal feeding system.
1. 概述:Generals
1.1 发生危险的因素 Risk factors
原煤和煤粉都具有可燃性,原煤主要是自燃着火,而煤粉具有自燃着火与爆炸的双重危
险。
The raw coal and coal powder are flammable, the former mainly autogenous ignition, and the
latter has double risks of spontaneous ignition and explosion.
1.1.1 自燃着火 Spontaneous ignition
自燃的主要原因是因为煤在较长时间堆积存放时,吸收空气中的氧气进行氧化反应所造
成的。煤在常温下也能缓慢地与氧发生反应,当反应产生的热量得不到扩散时煤的温度就上
升,温度越高氧化反应速度越快,当温度高到一定值时就能引起煤的自燃,根据不同煤的性
质和存放方式,煤的自燃现象也会有所变化。
The main cause of spontaneous ignition is, when the coal stacked and stored for a long time,
absorbing oxygen in the air, then there is the oxidation reaction. The coal can slowly react with
oxygen at room temperature, when the heat generated in the reaction can not diffused, the coal
temperature rises, the higher the temperature the faster the oxidation reaction; when the temperature
rising to a certain value, it will cause coal spontaneous combustion; depending on the different coal
properties and storage methods, the coal spontaneous combustion will vary.
消除煤的自燃方法是:
Methods to eliminate spontaneous ignition of coal:
a.煤及煤粉不要长时间堆放,应尽快使用
b.不要使煤及煤粉的温度升高
c.不要让带有油污的棉纱等混在煤和煤粉中
d.在长期于密闭容器中贮存煤或煤粉的情况下,用不可燃气体来稀释容器内氧的浓度。
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
a. Coal and pulverized coal not stacked for a long time, they should be used as soon as possible
b. Do not make coal and coal powder temperature rising
c. Do not mix the oil-polluted cotton and others in the coal and coal powder
d. In the case of long-term storage of coal or coal powder in a closed container, use the
non-combustible gas to dilute the concentration of oxygen in the container.
1.1.2 爆炸 Explosion
煤粉的爆炸必须同时满足下面三个条件:
The explosion of coal must meet the following three conditions:
a.可燃物的存在(煤粉或由煤产生的挥发性可燃气体)
b.着火源的存在(煤在自燃时产生的火星,设备的撞击与磨擦,电火花等)
c.有足够维护燃烧的氧气的存在
a. The existence of combustible materials (coal powder or volatile combustible gas produced
from coal)
b. The presence of ignition sources (coal spontaneous combustion produced sparks, equipment
impact and friction, electric sparks, etc.)
c. There is enough oxygen to maintain the combustion
其中煤粉的存在是必然的,要防止煤粉的爆炸,还要有效的清除火源的存在,同时不要
无意义地进行煤粉的搅拌,以免形成到达爆炸极限的煤粉----空气混合物,其它的措施同防止
煤的自燃的措施相同。
Wherein the existence of coal powder is inevitable, in order to prevent coal dust explosion, we
should effectively remove the ignition source, and do not meaninglessly stir coal powder, in
avoidance of forming the coal dust - air mixture reaching the explosive limit, other measures the
same as that to prevent coal spontaneous combustion.
2. 安全措施 Safety measures
2.1 系统的安全措施 Safety measures of system
2.1.1 为防止煤粉外逸,所有设备都设计成在零压或负压下运转。如果煤粉由于偶然原因
外逸或取样时带出时,要立即清扫,设备内部不要产生煤堆积现象。
In order to prevent the escape of pulverized coal, all devices are designed to operate at
zero pressure or negative pressure. If pulverized coal escaping due to any accidental cause or
sampling out, we should immediately clean, do not let the coal accumulated inside the device.
2.1.2 本系统在工艺设计中已考虑了不使用或不产生造成着火,爆炸原因的措施,如尽量
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
避免机械冲击和机械摩擦。
In the process design, this system has taken into consideration the measures of not using
or not causing fire, explosion, such as avoiding mechanical impact and mechanical friction.
2.1.3 为防止煤粉仓等设备着火、爆炸,用 CO2 气体,将煤粉仓内 O2 的 浓 度 稀 释 到 12%
以 下 。一 般 当 煤 粉 仓 的 煤 粉 温 度 达 到 85 oC 以上时,或由于紧急停车等原因使设备内部
残留一部分煤粉而停车时间较长(一般超过三天)时,应该喷入 CO2 气体。
In order to prevent fire, explosion of coal powder bin and other equipment, use CO2 gas to
dilute the concentration of O2 below 12% in the coal powder bin. Generally, when the coal powder
temperature in the bin reaches more than 85℃, or part of pulverized coal residual in the equipment
due to emergency stop or other reasons and stop a bit longer (typically over three days), it should be
injected with CO2 gas.
2.1.4 煤粉收尘器及煤粉管道上均设有防爆阀,当设备内部压力升高时,防爆阀的阀片自
动崩裂,可以从裂口处释放压力,防止设备被破坏。
There is the explosion-proof valve on the pulverized coal dust collector and pulverized
coal pipeline. When the pressure rises inside the equipment, the explosion-proof valve plate
automatically cracks, and the pressure is released, to prevent the equipment from damaging.
2.1.5 本系统的所有工艺管道或收尘器管道都有足够的倾斜度,在避免水平管道的同时采
用了比较高的管内风速以防止粉尘沉降,在管道外壁设置了保温层,可避免气体的结露现象,
防止管道内部煤粉附着。
There is sufficient inclination of all process piping or dust collector piping in the system,
which not only avoids the horizontal piping, but also using relatively high wind speed within the
pipe to prevent dust settling; the pipe wall is provided with insulation to avoid condensation of gas
and to prevent the adhesion of pulverized coal on the pipe inside.
2.1.6 为防止煤粉仓、袋收尘器的结露,要采取保温措施,灰斗要有足够的角度,易于煤
粉排出,防止积料。
In order to prevent condensation of coal dust bin, bag filter, take insulation measures,
there must be a sufficient angle of the hopper, easy for discharging pulverized coal and preventing
material deposit.
2.1.7 各设备之间的连接溜子有足够的角度,同时在容易积料的溜子上装设捅料孔,检查
门等,经常清扫检查,防止煤或煤粉在溜子内的堆积,使煤或煤粉在溜子内能顺利通过。
There is sufficient angle of trough conveyor between each equipment, and set the poke
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
hole, access door, etc. on the trough conveyor easy for material deposit, often clean and inspect to
prevent the accumulation of coal or pulverized coal in the trough conveyor, so as to make coal or
pulverized coal flow smoothly in it.
2.1.8 为掌握系统设备的运转情况,及时显示各种操作参数,保证安全运行,要装上各种
仪表对各部分压力,温度,风量及气体含量进行显示,控制和报警。
In order to master the operation condition of the system equipment, timely display various
operating parameters and ensure the safe operation, various instruments are to be installed to
display, control their pressure, temperature, air flow and gas content, and give alarms.
2.2 各设备的安全措施 Safety measures of each equipment
2.2.1 煤磨 Coal mill
在工艺设计中已考虑到烧成系统的喂煤量有变化这一情况,可以通过调节定量给料机来
控制煤磨的喂料量,这样可以避免煤粉过剩或不足时引起的操作不稳定和危险,磨机的烘干
热源来自窑尾废气及热风炉, 温度在 300oC 左右。设计中在磨机进风口之前设置了阀门掺入
温度低的循环风,可以随时调节磨风温度,在任何情况下,进磨的风温不得超过 250oC,一
般应控制在 200—250oC 的温度下操作。运转时,应使磨机出口气体温度保持在 75—85oC 的
范围内,不应让风温超过 85oC。
In the process design we had noticed the condition that the coal feeding is changing in the
clinkering system. The feed amount of coal mill can be controlled by adjusting the ration feeder,
and this will avoid unstable and dangerous operation caused by pulverized coal excess or shortage.
The mill drying heat is from the kiln rear exhaust gas and hot stove, the temperature about 300℃. In
the design, there sets the valve before the mill inlet to mix the low-temperature circulating air, to
adjust the air temperature at any time. In any case, the mill inlet temperature must not exceed 250℃,
it should be generally controlled at 200-250℃. In the operation, the mill outlet gas temperature
should be maintained within the range of 75-85℃, not exceeding 85℃.
2.2.2 原煤仓、煤粉仓 Coal bunker, pulverized coal bin
原煤仓及煤粉仓装有压力传感器,能直观地显示煤粉量的多少,在正常操作中应使煤粉
仓的煤粉保持一定值,可防止因煤粉贮存过多或不足而引起操作不正常。煤粉仓中煤粉的温
度也应控制在一定值以下,当温度升高超过设定值时就报警,也可以向煤粉仓内喷入 CO2 气
体。
There is the pressure sensor on the coal bunker and pulverized coal bin, directly showing the
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
amount of pulverized coal. In the normal operation, maintain the pulverized coal in the bin at a
certain value to prevent operation unusual caused by excessive or insufficient storage of pulverized
coal. The pulverized coal in the bin should be controlled at the temperature below a certain value,
when the temperature rises above the set value, it will alarm, or inject CO2 gas into the coal bin.
煤粉制备系统虽然有上述安全措施,但还应注意以下事项以确保安全。
In spite of the above-mentioned safety measures for the coal preparation system, the following
points should also be noticed to ensure safety.
1. 巡检 Inspection
1.1 每班至少巡检两次,在设备停止运转时,也必须坚持巡检。
Inspection at least twice per shift, when the device is stopped, we should still insist on the
inspection.
1.2 巡检中的注意事项 Inspection Notes
a.煤及煤粉是否外漏外逸;
b.车间内有否明火;
c.车间内的整洁情况,有无煤粉堆积情况;
d.是否有因为轴承摩擦,螺旋输送机的叶片与壳体磨擦等原因引起的设备发热;
e.为防止设备发热而需要的润滑油量
f.防爆阀闸片是否破裂;
g.各溜子是否堵塞;
a. If coal and pulverized coal leaking or escaping;
b. Whether there is fire in the workshop;
c. Tidiness in the workshop, if there is pulverized coal accumulated;
d. Is there any equipment heat caused by the bearing friction, friction between the screw
conveyor blade and the housing, and others;
e. The amount of lubricating oil needed to prevent equipment heat
f. If the explosion-proof valve plate is broken;
g. If any trough conveyor is blocked;
2. 清扫 Cleaning
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
2.1 不论在停机时或设备运转时,都应注意随时清扫,保持本系统内的清洁。
Regardless of the equipment stop or operation, pay attention to clean and keep clean of
the system at any time.
2.2 清扫时的注意事项:Precautions when cleaning
a.清扫前应先撒水,然后再清扫,应注意不要使楼板上的煤粉再次飞扬;
b.不要用压缩空气清扫地面;
c.清扫设备内部应在停车后进行,设备内部的煤粉应全部清扫干净;
a. Watering before sweeping, then cleaning, be careful not to make the coal dust rising on the
floor again;
b. Do not use compressed air to clean the ground;
c. Cleaning inside the device should be done after stopping, the pulverized coal inside the
device should be all cleaned;
3. 严禁烟火 Fire prohibition
3.1 车间内严禁烟火,不准在车间内吸烟,不准在车间内进行气割、气焊、电焊及使用
产生火花的砂轮。
Fire prohibited in the workshop, no smoking in the shop, not allowed gas cutting, gas
welding, electric welding and using the wheel producing sparks in the workshop.
3.2 在万不得已使用上述工具的情况下,应彻底清扫周围的煤及煤粉,对实施焊、割的
设备或溜子等彻底清扫内部、外部的煤或煤粉,同时对相邻的设备进行同样的清扫。
In the case of using the above tools is inevitable, thoroughly clean the coal, pulverized
coal around, thoroughly clean the coal or coal dust inside and outside the equipment or trough
conveyor, etc. where should implement welding, cutting, and the same cleaning on the adjacent
devices.
4. 系统运转前的安全检查 Security inspection before system operating
4.1 长期停车后开车时的安全检查:检查煤粉仓的易堵部位及输送设备内部,确认没有
煤粉及杂物等,同时应检查车间内是否有煤或煤粉的堆积。
Security checks when starting after long-term stopping: Check the coal powder bin of the
place easy blocked and the inside of conveying device, confirming there is no pulverized coal and
debris, etc., meanwhile check whether there is the accumulation of coal or coal dust in the
workshop.
4.2 短期停车后开车时的安全检查:确认输送设备内部没有煤粉。
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
Security checks when starting after short-term stopping: Confirm there is no coal dust
inside the conveying device.
4.3 排气:为防止开车时发生爆炸,应先启动排风机将煤磨,电收尘器等设备及管道中
可能产生的易爆气体全部排出。
Exhaust: In order to prevent explosion while starting, first start the exhaust fan to totally
discharge the possible explosive gas produced in the coal mill, electrostatic precipitator and other
equipment and in the pipe.
5. 运转中的安全检查 Running security checks
5.1 煤磨 Coal mill
a.煤磨出口气体温度应经常保持在 75~85oC,不能超过 85oC。
b.经常注意煤粉细度,减少过粉磨现象;
c.当喂煤量过高或过低时,应严密监视各部分的工艺操作参数,防止在这种情况下出现
事故;
d.每隔一定时间进行巡检,注意各溜子是否通畅。
a. The coal mill outlet gas temperature should be kept at 75 ~ 85℃, not exceeding 85℃.
b. Constantly pay attention to the coal fineness, reducing over-grinding;
c. When the coal feeding is too high or too low, closely monitor the process operating
parameters of each part, to prevent accidents in this case;
d. Inspection at regular intervals, pay attention to the smoothness of each trough conveyor.
5.2 其它设备:输送设备等不应存在堵塞现象;
Other equipment: there is no blockage of the conveying device and others;
5.3 管道:各工艺管道及收尘管道不应存在堵塞现象;
Pipeline: there is no blockage of each process piping and collecting duct;
6. 停车前后的安全检查 Security check before and after stopping
6.1 正常停车 Normal stop
a.把煤磨及输送设备里的煤粉全部排出后停车;
b.预计停车时间为 3 天以上时,煤粉仓中的煤粉要排空;停车 10 天以上时,原煤仓中
的原煤也要排空;
c.磨机喂料量减少时,不得使磨机出口废气温度超过 85oC。
d.煤磨停车后,应立即使排风机停车。
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
a. Stop after completely discharge the pulverized coal in the coal mill and conveying
equipment;
b. When the estimated stopping time is more than three days, empty the pulverized coal in the
bin; when stopping for more than 10 days, empty the coal in the bunker;
c. When the mill feed is reduced, the mill outlet exhaust gas temperature should not exceed
85℃.
d. After the coal mill stops, the exhaust fan should stop immediately.
6.2 紧急停车 Emergency stop
a.原煤输送设备紧急停车时,磨机出口废气温度不得超过 85oC。停车时间超过 20 分钟
时,按正常情况下停车操作顺序进行系统停车。
b.煤磨紧急停车时,磨机出口废气温度不得超过 85oC。
c.煤磨排风机紧急停车时,应严密监视磨机出口,各管道的温度,不得超过设定的报警
值,如果上述温度达到报警值并有再上升的趋势时,则必须采取措施如喷 CO2 气体、磨内喷
水等。
a. When the coal conveying equipment emergency stop, the mill outlet exhaust gas
temperature must not exceed 85℃. When stopping for more than 20 minutes, stop the system
according to the stop sequence under normal conditions.
b. When the coal mill emergency stop, the mill outlet exhaust gas temperature must not exceed
85℃.
c. When the coal mill exhaust fan emergency stop, closely monitor the mill outlet, temperature
of each pipe, which should not exceed the set alarm value, if the above temperature reaches the
alarm value and has the tendency to rise again, we must take measures such as spraying CO2 gas,
spraying water into the mill and others.
7. 出现危急情况的处理方法 Treatment for critical situations
当发现原煤仓或煤粉仓内部有烟头,煤粉温度持续异常上升时,为防止更大的事故发生,
必须采取如下处理方法:
When finding any cigarette butt inside the coal bunker or pulverized coal bin, the coal powder
temperature rising continuously and abnormally, in order to prevent further accidents, we must take
the following approach:
7.1 原煤仓、煤粉仓 Coal bunker, pulverized coal bin
a.停止向仓内继续给煤
b.原煤仓及煤粉仓出口输送设备停车,关闭出口闸门。
c.喷入 CO2 气体;
d.确认仓内温度已降到规定报警值 80oC 以下;
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
e.现场检查仓内的情况
a. Stop feeding the bunker or bin
b. Stop the conveying equipment at the outlet of coal bunker and pulverized coal bin, close the
outlet valve.
c. Inject CO2 gas;
d. Confirm the temperature in the bunker or bin has dropped to below the predetermined alarm
value -80℃;
e. Check the conditions in the bunker or bin at site.
① 进入设备内部检查时的安全措施
Security measures when entering the inside of equipment and making inspection
为排除设备内部的烟头,堆积的煤粉或清查设备内着火,爆炸的原因,在设备停车后要
进行内部检查,内部检查应注意:
In order to remove the cigarette butt, accumulated coal dust inside the equipment or remove
the cause of fire, explosion, the equipment should be made the internal inspection after stop, pay
attention to:
8.1 穿戴防护用具 Wearing protective appliances
8.2 需要照明的情况下,应使用安全防爆型移动灯或手电筒,严禁用明火照明。
Where lighting is needed, use safe and explosion-proof movable lights or flashlights, open
flames illumination prohibited.
8.3 仔细检查煤粉仓及设备内部有无煤粉的堆积,附着现象,有无烟火存在。
Carefully check the pulverized coal bunker and if there is the accumulation, adhesion of
coal dust inside the equipment, and if there is smoke/fire.
8.4 由于喷入气体,煤产生挥发性气体等原因,设备内部气体中的氧含量将减少,这时,
进入设备内部检查会因缺氧而造成危险,因此必须进行充分的通风使氧含量在 18oC 以上。
Because of the injected gas, coal producing volatile gases and other reasons, the oxygen
content inside the device will reduce, then, it will be dangerous for the personnel entering the device
and making inspection due to lack of oxygen, and therefore it must be adequately ventilated to keep
the oxygen content over 18℃.
9. 消防设施的准备与维护 Preparation and maintenance of fire-fighting facilities
9.1 为当发生火灾时能迅速灭火防止火灾蔓延,车间内各楼层必须配备足够数量的灭火
器,消防筒等消防设施。
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
In order for rapid extinguishing and to prevent fire spreading, each floor of the workshop
must be equipped with sufficient fire extinguishers, fire drenchers, and other fire-fighting facilities.
9.2 所有消防设施都要根据安全规范,定期进行检查维护,保证在必要时能正常使用。
All fire-fighting facilities must be regularly inspected and maintained in accordance with
the safety standards, to ensure normal service if necessary.
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