ZRD—40.5自身预热空气高炉煤气烧结点火炉使用说明书(对照).doc

使 用 说 明 书Operating Manual 一、 用途I. Use ZRD40.5/1.5m自身预热空气高炉煤气烧结点火炉，适用于以高炉煤气为点火燃料，给台车宽度1.5m的40.5烧结机进行料面点火及表层烧结。ZRD40.5/1.5m self-preheating air blast furnace gas ignition furnace applies to sintering machine(the width is 1.5m, area is 40.5)taking blast furnace gas as ignition fuel for charge level ignition and surface . 设备特点II. Equipment Features 1、采用自身预热空气技术，在点火炉保温段安装空气预热器，利用烧结料面辐射热和点火段部分热量预热空气，而不外加热源，即可提供150250助燃空气，提高高炉煤气理论燃烧温度，使烧结点火炉单烧高炉煤气点火时可达110050的点火温度要求。1. Apply self-preheating air technology, install air pre-heater on the holding zone of the ignition furnace, preheat air by using radiation heat of surface and partial heat of ignition part, providing 150250 combustion air without adding thermal resource, and it can improve the theoretical combustion temperature of blast furnace gas as well as making ignition furnace meet the ignition temperature requirements about 110050 when it ignites with blast furnace gas alone. 2、采用强旋流型小功率管式煤气烧嘴，混合充分，火焰长度缩短，炉膛高度550mm，减少炉墙散热损失，烧嘴不易堵塞。2. Apply strong rotational flow and low power tube-type gas burner to mix to a full extent as well as shorten the length of the flame, the height of the hearth box is about 550mm, besides, this will also reduce radiation loss of the chamber wall and the burner is not easy to block . 3、烧嘴布置合理：采用三排布置，能形成高温带状火焰，进行中低温，高热强度带式点火，降低点火热耗。3. The arrangement of the burner is reasonable: Apply three-row layout, which can form a high temperature ribbon flame to ignite in a low temperature and high thermal strength and reduce ignition thermal loss. 4、炉体采用车体式支承，炉顶和炉墙采用耐火预制构件砌筑，施工安装方便，周期短。4. Apply body type bearing for the furnace, construct furnace roof and chamber wall with refractory pre-cast, which will bring a convenient construction and installation and a short cycle. 三、设备系统组成III. Equipment System Components 四、主要技术性能. Main Technical Performance 序号名 称单 位 数 值备注1烧结机规格型式40.5带式2台车尺寸3台车速度4平面利用系数5烧结矿台时产量6点火温度7点火时间8高炉煤气热值9高炉煤气接点压力10高炉煤气含尘量11点火高炉煤气耗量12点火高炉煤气温度常温13点火助燃空气耗量14点火助燃空气温度15点火烧嘴形式套管式烧嘴16点火烧嘴数量15(3排)17点火烧嘴嘴前空气压力18点火烧嘴嘴前煤气压力19建议点火炉用助燃风机(2台；一用一备)9196.3A 电机Y225M2 18.5KW Q=32205153Nm3/h H=91499055PaNo.Name Unit Value Notes 1Sintering machine specifications and types 40.5 draper-type2Trolley dimension3Trolley speed 4Plane utilization factor 5Output of mine 6Ignition temperature 7Ignition time 8Blast furnace gas thermal value9Blast furnace gas contact pressure10Blast furnace gas dust content11Ignition blast furnace gas consumption 12Ignition blast furnace gas temperature Normal temperature 13Ignition combustion air consumption 14Ignition combustion air temperature 15Ignition burner formExtension-type burner16Ignition burner amount 15(3 rows)17Air-pressure in front of the ignition burner 18Gas pressure in front of the ignition burner19Suggesting using combustion-supporting fan for ignition furnace(two sets, one for using, and the other for alternation)9196.3A, electrical motor Y225M2 18.5KW Q=32205153Nm3/h H=91499055Pa五、设备及系统安装(详见安装说明). Equipment and installation for system (see installation instructions for details)1、烧结点火炉安装：1. Installation of ignition furnace 1.1、点火炉炉壳钢结构在烧结机点火炉安装轨道上按图安装就位。1.1 Install in place the ignition furnace mantle steel structure on the attachment rail of the sintering machine ignition furnace. 1.2、点火炉砌筑耐火炉衬按图在点火炉炉壳钢结构内部砌筑。1.2 Construct the ignition furnace masonry refractory lining into the ignition furnace mantle steel structure according to the drawing. 1.3、按图安装管式点火煤气烧嘴。1.3 Install tube-type ignition gas burner according to the drawing. 1.4、空气预热器按图在炉体内就位。1.4 Install in place the air pre-heater inside the furnace according to the drawing. 1.5、按图安装炉前空、煤气管路和相关调控阀门、放散、吹扫管路；安装石油液化气引火烧嘴；安装点火炉助燃风机炉前空、煤气管路与空、煤气总管碰接；1.5 Install air and gas pipeline in front of the furnace and relevant adjusting valve, emission pipeline and sweeping pipeline according to the drawing; Install liquefied petroleum gas ignition burner; install ignition furnace combustion-supporting fan, providing a connection for air and gas pipeline in front of the furnace with air and gas main pipeline; 1.6、安装温度、压力、流量测试仪表；1.6 Install temperature, pressure, and rate test instrumentation; 1.7、用木材和煤气按烘炉曲线烘炉。1.7 Baking according to the baking curve with woods and gas. 2、管路安装要求：2. Installation requirements for pipeline2.1.管道安装前应对每一段管道管件、阀门等进行检查，清除管内氧化皮、焊渣及杂物等。2.1 Check pipe fittings and valves of each section pipeline before installation, clear roll scale, welding slag and other sundries inside the tube. 2.2、安装时应按照GBJ235-82工业管道工程施工及验收规范（金属管道篇）及设计图中有关技术要求进行。2.2 Install according to the relevant technical requirements in GBJ235-82 Industrial pipe construction and acceptance specification (metal pipe).2.3、整体系统管路联接后进行气密性试验：煤气管路试验压力35 KPa，1小时压降1%；空气管路试验压力25 KPa，1小时压降2%。试验合格后方可投产。2.3 Testing air tightness after the overall system piping is connected: gas pipeline testing pressure is 35kpa, pressure drop is less than 1% every hour; while air pipeline testing pressure is 25kpa, and the pressure drop is less than 2%. Put it into production if the testing result is qualified. 2.4、点火炉在预留测点及指定位置安装必要的温度、压力和流量指示仪表、控制装置及报警装置。炉前空、煤气管路、煤气总管下设吹扫管，在管路系统最高点设放散管，煤气发火试验管；煤气管路最低点设疏水管路阀门。2.4 Install essential temperature, pressure, and flow indicating instruments, control devices and alarm devices on reserved measurement points and assigned position of the ignition furnace. Set up purge tube under the air, gas pipeline in front of the furnace, then set up exhaust stack, and gas ignition testing tube to the highest position of the piping system; lastly, install hydrophobic piping valves to the lowest position of the gas pipeline. 六、安全生产操作规程. Operational specifications for safety production （一）、点火试车、投产调试前的设备检查、准备工作(1) Checking and preparatory procedures of Equipments before ignition test, production and adjusting. 1、细致检查整套点火炉是否按设计图纸安装正确，是否有遗漏的部分。特别要检查各空煤气管路走向、连接是否正确。煤气放散管是否安装。点火烧嘴排列是否在烧结机风箱之内。清理炉膛内杂物。1. Examine carefully whether the installation of the whole ignition equipment is correct according to the designing drawing, and if there is a missing part. Especially to check that whether the direction and connection of each air, gas pipeline is correct. Whether the gas exhaust stack has been installed, and whether the arrangement of the ignition burner is within the sintering machine bellows. Lastly, clean up the debris inside the furnace. 2、对助燃风机；热工测量一二次仪器、仪表；各信号指示灯；操作台各开关、操作器；各手动、电动调节控制阀们进行检查(点火前各种阀门应全处于关闭状态，点火调试时根据程序、按要求逐一打开调节)。确认无故障、都能正常灵活操作使用后准备点火调试。2. Check combustion fan, primary and secondary thermal measurement instruments and meters; each signal indicator; each switch and operator on the control console; all manual or electrical adjustable control valves (all valves should be off before ignition, open them one by one when igniting and debugging according to the procedures and requirements). To ignite and debug after confirming that everything is right and all can operate flexibly. 3、按照GBJ235-82工业管道工程施工及验收规范（金属管道篇）及设计图中有关技术要求，对整体系统安装连接完成后的空煤气管路和各阀门连接处进行气密性打压试验(通常情况下煤气管路试验压力35 KPa，保压1小时压降1%；空气管路试验压力25 KPa，保压1小时压降2%)，试压合格后方可投产。同时投产前用蒸汽或氮气吹扫煤气管路，打开放散阀门进行放散，吹扫放散时间为1520分钟。打开风机吹扫空气管路10分钟。3. According to the relevant technical requirements in GBJ235-82 Industrial pipe construction and acceptance specification (metal pipe), Testing air tightness for the air and gas pipeline and the connecting place of each valve after the overall system piping is installed and connected (usually, gas pipeline testing pressure is 35kpa, pressure drop is less than 1% every hour; while air pipeline testing pressure is 25kpa, and the pressure drop is less than 2%). Put it into production if the testing result is qualified. In the same time, sweep gas pipeline with steam or nitrogen before production, open the elution valve for elution, the elution time is about 15 to 20 minutes. Then turn on the blower to purge air pipeline for ten minutes. 4、由动力部门检查确认进入烧结厂房煤气节点压力是否在生产要求范围内（4.5Kpa）。经确认后方可投产。4. The power department should check and confirm whether the pressure of gas node entering plant is within the production requirements (4.5Kpa). Put it into operation after confirmation. 5、严格按烘炉曲线用木材和煤气进行烘炉。最好烘炉完成后立即点火试车、投产调试。5. Bake with wood and gas strictly follows the baking curve. It is better to take ignition and production debugging immediately after the baking is finished. 6、通过点火炉煤气取样管(通常安装在点火炉顶部煤气放散管上)提取煤气作发火试验，以确认点火用煤气已接引至点火炉煤气管路内，可以点火试车、投产调试。6. Extract gas through the gas sampling tube of ignition furnace (usually installed on the gas exhaust stack which is on the top of the ignition furnace) for ignition test, thus to ensure that the gas used for ignition has been guided inside the gas pipeline of the ignition furnace, then ignition test and production debugging can be put into operation. (二)、点火启动(II) Ignition starting点火启动前要切记点火炉炉膛内一定要有足够的明火存在，以保证煤气不外泄，不灭火，不爆燃，保证安全、成功点火。Do remember that there is enough open flame inside the ignition furnace before starting ignition to ensure that these is no gas leak, no fire, no deflagration, which in turn will ensure a safe and successful ignition. 1、开启点火炉助燃风机、空气总管路控制阀门；煤气总管路控制阀门；烧结机主抽风机。将空气、煤气输送至点火炉各分支管阀门前，适当开启烧结机主抽风箱闸板。1. Open the combustion fan of ignition furnace, control valve of air pipeline; control valve of gas pipeline; spindle ventilator of sintering machine. Transport air and gas to each branch pipe valve of ignition furnace, as well as open spindle ventilator flashboard of sintering machine appropriately. 2、点燃点火炉点火烧嘴有以下几种方式：在炉膛内点火烧嘴的下方、一定范围内将一定量劈柴或油布点燃，火焰范围、强度要大些烘炉完成后保持炉膛内明火直接点燃。2. There are several ways for igniting ignition furnace burner: Ignite a certain amount of firewood or linoleum below the ignition burner and within a certain range, the range and intensity of the flame should be larger. Ignite directly the open flame inside the furnace after the baking is finished. 3、点燃点火烧嘴应按“先煤气后空气；明火点燃；小流量点火”的原则操作。在有明火的前提下，先小量（开启约1/31/4开度）开启点火炉空、煤气支管调节阀门、然后小量逐台或逐排开启（开启约1/31/4开度）点火烧嘴空、煤气进口调节阀门(如果有的话)，将每台或每排烧嘴全部点燃。待点火炉烧嘴都点燃成功后，再保证烧嘴不脱火、灭火前提下，逐步加大供给空、煤气量，将空、煤气量调节达到最佳的设计配比，使煤气充分燃烧，同时调整开大烧结机主抽风箱闸板。点火成功。3. Ignition of the burner should be operated according to “air after gas; open flame ignition and small flow ignition”. If open flame is available, first open the air and gas pipe adjusting valve of ignition furnace in a small amount (about 1/3 to 1/4), then open the air and gas import adjusting valve of ignition burner (if any: about 1/3 to 1/4) one by one or row by row, ignite each burner or every row of burners. When the burners of ignition furnace are all ignited successfully, please ensure to gradually increase the supply of air and gas in the premise of that the burner will not be off fire, in this way, adjust the amount of air and gas to the best design ratio and get the gas fully combusting, in the same time adjust and open the spindle ventilator flashboard of the sintering machine. In this case, the ignition has been successfully operated. 4、若点火不成功，应立即关闭煤气阀门，再关闭空气阀门，把煤气管路内煤气放散干净后，查找原因，调整合适后再按以上程序重新点火。4. If the ignition is not successful, it should turn off the gas valve immediately, and then turn off the air valve until the gas inside the gas pipeline has been released totally, then find out the reasons and reignite according to the above procedures after appropriate adjustment.(三)、调试(III) Debugging 1、点火炉点火试车、投产调试要保证煤气燃烧完全，火焰长度适中，温度场均匀，点火炉炉膛内在负压或微正压下工作，点火温度符合设计、生产的要求。1. When using ignition furnace for ignition test and production debugging, ensure that gas can combust completely, the flame length is moderate and the temperature field is uniform, as well as that the ignition furnace chamber is working under sub-pressure of pressure-fired and the ignition temperature is in line with the requirements of designing and production. 2、在点火成功的情况下，应逐步调节烧结机主抽风箱闸板的开启度和点火炉各空气、煤气调节阀门的开启度，让点火烧嘴火焰高温部分接触到烧结矿的料面，即保证火焰长度让外焰接触料面，尽量使料面上火焰区域内无黑影出现，如果有黑影说明火焰高温区不在料面上或煤气燃烧不完全，将会影响点火效果、点火温度。2. If the ignition is successful, it should gradually adjust the opening degree of the spindle ventilator flashboard and that of each air and gas adjusting valves to make sure that high-temperature part of the ignition burner flame can contact with the surface of the sintering ore, that is to say, ensure that the length of the flame can keep the outer flame be in contact with charge level to try to keep the flame of the charge level away from any shadows, if there is any shadows, this indicates that the high-temperature zone is not on the charge level or the combustion of the gas is not sufficient, which will affect the ignition effect and temperature. 3、调整最佳火焰状态以获得较高的点火温度。3. Adjust the furnace to the best flame status to obtain a higher ignition temperature. 3.1、正常情况下点火炉炉膛内为微负压,火焰不外溢,火焰颜色为白色明亮。若火焰颜色发黄并混浊说明助燃空气供给量大,煤气供给量小,则应加大煤气供给量，减少助燃空气供给量。若火焰颜色发蓝且混浊说明煤气供给量大, 助燃空气供给量小,则应减少煤气供给量,加大助燃空气供给量。3.1 Normally, the pressure inside the ignition furnace is slight negative pressure, the flame will not spill, and the flame color is bright white. Yellow and turbid flame color indicates that the supply amount of combustion air is sufficient and that of gas is less, in this case, it needs increasing the supply amount of gas and reducing that of combustion air. While blue and turbid flame color indicates that the supply amount of gas is sufficient and that of combustion air is less, in which case needs reducing the supply amount of gas and increases that of combustion air. 3.2、在调整烧嘴燃烧火焰状态时，煤气量要逐渐加大，不要一下加到量，随着煤气量的加大，同时也要逐渐加大助燃空气量，让煤气与助燃空气达到一个合理的、最理想的配比，并不是说煤气量供给的越多点火温度越高，只有空煤比合理以使煤气充分完全燃烧，才能达到最佳点火温度和效果。3.2 When adjust the combustion flame state of the burner, it should gradually increase gas volume, not to add to the amount one time, but also gradually increase the amount of combustion air with the increase of gas amount to make gas and combustion air achieve a reasonable and ideal ratio, while this does not mean about more supply of gas and higher ignition temperature, an optimum ignition temperature and effect can be achieved only when the ratio of gas and air is reasonable for gas to combust completely. 3.3、点火温度较高、点火效果较好的情况下，烧结矿表层呈现兰黑色，烧结矿为半熔化状态，互相粘接的较好、强度较高。3.3 In the case of a higher ignition temperature and better ignition effect, the surface of sintering ore will show dark blue and sintering ore is in semi-molten state, this means that they are bonded better and the strengthen is higher. 3.4、如果炉膛两侧烧嘴火焰向烧结台车栏板外溢，应适当调小两侧烧嘴燃烧能力、减少空煤气的供给，以减弱外溢现象。如果火焰突然外溢现象严重，也可能是受烧结混合料透气性不好，含水量过小，或主抽风箱堵塞等因素影响，要逐一检查排除调整处理。如果烧结台车两边料面点火效果、强度较差，则应适当调大两侧烧嘴燃烧能力、加大空煤气的供给，以减弱烧结边缘点火效果、强度较差的现象。3.4 If the burner flame on both sides of the furnace spills over the sintering machine sideboard, it should appropriately turn down the combustion power and reduce the supply of gas in order to weaken the spillover phenomenon. Serious spilling means that the air permeability of sinter mixture is poor, moisture content is too small or the spindle ventilator is block, which needs checking, excluding, adjust, and processing one by one. If the ignition effect and strength of both sides of sintering machine is poor, it should improve the burner combustion capacity on both sides and increase the supply of air and gas to weaken the poor ignition effect and strength of the edge of sintering machine. (四)、熄火停机（分正常熄火停机、应急熄火停机两种）(IV) Flameout (including normal flameout, emergency flameout) 1、正常熄火停机：1. Normal flameout1.1、熄火顺序：先关点火烧嘴，最后关助燃风机。1.1 Order of flameout: first to turn off the ignition burner, and then turn off the combustion fan. 1.2、要先关闭煤气管路上的阀门，至烧嘴熄灭，空气在小量供给2分钟，再关闭空气管路上的阀门，然后在空、煤气管路内通入蒸汽或氮气，打开放散管路阀门，将残余空煤气放散干净，准备下一次点火投产。1.2 First close the valve of the gas pipeline until the burner is off, supplying air in a small amount for about two minutes, and then close the valve of the air pipeline, inletting steam or nitrogen into the air, gas pipeline, lastly, open valve of exhaust stack to release the residual air and gas clearly for the next ignition and operation. 2、应急熄火停机：2. Emergency flameout 当风机故障；停电；空、煤气压力过低快速切断；短时停修时，应及时打开煤气放散管路，关闭点火炉前煤气支管阀门，再关闭点火烧嘴前煤气进口阀门，必要时可打开蒸汽或氮气管路吹扫并放散空煤气管道。If there is something wrong with the fan; it needs to cut off power, when the pressure of air, gas is too low, it is better to cut off power quickly; during a short-term stop for repairing, it should open the gas exhaust stack in time, turn off the gas branch pipe valve in front of the ignition furnace, then turn off the gas imported valve in front of the ignition burner, open the steam or nitrogen piping to purge and elute the gas pipeline if necessary. (五)、生产中需注意的事项(V) Notes for production 1、若调整助燃空气或煤气阀门开度时，即使阀门已开到最大, 助燃空气或煤气供给量；点火烧嘴燃烧状态；点火温度都没有太大变化，遇到这种情况通常说明系统上的阀门出现故障,应从点火炉前开始逐个检查，排除故障后再行操作调试。1. When adjust the opening of combustion air or gas, even the valve has been opened to the maximum extent, the supply amount of combustion air and gas, combustion state of the ignition burner and ignition should not change too much, what happens here indicate that there is something wrong with the valve of the system, which makes it necessary to check one by one in front of the ignition furnace and re-debug after the error is ruled out. 2、调整完助燃空气或煤气阀门阀板开度时，助燃空气或煤气量的变化，点火烧嘴燃烧状态的变化，点火温度的变化，都要有一定延时才能显现效果。所以调整完阀门开度时，要观察一会效果，再决定进行下一步操作，避免盲目混乱操作而不能达到调试效果。2. After the adjustment of the valve plate opening of combustion air and gas, th