立磨工艺和功能说明.doc

Process and Function Description工艺和功能说明of a Typical Slag Grinding Plantwith POLYSIUS Vertical Roller Mill Type RMS伯利休斯典型的RMS矿渣立磨系统(Issue Aug. 2004) 2004年8月发行2004年10月26日Contents目录1. Plant description工厂说明. . 41.1 Design and function of the slag grinding plant矿渣研磨厂的设计和功能. . 61.1.1 Raw material feeding原料进料.61.1.2 Roller mill RMS 51/26 辊式磨. .7Figure 1: Design of the roller mill 图1: 立式辊磨的设计.91.1.2.1 Mill housing 磨机外壳101.1.2.2 Feed chute 围料槽101.1.2.4 Grinding table 磨盘121.1.2.5 Wear of grinding elements and dam ring heightener 耐磨件的磨损和挡料圈高度131.1.2.6 External circulation of material 外循环物料161.1.2.7 Drive unit 驱动装置171.1.2.8 Water injection (item 5F1.RM01.WTJ01) 喷水装置181.1.2.9 Confining air system (item 5F1.RM01.CAS01 and 5F1.RM01.CAS02) 密封风机系统181.1.3 Dynamic separator SEPOL RMS (Item项目5F1.RM01.SDR01) 动态选粉机.18 1.1.4 Gas routes风管路径 . .201.1.5 Finished product route 产品路 径 .201.2 Control concept 控制方案 .211.2.1 Control of gearbox lubrication (5F1.RM01.GLS01) 减速机润滑的控制.231.2.2 Control of auxiliaries 辅助设备的控制. . .241.2.3 Control of finished product conveyance 成品输送的控制. . . .251.2.4 Control of gas routes (5F1.GP01 to 5F1.GP05)气体路线的控制. . .251.2.5 Control of the hot gas producer (5F1.HG01)热风炉的控制. .251.2.6 Control of main drive unit of mill (5F1.RM01.DRU01) and of new material delivery磨机主传动装置和原料供给的控制 . . . .261.2.7 Control of water injection (5F1.RM01.WTJ01) 喷水的控制 .261.2.8 Control of grinding pressure 碾磨压力的控制.262. Material properties 物料特性. . 273.Operation of the grinding plant 碾磨厂的操作. 293.1 Philosophy of operation 操作原理.293.2 Start-up / Shutdown sequence 启动 /停机顺序 .313.2.1 Start-up sequence 启动顺序. .313.2.2 Shutdown sequence 停机顺序.323.3 Control loops 控制回路环. .333.3.1 Control of differential pressure of mill 磨机压差的控制. . .343.3.2 Control of temperature downstream of mill 磨机后温度的控制. .343.3.3 Control of pressure upstream of mill 磨机前压力的控制. . .353.4 Operation under extraordinary conditions 特殊情况下的操作.353.4.1 Start-up of plant 系统设备启动. .353.4.2 Shutdown of plant 系统设备的停止. .363.4.3 Operation with insufficient material quantity 喂料不足的操作. . .363.4.4 Overfilling of mill磨机过量喂料. .363.5.5 Significant decrease of mill exit gas temperature 磨机出口风温度明显降低.37List of figures插图清单Figure 1: Design of the roller mill图 1: 辊式立磨的设计.8Figure 2: Wear protection of the feed chute图 2: 进料料槽的耐磨保护. .9Figure 3: Grinding roller carrier with roller pair unit图 3: 磨辊桥架和磨辊对装置.10Figure 4: Grinding table图 4: 碾磨磨盘 . .11Figure 5: Arrangement of the dam rings图 5: 挡料圈的设置.12Figure 6: Dam ring heightener图 6: 挡料圈增高.13Figure 7: Materials at the nozzle ring图 7:喷嘴环处的物料.14Figure 8: Collector for light section steel图 8:小铁颗粒收集.15Figure 9: Mill drive system with lubrication system图 9: 带润滑系统的磨机传动系统.16Figure 10: Confining air system for grinding roller bearings图 10:磨辊轴承的密封空气系统.17Figure 11: Structure of the SEPOL separator图 11: SEPOL选粉机的结构.18Figure 12: Basic setting of guide vanes图 12: 导向叶片的基本设定.19Figure 13: Control scheme图 13: 控制方案. .331. Plant description 工厂说明Below, please find a process and function description of a typical slag grinding plant. Thedesignations (item numbers) used in the text refer to the flowsheets.以下是一个典型的矿渣粉磨系统的工艺和功能说明。文中用到的代码(项目号)参考流程图中的设备编号。The slag grinding plant basically consists of the raw slag feeding system, the roller mill with the dynamic separator and external material circuit with the fine metal extraction unit, a hot gas generator, the gas routes including the system fan, the bag filter and finished material transport. 矿渣粉磨系统由：矿渣喂入装置、动态选粉机、带除细铁颗粒装置外物料循环、磨机本体、一台热风炉、包括风机的热风管路、袋收尘器和和产品输送装置。The roller mill is a POLYSIUS mill type RMS with a dynamic separator type SEPOL RMS. The grinding plant is heated by a hot gas generator, which normally is fired with blast furnace gas, natural gas, heavy oil, light oil or coal dust.立磨型号为RMS的伯利休斯磨配有型号为SEPOL RMS的动态选粉机。粉磨系统由一台热风炉供热风，热风炉一般采用高炉煤气、天燃气、重油、轻油或用煤粉。The following basis values apply to a typical 90 t/h slag grinding plant only:下列基本参数仅适用于一个典型的 90 t/ h矿渣粉磨系统：Mill feed material磨机喂料: blast furnace slag 高炉矿渣Mill type磨机型号: RMC 51/26/435 Throughput产量: 90 tph (吨/每小时)Product fineness产品细度: 4200 cm2/g 4500 cm2/gDiameter of mill housing磨壳直径: 7000 mmDiameter of grinding table磨盘直径: 5260 mmDiameter of grinding rollers磨辊直径: 2600 mmWidth of the grinding rollers磨辊宽度: 730 mmQuantity of the grinding rollers磨辊数量: 4Inst. power of main drive unit安装的主马达功率: 2800 kWSeparator type选粉机型号: SEPOL 435 RMSDiameter of separator rotor选粉机转子直径: 4350 mmDiameter of separator housing选粉机壳体直径: 8500 mm Inst. drive unit安装的马达功率: 250 kWRotor speed转子速度: 26 - 154 1/min Hot gas producer热风炉: .Max. heating capacity最大的加热容量: 45 55 GJ/hMax. hot gas quantity最大的热气量: . m3/hFuels燃料: natural gas or blast furnace gas: 高炉煤气, 天燃气, 重油, 轻油或煤粉Filter area收尘面积: 约 5000 mDust load粉尘浓度: 300 350 g/mExhaust air volume 排气量: 28,000 31,000 m3/hFilter medium 过滤介质: Polyacrylonitrile聚丙烯月青Air to cloth ratio:空气对滤布比例 1.2 m/(m*min)Pressure drop:压降 15 mbarCompressed air consumption:压缩空气消耗约 500 Nm/h at 7 bar1.1 Design and function of the slag grinding plant矿渣研磨厂的设计和功能Details of the design and functioning of the individual machines or plant components of the slag grinding plant are given below.以下是矿渣粉磨系统内各单个设备或部件的设计和功能。1.1.1 Raw material feeding 原料进料The raw material which consists of slag and gypsum is conveyed via the speed-controlled weighbelts, item no. 5D1.WE01, 5D1.WE02 and 5D1.WE03 and is guided in a controlled flow rate in the troughed belt conveyor 5D1.BC01 in accordance with the set mix-ture.原料包括矿渣和石膏，经过调速皮带称(项目号5D1.WE01，5D1.WE02)流量控制，按照设定的混合比用槽形皮带机(5D1.BC01)输送。To protect the roller mill from metallic foreign bodies a suspended magnetic separator, item 5D1.MS01.MSJ01 and a metal detector, item 5D1.MT01.MTJ01 are installed above the common conveyor belt 5D1.BC02 of the raw material components. The suspended mag-netic separator basically consists of a permanent magnet, which is enclosed by a belt con-veyor provided with transverse galleries. During operation the iron parts attracted by the magnet are brought with this belt conveyor out of the area of the magnetic field and are dis-charged in a collecting container.为保护辊磨，清除金属异物，原料输送皮带机(5D1.BC02)上装有悬挂式电磁除铁器和金属探测器(项目号5D1.MS01.MSJ01和5D1.MT01.MTJ01)。悬挂式电磁除铁器主要包括一个永磁铁，配有一条横向的回转皮带。在操作中铁块物被磁铁吸起，当回转皮带超出磁力范围后铁块物掉落至收集箱内。We know from experience that the suspended magnetic separator alone does not remove alliron parts. Thick material layers on the troughed belt conveyor, coarse grain size ranges orsticky and moist material can make removal of the iron more difficult. Non-magnetic trampmetal also is no collected. Therefore, an additional metal detector (item 5D1.MT01.MTJ01)also is installed.根据经验，我们知道仅仅使用悬挂式电磁除铁器是不能除去所有铁颗粒的。皮带机上较厚的料层，较粗的进料粒径以及粘稠潮湿的物料都使除铁变得更加困难。另外，也无法除去无磁性的夹杂金属物，因此，需增加安装金属探测器。The metal detector contains transmitting and receiving coils with an alternating magnetic fieldof high frequency between them which is generated by an oscillator in the controller. When ametal part passes the field, eddy currents form as a result of induction and take away energyfrom the oscillator. A signal is formed from this which is relayed to the control system of thechange-over flap, item 5D1.CF01.CFJ01. The change-over flap removes the metal con-taining new feed material and discharges it in a container. To avoid frequent removals, it isnecessary not to detect tramp metal which is not greater than a minimum size. The smalltramp metal passes in the raw mill and is collected for the most part in the collecting devicefor light section steel of the bucket elevator.金属探测器包括转换器和在控制器中由振荡器产生高频的交变磁场的接收组件。当金属物通过 磁场时会产生涡流，结果形成感应并从振荡器中带走能量。从这里产生一个信号并延时传给转向阀(项目号5D1.CF01.CFJ01)的控制系统。转向阀将夹杂金属物的物料排放至收集箱中。为避免频繁的除去，不需要探测小于最小尺寸的夹杂金属。小的夹杂金属通过磨机进入提升机，大部分细铁颗粒在提升机装置内的收集器被收集。The rotary airlock feeder, item 5F1.CV01.CVJ01 is used as airlock for the roller mill. Toavoid caking of the slag the rotary airlock feeder is heated by a gas stream. The material isguided onto the grinding table via a chute which is also heated.锁风转饲机(项目号5F1.CV01.CVJ01)为辊磨密封空气用。为避免矿渣结块旋转喂料机通有热气加热。物料导入磨盘经过的料槽也被加热。1.1.2 Roller mill RMC 51/26 立式辊磨The general design of the roller mill is explained with Figure 1.立磨总图设计见图 1。The essential component of the roller mill is the grinding table with two concave grindingtracks (on the inside and outside) and the two roller pair units (designation 3) which run onthe bed of material. The grinding table is driven by the motor (2), the grinding rollers arefixed in their position. The raw material is fed to the mill via a chute and falls directly onto the centre of the grinding table. The material is then carried under the rollers by the rotation of the table. The ground material is flung outwards over the edge of the grinding table and en-trained in the stream of gas from the nozzle ring (9). All of the material ejected from thegrinding table, or a certain proportion of it is carried in the gas stream to the separator (10).辊式磨主要是由有2道凹形磨辊轨迹(内轨和外轨)的磨盘和运转在料床上的2组磨辊对(每组一对磨辊，标示3)组成。磨盘由马达(标示2)驱动，磨辊被固定在原位置。原料通过一个喂料槽直接落在磨盘的中心。然后料被转动的磨盘带动进入磨辊。被碾磨过的料向外甩出越过磨盘的边界进入从喷嘴环(标示9)来的气流中。被磨盘甩出的物料，全部或者一部分被气流带至选粉机(标示10)。The grinding force of the rollers is hydraulically applied on the material via the tie rods (5).The confining air system (7) protects the grinding roller bearings from entering dust. The bedof material can be stabilised with the water injection system (11).磨辊的碾磨压力来自液压系统，通过拉杆(标示5)加载在碾磨物料上。空气密封系统(标示7)保护磨辊轴承防止灰尘进入。喷水(标示11)可以稳定料床。The separator (10) classifies the ground material into finished product and oversize. Theoversize material falls back onto the centre of the grinding table (4), while the finished prod-uct is carried to the downstream filter by the stream of gas.选粉机(标示10)将研磨过的料分离成成品和过粗料。粗粉料落回磨盘(标示4)中心，成品则被气流带入下一步的收尘机中。The gas velocity in the nozzle ring (9) of the roller mill can be adapted to the grinding plantrequirements by adjusting the nozzle segments. Material lumps which cannot be carried tothe separator in the hot gas stream fall through the nozzle ring and are returned to the millvia the recirculating bucket elevator.磨机内喷嘴环(标示9)处的气流速度可以通过调整喷嘴截面来满足粉磨系统要求。粗物料无法被热气带至选粉机而掉落入喷嘴环内，通过外循环提升机送回到磨中。圖1：立磨总图設計Housing (1)壳体Drive Unit (2)驱动装置Roller pair units (3)辊轮组Grinding table (4)磨盘Tie rods (5)拉杆Hydraulic system (6)液压系统Confining air system (7)空气密封系统Dismounting device (8)拆解装置Nozzle ring (9)喷嘴环Seperator (10)选粉机Water injection (11)喷水1.1.2.1 Mill housing 磨机外壳Doors for inspection, maintenance, assembly and installation purposes are installed in theupper housing section of the roller mill. In sections particularly exposed to wear, the housingis provided with replaceable wear protection. The nozzle ring consists of Hard Faced Com-pound Steel Plate (VAUTID, EURODUR; or similar). Above the nozzle ring, DENSIT cas-settes(Ceramic Mortar) are installed at the lower end, and above them a scaled wear liningmade of a special AR-plate (CREUSABRO 4000).安装在磨机上部外壳上的门是为了检查、维护保养、组装及安装的目的。尤其在易受磨损的部位，磨机外壳提供了可更换的磨损保护件。喷嘴环是由表面硬化的复合耐磨钢板(VAUTID, EURODUR;或类似的)构成。在喷嘴环上面，较低部位安装的是DENSIT盒(陶磁砂浆)，上面部位是由特别的AR板(CREUSABRO 4000)制成的片状耐磨衬板。Hot gas is supplied to the roller mill housing via two hot gas pipe sockets. The seal betweenthe casing and the grinding table is a sliding contact seal. Dust cannot deposit, as alwayssmall quantities of false air enter through this seal.热风通过2个热风进口管接口进入磨机。在磨机外壳和磨盘间的密封是滑动接触式密封。因为密封间总是存在少量漏风，粉尘不能附着。To control the hot gas supply in the mill interior, the nozzle ring is installed above the hot gaspipe socket. The nozzle ring consists of several adjusting segments for varying the gas ve-locity by altering the cross-sections. The hot gas stream emerges at high velocity, entrainsthe material from the grinding table and carries it upwards to the SEPOL separator. The gasvelocity in the nozzle ring is a crucial parameter for the grinding process. The cross-sectionof the nozzle ring can be altered from outside.为控制磨机内的热风量，喷嘴环位于热风管接口之上。喷嘴环由数个可调节阀块组成，通过改变喷嘴截面可以调整气流速度。热风以高速流入，夹带着从磨盘甩出的物料，并将其向上带入SEPOL选粉机。在粉磨工艺操作中喷嘴环的气体流速是极重要的参数。喷嘴环的截面可以从磨机外面调整。復合式耐磨鋼板盒 子進 料1.1.2.2 Grinding rollers 磨辊The material on the grinding table is carried under the rollers by the rotation of the table. Thegrinding is performed by a total of 4 grinding rollers set in pairs which can rotate independ-ently. The bearing assembly is sealed by the rotary shaft seal. With the roller carrier, confining air is carried to the rollers in order to prevent dust from entering the grinding roller bear-ings. The roller tyres consist of wear-resistant Ni HARD IV or similar and are fixed on the roller body with clamping rings and studs.磨 輥磨輥架密封空氣接口磨盘上的物料被转动的磨盘带入磨辊下。共有4个磨辊以对辊方式作用，对辊中每个磨辊轮可以独立旋转。轴承组由旋转轴封密封。在磨辊架，密封空气被带入目的是为了防止灰尘进入磨辊的轴承。辊轮的辊胎是由耐磨的Ni HARD IV或类似的材料组成，辊胎用紧固夹和双头螺栓固定在辊体上。 The grinding roller guide and the single grinding-force application system allows the rollerpair units freedom of movement in all three planes. They can, for instance, move verticallyand pivot horizontally on their guide axle. If the inner roller is raised by coarse feed, theouter roller presses down with greater force on the material. Each roller thus supports theaction of the other. This interactive functioning of the rollers results in highly efficient grind-ing.磨辊导向轴和单辊压力平衡系统允许磨辊对可在3个自由度上移动。例如，它们能在垂直和水平方向围绕它的导向轴移动。如果内辊轮被加入的粗料顶起，则外辊轮会向下以更大的压力压料。每一对磨辊如此这般互相作用。这样的相互配合的功能实现了高效率的碾磨。The grinding force required for grinding the material is generated by a hydraulic system.Each grinding roller is running in antifriction bearings on an axle clamped in the roller carrier.The roller pair units are so guided by pins in corresponding guides that they can move verti-cally and pivot horizontally on their horizontal axle. They can therefore very well adapt them-selves to changes in the material bed depth and the entire grinding surface always remainsfully effective.粉磨物料需要的粉磨压力是由液压系统产生的。每个辊轮装在耐磨滚动轴承上，轴承安装于紧固在磨辊桥架的辊轴上。磨辊对由导向销引导，使得它们可以在垂直和中心水平围绕着水平轴运动。它们由此可在改变料床的深度时很好的调整自己，并使得整个碾磨表面一直保持有效的碾磨。1.1.2.3 Grinding table 磨盘The material falls directly onto the centre of the grinding table and is carried by the centrifu-gal force before the rollers.入磨物料直接落在磨盘中心上，并且通过离心力被带至磨辊下面。磨 盘磨盘衬板The grinding table is mounted direct onto the driving flange of the gear unit. It consists es-sentially of the following components:磨盘直接被固定在减速机的转动法兰上。它包括以下最主要的组件：_ the grinding