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)

1、ZRD40.5自身预热空气高炉煤气烧结点火炉使用说明书(对照)使用说明书OperatingManual用途UseZRD40.5川/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川烧结机进行料面点火及表层烧结。ZRD40.5m2/1.5mself-preheatingairblastfurnacegasignitionfurnaceappliestosinteringmachine(thewidthis1.5m,areais40.mn2)takingblastfurnacegasasignitionfuelforchargeleveligniti

2、onandsurface.设备特点EquipmentFeatures1、 、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150?250C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110050C的点火温度要求。Applyself-preheatingairtechnology,installairpre-heaterontheholdingzoneoftheignitionfurnace,preheatairbyusingradiationheatofsurfaceandpartialheato

3、fignitionpart,providing150?250Ccombustionairwithoutaddingthermalresource,anditcanimprovethetheoreticalcombustiontemperatureofblastfurnacegasaswellasmakingignitionfurnacemeettheignitiontemperaturerequirementsabout*Cwenitigniteswithblastfurnacegasalone.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，

4、烧嘴不易堵塞。Applystrongrotationalflowandlowpowertube-typegasburnertomixtoafullextentaswellasshortenthelengthoftheflame,theheightofthehearthboxisabout550mm,besides,thiswillalsoreduceradiationlossofthechamberwallandtheburnerisnoteasytoblock.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。Thearrangementofth

5、eburnerisreasonable:Applythree-rowlayout,whichcanformahightemperatureribbonflametoigniteinalowtemperatureandhighthermalstrengthandreduceignitionthermalloss.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。Applybodytypebearingforthefurnace,constructfurnaceroofandchamberwallwithrefractorypre-cast,whichwillbring

6、aconvenientconstructionandinstallationandashortcycle.三、设备系统组成EquipmentSystemComponents四、主要技术性能IV?MainTechnicalPerformance序号名称单位数备注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建议点火炉

7、用助燃风机（2台；一用一备）919M6.3A电机Y225M218.5KWQ=3220-5153Nrr/hH=9149?9055PaNo.NameUnitValueNotes1Sinteringmachinespecificationsandtypes40.5draper-type2Trolleydimension3TrolleyspeedPlaneutilizationfactor5Outputofmine6Ignitiontemperature7Ignitiontime8Blastfurnacegasthermalvalue9Blastfurnacegascontactpressure10B

8、lastfurnacegasdustcontent11Ignitionblastfurnacegasconsumption12IgnitionblastfurnacegastemperatureNormaltemperature13Ignitioncombustionairconsumption14Ignitioncombustionairtemperature7/2615IgnitionburnerformExtension-typeburner16Ignitionburneramount15(3rows)17Air-pressureinfrontoftheignitionburner18G

9、aspressureinfrontoftheignitionburner19Suggestingusingcombustion-supportingfanforignitionfurnace(twosets,oneforusing,andtheotherforalternation)919M6.3A,electricalmotorY225M218.5KWQ=3220-5153NrmhH=9149?9055Pa五、设备及系统安装(详见安装说明)V.Equipmentandinstallationforsystem(seeinstallationinstructionsfordetails)1、烧

10、结点火炉安装：Installationofignitionfurnace1.1、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。Installinplacetheignitionfurnacemantlesteelstructureontheattachmentrailofthesinteringmachineignitionfurnace.、点火炉砌筑耐火炉衬按图在点火炉炉壳钢结构内部砌筑。Constructtheignitionfurnacemasonryrefractoryliningintotheignitionfurnacemantlesteelstructureaccordi

11、ngtothedrawing.、按图安装管式点火煤气烧嘴。Installtube-typeignitiongasburneraccordingtothedrawing.、空气预热器按图在炉体内就位。Installinplacetheairpre-heaterinsidethefurnaceaccordingtothedrawing.、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；Installairandgaspipelineinfrontofthefurnaceandrelevantadjustingva

12、lve,emissionpipelineandsweepingpipelineaccordingtothedrawing;Installliquefiedpetroleumgasignitionburner;installignitionfurnacecombustion-supportingfan,providingaconnectionforairandgaspipelineinfrontofthefurnacewithairandgasmainpipeline;、安装温度、压力、流量测试仪表；Installtemperature,pressure,andratetestinstrumen

13、tation;、用木材和煤气按烘炉曲线烘炉。Bakingaccordingtothebakingcurvewithwoodsandgas.2、管路安装要求：Installationrequirementsforpipeline2.1.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。Checkpipefittingsandvalvesofeachsectionpipelinebeforeinstallation,clearrollscale,weldingslagandothersundriesinsidethetube.、安装时应按照GBJ235-82工业管道工程施

14、工及验收规范(金属管道篇)及设计图中有关技术要求进行。InstallaccordingtotherelevanttechnicalrequirementsinGBJ235-82Industrialpipeconstructionandacceptancespecification(metalpipe).、整体系统管路联接后进行气密性试验：煤气管路试验压力35KPa，1小时压降v1%空气管路t佥压力25KPa1小时压降V2%式验合格后方可投产。Testingairtightnessaftertheoverallsystempipingisconnected:gaspipelinetestingp

15、ressureis35kpa,pressuredropislessthan1%everyhour;whileairpipelinetestingpressureis25kpa,andthepressuredropislessthan2%.Putitintoproductionifthetestingresultisqualified.、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。Installessentialtemperature,pressur

16、e,andflowindicatinginstruments,controldevicesandalarmdevicesonreservedmeasurementpointsandassignedpositionoftheignitionfurnace.Setuppurgetubeundertheair,gaspipelineinfrontofthefurnace,thensetupexhauststack,andgasignitiontestingtubetothehighestpositionofthepipingsystem;lastly,installhydrophobicpiping

17、valvestothelowestpositionofthegaspipeline.六、安全生产操作规程W.Operationalspecificationsforsafetyproduction（一）、点火试车、投产调试前的设备检查、准备工作CheckingandpreparatoryproceduresofEquipmentsbeforeignitiontest,productionandadjusting.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。Exam

18、inecarefullywhethertheinstallationofthewholeignitionequipmentiscorrectaccordingtothedesigningdrawing,andifthereisamissingpart.Especiallytocheckthatwhetherthedirectionandconnectionofeachair,gaspipelineiscorrect.Whetherthegasexhauststackhasbeeninstalled,andwhetherthearrangementoftheignitionburneriswit

19、hinthesinteringmachinebellows.Lastly,cleanupthedebrisinsidethefurnace.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。Checkcombustionfan,primaryandsecondarythermalmeasurementinstrumentsandmeters;eachsignalindicator;eachswitchandope

20、ratoronthecontrolconsole;allmanualorelectricaladjustablecontrolvalves（allvalvesshouldbeoffbeforeignition,openthemonebyonewhenignitinganddebuggingaccordingtotheproceduresandrequirements）.Toigniteanddebugafterconfirmingthateverythingisrightandallcanoperateflexibly.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

21、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35KPa保压1小时压降v1%空气管路试验压力25KPa,保压1小时压降v2%），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15?20分钟。打开风机吹扫空气管路1013/26分钟。AccordingtotherelevanttechnicalrequirementsinGBJ235-82Industrialpipeconstructionandacceptancespecification(metalpipe),Testingairt

22、ightnessfortheairandgaspipelineandtheconnectingplaceofeachvalveaftertheoverallsystempipingisinstalledandconnected(usually,gaspipelinetestingpressureis35kpa,pressuredropislessthan1%everyhour;whileairpipelinetestingpressureis25kpa,andthepressuredropislessthan2%).Putitintoproductionifthetestingresultis

23、qualified.Inthesametime,sweepgaspipelinewithsteamornitrogenbeforeproduction,opentheelutionvalveforelution,theelutiontimeisabout15to20minutes.Thenturnontheblowertopurgeairpipelinefortenminutes.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。Thepowerdepartmentshouldcheckandconfirmwhetherthepressure

24、ofgasnodeenteringplantiswithintheproductionrequirements(4.5Kpa).Putitintooperationafterconfirmation.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。Bakewithwoodandgasstrictlyfollowsthebakingcurve.Itisbettertotakeignitionandproductiondebuggingimmediatelyafterthebakingisfinished.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）

25、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。Extractgasthroughthegassamplingtubeofignitionfurnace（usuallyinstalledonthegasexhauststackwhichisonthetopoftheignitionfurnace）forignitiontest,thustoensurethatthegasusedforignitionhasbeenguidedinsidethegaspipelineoftheignitionfurnace,thenignitiontestandproduc

26、tiondebuggingcanbeputintooperation.（二）、点火启动Ignitionstarting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。Dorememberthatthereisenoughopenflameinsidetheignitionfurnacebeforestartingignitiontoensurethattheseisnogasleak,nofire,nodeflagration,whichinturnwillensureasafeandsuccessfulignition.1、开启点火炉

27、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。Openthecombustionfanofignitionfurnace,controlvalveofairpipeline;controlvalveofgaspipeline;spindleventilatorofsinteringmachine.Transportairandgastoeachbranchpipevalveofignitionfurnace,aswellasopenspindleventilatorflashboardofsintering

28、machineappropriately.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。Thereareseveralwaysforignitingignitionfurnaceburner:Igniteacertainamountoffirewoodorlinoleumbelowtheignitionburnerandwithinacertainrange,therangeandintensityoftheflameshouldbelargerIgnitedirectlytheopenf

29、lameinsidethefurnaceafterthebakingisfinished.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1/3?1/4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1/3?1/4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。Ignitionoftheburnershouldbeoper

30、atedaccordingto“airaftergas;openflameignitionandsmallflowignition”o.pIfenflameisavailable,firstopentheairandgaspipeadjustingvalveofignitionfurnaceinasmallamount(about1/3to1/4),thenopentheairandgasimportadjustingvalveofignitionburner(ifany:about1/3to1/4)onebyoneorrowbyrow,igniteeachburneroreveryrowof

31、burners.Whentheburnersofignitionfurnaceareallignitedsuccessfully,pleaseensuretograduallyincreasethesupplyofairandgasinthepremiseofthattheburnerwillnotbeofffire,inthisway,adjusttheamountofairandgastothebestdesignratioandgetthegasfullycombusting,inthesametimeadjustandopenthespindleventilator17/26flash

32、boardofthesinteringmachine.Inthiscase,theignitionhasbeensuccessfullyoperated.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。Iftheignitionisnotsuccessful,itshouldturnoffthegasvalveimmediately,andthenturnofftheairvalveuntilthegasinsidethegaspipelinehasbeenreleasedtotally,thenfindoutthe

33、reasonsandreigniteaccordingtotheaboveproceduresafterappropriateadjustment.（三）、调试Debugging1、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。Whenusingignitionfurnaceforignitiontestandproductiondebugging,ensurethatgascancombustcompletely,theflamelengthismoderateandthetemperaturefield

34、isuniform,aswellasthattheignitionfurnacechamberisworkingundersub-pressureofpressure-firedandtheignitiontemperatureisinlinewiththerequirementsofdesigningandproduction.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

35、效果、点火温度。Iftheignitionissuccessful,itshouldgraduallyadjusttheopeningdegreeofthespindleventilatorflashboardandthatofeachairandgasadjustingvalvestomakesurethathigh-temperaturepartoftheignitionburnerflamecancontactwiththesurfaceofthesinteringore,thatistosay,ensurethatthelengthoftheflamecankeeptheouterfl

36、amebeincontactwithchargeleveltotrytokeeptheflameofthechargelevelawayfromanyshadows,ifthereisanyshadows,thisindicatesthatthehigh-temperaturezoneisnotonthechargelevelorthecombustionofthegasisnotsufficient,whichwillaffecttheignitioneffectandtemperature.3、调整最佳火焰状态以获得较高的点火温度。Adjustthefurnacetothebestflam

37、estatustoobtainahigherignitiontemperature.、正常情况下点火炉炉膛内为微负压,火焰不外溢,火焰颜19/26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。Normally,thepressureinsidetheignitionfurnaceisslightnegativepressure,theflamewillnotspill,andtheflamecolorisbrightwhite.Yell

38、owandturbidflamecolorindicatesthatthesupplyamountofcombustionairissufficientandthatofgasisless,inthiscase,itneedsincreasingthesupplyamountofgasandreducingthatofcombustionair.Whileblueandturbidflamecolorindicatesthatthesupplyamountofgasissufficientandthatofcombustionairisless,inwhichcaseneedsreducing

39、thesupplyamountofgasandincreasesthatofcombustionair.、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。Whenadjustthecombustionflamestateoftheburner,itshouldgraduallyincreasegasvolume,nottoaddtotheamountonetime,butalsogradua

40、llyincreasetheamountofcombustionairwiththeincreaseofgasamounttomakegasandcombustionairachieveareasonableandidealratio,whilethisdoesnotmeanaboutmoresupplyofgasandhigherignitiontemperature,anoptimumignitiontemperatureandeffectcanbeachievedonlywhentheratioofgasandairisreasonableforgastocombustcompletel

41、y.、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。Inthecaseofahigherignitiontemperatureandbetterignitioneffect,thesurfaceofsinteringorewillshowdarkblueandsinteringoreisinsemi-moltenstate,thismeansthattheyarebondedbetterandthestrengthenishigher.、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

42、。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。Iftheburnerflameonbothsidesofthefurnacespillsoverthesinteringmachinesideboard,itshouldappropriatelyturndownthecombustionpowerandreducethesupplyofgasinordertoweakenthespillover

43、phenomenon.Seriousspillingmeansthattheairpermeabilityofsintermixtureispoor,moisturecontentistoosmallorthespindleventilatorisblock,whichneedschecking,excluding,adjust,andprocessingonebyone.Iftheignitioneffectandstrengthofbothsidesofsinteringmachineispoor,itshouldimprovetheburnercombustioncapacityonbo

44、thsidesandincreasethesupplyofairandgastoweakenthepoorignitioneffectandstrengthoftheedgeofsinteringmachine.（四）、熄火停机（分正常熄火停机、应急熄火停机两种）Flameout（includingnormalflameout,emergencyflameout）1、正常熄火停机：1. Normalflameout、熄火顺序：先关点火烧嘴，最后关助燃风机。Orderofflameout:firsttoturnofftheignitionburner,andthenturnoffthecombu

45、stionfan.、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22/26净，准备下一次点火投产。Firstclosethevalveofthegaspipelineuntiltheburnerisoff,supplyingairinasmallamountforabouttwominutes,andthenclosethevalveoftheairpipeline,inlettingsteamornitrogenintotheair,gaspipeline,lastly,openv

46、alveofexhauststacktoreleasetheresidualairandgasclearlyforthenextignitionandoperation.2、应急熄火停机：2. Emergencyflameout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。Ifthereissomethingwrongwiththefan;itneedstocutoffpower,whenthepressureofair,gasistoolow,itisbe

47、ttertocutoffpowerquickly;duringashort-termstopforrepairing,itshouldopenthegasexhauststackintime,turnoffthegasbranchpipevalveinfrontoftheignitionfurnace,thenturnoffthegasimportedvalveinfrontoftheignitionburner,openthesteamornitrogenpipingtopurgeandelutethegaspipelineifnecessary.（五）、生产中需注意的事项Notesforp

48、roduction1、 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. Whenadjusttheopeningofcombustionairorgas,eventhevalvehasbeenopenedtothemaximumextent,thesupplyamountofcombustionairandgas,combustionstateoftheignitionburnerandignitionshouldnotchange

49、toomuch,whathappenshereindicatethatthereissomethingwrongwiththevalveofthesystem,whichmakesitnecessarytocheckonebyoneinfrontoftheignitionfurnaceandre-debugaftertheerrorisruledout.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。3、 Aftertheadjustmentofthevalveplateopeningofcombust