烧成系统
Burning System
1. 概述 General 烧成系统包括生料均化库的生料出库系统和生料入窑（337/338 子项）、烧成窑尾（417/418 子 项）、烧成窑中（437/438 子项）、烧成窑头（447/448 子项）、熟料库及熟料输送的进库系统（457/458 子项）、旁路放风及回灰输送（427/428）共 6 个子项。 本系统的核心部分：烧成窑尾、烧成窑中、烧成窑头的主机分别由 SINOMA 提供了在线旋喷 式分解炉和双系列六级预热器组合成的窑外分解系统；SINOMA 提供了 Φ6.2×92m 回转窑；IKN 提 供了中部带辊式破碎机的推动篦式冷却机；PILLARD 提供了窑和分解炉燃烧器系统等，另外配置有 旁路放风系统。 本操作规程是根据本系统特点和要求，为保证系统正常运行和生产而提出的主要操作事项。操 作人员须在全面掌握规程中各项操作要领的同时，还必须通晓系统中每台设备的性能和操作维护等 方法与要求，以便在实际生产操作中能及时解决随时可能出现的各种问题，并可根据实际情况灵活 调整，系统中每台设备性能和操作维护的详细方法与要求，请参阅各相应设备供货厂商另行提供的 单机使用说明书。当其内容与本操作手册有矛盾时，以设备供货厂商提供的单机使用说明书为准。 本操作手册仅限于 HOFUF CEMENT PLANT 5TH/6TH EXTENSION PROJECT 2×10000t/d 熟料水泥生产线的烧成系统生产操作使用。The burning system includes the raw meal delivery system of a raw meal homogenizing storage and a total of six subitems, such as raw meal into kiln (Subitem 337/338), calcinating kiln inlet (Subitem 417/418), calcinating kiln middle (Subitem 437/438), calcinating kiln outlet (Subitem 447/448), clinker storage and storage entry system for clinker conveyance (Subitem 457/458), and bypass and returned ash conveyance (Subitem 427/428).
For the core part of this system, the main machines for the calcinating kiln inlet, calcinating kiln middle and calcinating kiln outlet, SINOMA has provided the on-line rotary spray precalciner and the outside-the-kiln decomposition system combined by Two-string six-stage preheaters , SINOMA has provided the Φ 6.2 × 92 m rotary kiln, IKN has provided the pendulum grate cooler for the middle roll crusher, and PILLARD has provided the kilns the precalciner burner system, etc. Besides, a bypass system has been arranged.
This operating procedure has some main items put forward according to this system’s characteristics and requirements, and for ensuring its normal running and production. An operator shall thoroughly understand the performance, operation, maintenance and so on of each piece of equipment in the system at the time of grasping various operating essentials in the procedure so as to in time solve various problems that may appear at any time in actual production and operation, and according to an actual circumstance, shall make flexible adjustment. For the detailed methods and requirements for the performance, operation and maintenance of each piece of equipment in the system, please refer to a single machine instruction book provided by a corresponding equipment supplier. If the contents of the book with those of the single machine instruction book provided by equipment supplier conflict, those of the single machine instruction
book provided by equipment supplier will be finalized.
This operating manual is used only for the production and operation of the burning system of the clinker cement production line in the Hofuf Cement Plant 5th/6th Extension Project 2 ×10,000 t/d. 2．生产工艺流程简述 Brief Description of Production Process Flow
烧成系统的范围从生料由均化库充气卸料开始，经预分解系统预热、预分解后入回转窑煅烧成 水泥熟料，经过推动篦式冷却机的冷却和破碎后，由链斗输送机送至熟料库顶为止。 本系统可分为生料入窑、生料预热与分解（烧成窑尾）、窑头热风引至分解炉（三次风管）与 熟料煅烧（烧成窑中）、熟料冷却与废气处理和窑头燃烧系统（烧成窑头）、熟料输送、旁路放风及 回灰输送六大部分。 烧成系统的范围从生料由均化库充气卸料开始，经预分解系统预热、预分解后入回转窑煅烧成 水泥熟料，经过推动篦式冷却机的冷却和破碎后，由链斗输送机送至熟料库顶为止。 本系统可分为生料入窑、生料预热与分解（烧成窑尾）、窑头热风引至分解炉（三次风管）与 熟料煅烧（烧成窑中）、熟料冷却与废气处理和窑头燃烧系统（烧成窑头）、熟料输送、旁路放风及 回灰输送六大部分。
The range of the burning system starts from raw meal gas filling and unloading in the homogenizing storage, preheating in the predecomposition system, the calcination into cement clinker in the rotary kiln after precalcining system, the cooling and crushing of the pendulum grate cooler, and ends at the sending to the top of the clinker storage by the chain bucket conveyor. This system may be divided into the six parts, including raw meal into kiln, raw meal preheating and precalcining (calcinating kiln inlet), kiln outlet hot wind introduction into the precalciner (tertiary
air duct) and clinker calcination (calcinating kiln middle), clinker cooling, waste gas treatment and kiln outlet combustion system (calcinating kiln outlet), clinker conveyance, bypass, and returned ash conveyance.
The range of the burning system starts from raw meal gas filling and unloading in the homogenizing storage, preheating，precalcining in the system, the calcination into cement clinker in the rotary kiln system, the cooling and crushing of the pendulum grate cooler, and ends at the sending to the top of the clinker storage by the chain bucket conveyor.
This system may be divided into the six parts of raw meal kiln entry, raw meal preheating and precalcining (calcinating kiln inlet), the hot air out of kiln outlet introduced into the precalciner (tertiary air duct) and clinker calcination (calcinating kiln middle), clinker cooling, waste gas treatment and kiln outlet combustion system (calcinating kiln outlet), clinker conveyance, bypass, and returned ash conveyance.
2.1 生料入窑 Feeding Raw Meals into the Kiln
生料均化设置了一座Φ28m、储量为 40000t的连续式生料均化库（337SB1/338SB1），生料经 过库底外环区轮流分区充气均化，进入中心混合仓，在混合仓被充气搅拌均匀后，由流量控制阀
（337DV1,DV2/338DV1,DV2）卸出，DV1 与DV2 互为备用，卸料能力：1000t/h，卸出的料经空气
输 送 斜 槽（ 337AS2/338AS2 ） 和 胶 带 斗 式 提 升 机 （ 337BE4/338BE4 ） 再 经 空 气 输 送 斜 槽
称重传感器（337LI1/338LI1）控制库底流量阀（337DV1，DV2，/338DV1，DV2）开度，保证计 量仓内有相对的固定料位。计量仓内的生料经过仓底流量控制阀（337DV3，DV4，DV5/338DV3， DV4，DV5）、固体流量计（337FM1，FM2，FM3/338FM1，FM2，FM3）后，再由空气输送斜槽 （337AY1，AY2，AS4，AS5，AS6/338AY1，AY2，AS4，AS5，AS6）、胶带斗式提升机（337BE5， BE6，BE7/338BE5，BE6，BE7）、预热器顶部斜槽（337AS7，AS8/338AS7，AS8）输送，经回 转锁风阀 （337RF7，RF8/338RF7，RF8）、气动闸板阀（337SGL，SGM/337SGL，SGM）分别 喂入窑尾双系列预热器（417PH1/418PH1）。计量仓底流量控制阀至喂料提升机为两用一备。其中 仓 底 流 量 控 制 阀 （ 337DV3/338DV3 ）、 固 体 流 量 计 （ 337FM1/338FM1 ）、 空 气 输 送 斜 槽 （337AS4/338AS4）、喂料提升机（337BE6/338BE6）为备用系统。另外提升机出口设有多个电动 开关阀，用于控制生料是入窑还是返回均化库。 固体流量计的流量信号控制仓底流量控制阀的开度，以保证生料以设定的流量稳定地喂入窑尾 系统。计量仓底设置备用出口的目的是当主出口有故障时，生料经由备用出口喂入。
A Φ28m continuous raw meal homogenizing storage (337 SB1/338 SB1) with a storage capacity of 40,000t has been built. An raw meal passes the storage bottom outer ring area for alternation zoning gas filling and equalization, enters the central blending bin, and after the gas filling and uniform agitation in the bin, is unloaded from the flow control valves(337 DV1, DV2/338 DV1, DV2). DV1 and DV2 is on stand by for each other. The unloading capacity is 1,000t/h. The unloaded material enters the raw meal measuring bin (337 BI1/338 BI1) through theair slide (337 AS2/338 AS2) and the belt bucket elevators (337 BE4/338 BE4) and through the the air slide (337 AS3/338 AS3). The capacity of the measuring bin is 250m3 .The weighing sensors(337 LI1/338 LI1) in the measuring bin control the spans of the storage bottom flow valves(337 DV1, DV2, /338 DV1, DV2) to ensure that the measuring bin has a relatively fixed material level. An raw meal in the measuring bin passes the bottom flow control valves(337 DV3, DV4, DV5/338 DV3, DV4, DV5),the solid flow rate gages(337 FM1, FM2, FM3/338 FM1, FM2, FM3), then is transported through the the air slide (337 AY1, AY2, AS4, AS5, AS6/338 AY1, AY2, AS4, AS5, AS6),belt bucket elevators (337BE5，BE6，BE7/338BE5，BE6，BE7) and the preheater top chute(337 AS7, AS8/338 AS7, AS8), and finally is fed into the kiln inlet double series preheaters(417 PH1s/418 PH1s) through the rotary air-lock valve (337RF7，RF8/338RF7，RF8) and the pneumatic paddle valves (337 SGL, SGM/337 SGL, SGM) respectively. For the flow control valve of on the measuring bin bottom and the feeding elevators, two of them are in use and one is on stand by. Among them, the flow control valves on the measuring bin bottom (337 DV3/338 DV3), solid flow rate gages (337 FM1/338 FM1), the air slide (337 AS4/338 AS4) and the feeding elevator s(337 BE6/338 BE6) are standby systems. In addition, an elevator outlet is equipped with many dynamoelectric switch valves, used for determining whether a raw meal is to go into a kiln or return to the homogenizing storage.
A flow signal of a solid flow gage controls the span of a storage bottom flow control valve to ensure that an raw meal is stably fed into the kiln inlet system at a preset flow rate. The aim of a standby outlet built on the measuring bin bottom is that when the main outlet has a fault, an raw meal will be fed in via a standby outlet.
2.2 生料预热与分解（烧成窑尾）Preheating and precalcining of Raw Meals (Calcinating Kiln
Inlet)
顶部旋风筒为一级即C1，底部旋风筒为六级即C6，旋风筒的规格：4-C1：Φ6200mm，2-C2，C3： Φ8400mm，2-C4：Φ8800mm，2-C5，C6：Φ9000mm。生料粉经计量由提升机等输送设备送入 C2旋风筒气体出口管道内，在气流作用下立即分散、悬浮在气流中，并随气流进入C1旋风筒。气料 分离后，料粉通过重锤翻板阀进入C3旋风筒气体出口管道，并随气流进入C2旋风筒。这样经过五级 热交换后，生料粉得到了充分预热，经C5旋风筒气料分离后通过重锤翻板阀喂入分解炉，物料在分 解炉内吸热分解后，随气流进入C6旋风筒，分离后喂入窑内，此时物料的分解率可达到95%左右。 而废气沿着逐级旋风筒及气体出口管道上升，最后由一级旋风筒出风管排出，经高温风机337IF1， IF2/338IF1，IF2）送往原料粉磨和窑尾废气处理系统。 为防止气流沿下料管返窜而影响分离效率，在各级旋风筒下料管上均设有带重锤平衡的翻板阀。 正常生产中应检查各翻板阀动作是否灵活，必要时应调整重锤位置，控制翻板动作幅度小而频繁， 以保证物料流动顺畅、料流连续均匀，避免大幅度地脉冲下料。为了防止旋风筒锥部和下料管结皮、 堵塞，在C6~C3旋风筒的锥部和C6~C4旋风筒下料管的拐点处设有空气炮（417BQ1~K/418BQ1~K） 清堵系统。
The kiln inlet system uses double-serial six- stage preheaters and consists of cyclones, connecting pipes, feeding pipes, an on-line rotary spray precalciner, etc. A top cyclone is Class 1, namely C1, and a bottom cyclone is Class 6, namely C6. The specifications of a: 4-C1: Φ 6200 mm, 2-C2, C3: Φ 8400 mm, 2-C4: Φ 8800 mm, 2-C5, C6:Φ 9000 mm. After measurement, raw meal powder is sent into a C2 cyclone gas outlet pipe from such conveyance equipment as an elevator, etc. is immediately dispersed and suspended in an air flow by the agency of the air flow, and with the air flow, enters a C1 cyclone. The material powder passes a heavy bob flap valve to enter a C3 cyclone gas outlet pipe after the separation material out off gas, and with an air flow, enters a C2 cyclone. Thus after five-level heat exchange, raw meal powder receives full preheating, and after the separation of a C5 cyclone gasified material and through a heavy bob flap valve, is fed into the precalciner. After a material absorbs heat and is decomposed in the precalciner, it will enter a C6 cyclone, and after separation, it will be fed into a kiln. At this time, the decomposition rate of the material can attain to 95% or so. And the waste gas will rise along various cyclones and gas outlet pipes, and finally is discharged by one air duct and sent by high temperature induce draft fan (337 IF1s, IF2/338 IF1s, IF2) to a raw material powder mill and a kiln inlet waste gas treating system.
In order to prevent an air flow from returning along a discharging pipe so as to influence the separation efficiency, a discharging pipe in each cyclone is equipped with a flap valve with heavy bob balance. In normal production, check whether the movement of each flap valve motion is vivid or not. When it's necessary, adjust the position of a heavy bob and make sure that the movement range of a flap valve is small and frequent so as to ensure a material flow is smooth, continuous and even and to avoid significant pulse discharge. In order to prevent the conic section of a cyclone and a discharging pipe from surface crusting and blockage, the inflection points at the conic sections of the C6~ C3 cyclones and C6~ C4 cyclone discharging pipes are equipped with air cannon(417 BQ1~ K/418 BQ1~K) blockage-clearing system.
分解炉（Φ8.8×37m）采用了在线旋喷形式。分解炉燃烧所需的三次风分别从锥部两侧割向对 旋进入，形成旋转上升气流，窑尾烟室的烟气从分解炉底部进入，被包裹在中间，使氧浓度形成了 外圈高，中心低的分布。分解炉柱体下部设有4个燃烧器（417BU1~4/418BU1~4）间隔互为90°，4 个燃烧器的喷出气流又构成了旋转流场，环形的富氧浓度区为4个燃烧器形成的环形火焰区提供了良
好的燃烧条件。物料在分解炉柱体下部由两侧喂入，由于喂料落差造成的下降惯性，物料在入炉的 瞬间打击在撒料板上被分散，炉底部的旋转上升气流强化了分散效果，并携料在上升气流中快速分 解。
The precalciner(Φ 8.8×37 m) uses the on-line rotary spray form. The tertiary air needed by the combustion in the precalciner enters the two sides of the conic section in a disrotatory way, forming a spiraling-up air current. The fumes from the kiln inlet smoke chamber go in from the bed of the precalciner and are wrapped up in the middle, making the oxygen concentration form a distribution of being high on the outer ring and low at the center. The lower part of a precalciner column is equipped with 4 burners (417 BU 1~4/418 BU 1~4) at intervals of 90 °with each other. The ejected air current from the 4 burners forms a rotary flow field. The annular rich oxygen concentration zone provides a good combustion condition for the annular flame zone that the 4 burners form. A material is fed in from the two sides of the lower part of the precalciner columns. Because of the descending inertia resulted in by a feeding falling head, the moment the material goes into the furnace, it is struck onto the distribution board and dispersed. The spiraling-up air current from the furnace bottom enhances the dispersion effects, and together with a rising air flow, is quickly decomposed in an ascending air current.
为分解炉配置的4个燃烧器由Pillard供货，可燃烧原油和天然气。燃烧器的总能力：260GJ/h， 每个燃烧器的燃油量（5200kg/h，normal；5900kg/h，max）或燃气量（6900Nm3/h，normal； 7900Nm3/h，max）。4个燃烧器燃油或燃气时，分别由4个燃油（417VT2~5/418VT2~5）或燃气 （ 417VT7~a/418VT7~a ） 的 小 阀 组 控 制 ， 而 4 个 燃 油 或 燃 气 的 小 阀 组 又 分 属 于 燃 油 （417VT1/418VT1）或燃气（417VT6/418VT6）的大阀组控制。原油由专供分解炉的双联高压泵 （L37FP1/ L38FP1）送至燃油的大阀组。一般情况下，燃料量的调节是在中控室通过调节大阀组上 的流量阀实现，小阀组上的阀需要现场调节，通常调试好后基本保持不变，通过阀组的显示仪表判 断各燃烧器的工作状态。燃烧器的燃烧空气的4~6%由燃烧器风机（417FN1/418FN1）提供，风机 的性能参数为：风量：473.3m3/min，风压：12000Pa，功率：160kW。该风机除提供燃烧器的燃 烧空气外，在系统正常或故障停机时，用于燃烧器的冷却。
The 4 burners arranged for the precalciner was supplied by Pillard, and they can burn crude oil and natural gas. The total capacity of the burners: 260 GJ/h, the burnt oil capacity of each burner(5200 kg/h, normal;5900 kg/h, max)or the burnt gas capacity (6900 Nm3/h, normal;7900 Nm3/h, max). While the 4 burners are burning oil or gas, they are respectively controlled by 4 small valve train for burning oil( 417 VT 2~5/418 VT 2~5) or 4 for burning gas(（417VT7~a/418VT7~a）.The 4 small valve train for burning oil or gas are controlled by the big valve train for burning oil(417 VT1/418 VT1) or for burning gas(417 VT6/418 VT6). The crude oil is sent by the duplex high pressure pumps （L37FP1/ L38FP1）special for the precalciner to the big valve train used for burning oil. Under a general circumstance, the adjustment of a fuel quantity is carried out by adjusting a flow rate valve of a big valve train in the central control room, while a valve of a small valve train needs to be adjusted on the spot. Usually, the debugging is kept fundamentally constant. From an indicating instrument of a valve train, you can judge the operating state of each burner. 4~6% of the burnable air of the burners is provided by the burner fan (417 FN1/418 FN1). The performance parameters of the fan are: air volume: 473.3 m3/min, air pressure:12,000 Pa, power:160 kW. In addition to providing burnable air for the burners, the fan is used for the cooling of a burner after the system’s normal or disorderly closedown.
预分解系统中的每级旋风筒的出口风管上均设有温度、压力测点，旋风筒锥部设有压力测点， 料管设有温度测点。分解炉中部和出口设有温度、压力测点。窑尾烟室、分解炉出口、C1 出口风管 均设有在线气体分析仪，C6 下料管上设有在线热料取样和送样系统，可随时可监视系统的预热、煅 烧、分解和运行状况。 正常情况下，系统的总阻力损失为 5800~6500Pa，出一级筒飞灰量约 70g/Nm3，废气温度为 280～310℃。炉出口温度可控制在 860～880℃之间，入窑物料表观分解率可达 90%以上。 由于该项目的原料中，氯含量超标，在窑尾上升烟道上设有旁路放风的抽风口，该部分见后面的专 题介绍。
The outlet air duct of each cyclone in the precalcining system is furnished with temperature and pressure measuring points, the conic section of a cyclone has pressure measuring points and a discharging pipe has temperature measuring points. A kiln inlet smoke chamber, a precalciner outlet or a C1 outlet air duct is equipped with an on-line gas analysis instrument, and a C6 discharging pipe is furnished with an on-line hot material sample-taking and sample-sending systems, which can at any time monitor the preheating, calcination, decomposition and operation in a system.
Under a normal circumstance, the total resistance loss of the system is 5800~6500Pa, the outlet air duct of C1 dust content is about 70 g/ Nm3
, and the exhaust temperature is 280-310 ℃.The furnace outlet temperature can be controlled at 860-880 ℃, and the apparent decomposition rate for a kiln-entering material can reach 90% or above.
As in the raw material for this project, the chlorine content has exceeded the standard, bypass air vents have been built on a kiln inlet ascending smoke flue. For the contents of this part, see the special-subject introduction at the back.
尽管该项目设有旁路放风系统，本系统在生产过程中仍必须充分重视可能发生的结皮堵塞现 象，并在生产操作中严加防范。一般在系统易结皮或堵塞的部位均设有清灰孔或捅料孔，可根据实 际生产具体情况定期清理结皮或处理积料；经长期生产经验证实某些不必要的孔洞也可封死，以减 少系统漏风。另外，在系统中还预留了一些空气炮的安装孔，可根据实际生产中结皮、堵塞的具体 情况，调整空气炮的安装位置。
Though the project is equipped with a bypass system, it is necessary to fully value the surface crusting and blockage phenomena that may occur in the procedure in production and sternly guard against them in production and operation. Generally, a part of the system with easy surface crusting or blockage has ash-clearing holes or material-poking holes, which, according to a concrete production circumstance, can periodically help clear off the surface crusting or treat accumulated materials. It is verified from long-time production experience that some otiose holes may also be sealed dead to reduce air leaks in the system. Besides, the system has also reserved some installation holes for air cannons. You can adjust the installation position of an air cannon according to a concrete circumstance of surface crusting or blockage in actual production.
2.3 窑头热风引至分解炉与熟料煅烧（烧成窑中） Leading hot air at the kiln outlet into the
Precalciner and clinker calcinating (Middle of the Calcinating Kiln)
两根外径为 Φ3000mm 的三次风管（437TD1，TD2/438TD1，TD2），一端与篦冷机的前端两侧
有电动闸板阀（437TV1，TV2/438TV1，TV2），通过调节窑尾的 ID 风机的转速和电动闸板阀的开 度来控制三次风的用量。
For one of the two tertiary air ducts (437 TD1, TD2/438 TD1, TD2)with an outside diameter of Φ 3000 mm, one end is connected with the tuyeres of the front-end two sides of a grate cooler, and the other end, with the precalciner. Its function is to guide the high temperature gas recovered by the cooler lead into the precalciner. A tertiary air duct has electric dampers (437 TV1, TV2/438 TV1, TV2), which control the amount of tertiary air by adjusting the revolving speed of kiln inlet ID wind machine and the span of an electric dampers.
三次风管的电动闸板阀上还配有冷却风机（437FNM，FNN/438FNM，FNN），用于冷却闸板， 以延长闸板的使用寿命。
A tertiary air duct’s electric dampers are also equipped with cooling fan (437 FNM, FNN/438 FNM, FNN), used for cooling the paddle to lengthen its useful life.
经C6旋风筒分离出的分解后的热料粉顺着下料斜坡喂入回转窑（437KL1/438KL1）的进料端， 并借助回转窑的旋转慢慢地向窑头运动。在运动过程中，继续与窑内的热烟气换热，实现窑内的系 列化学反应，最终在烧成带用窑头燃烧器提供的燃烧热将其烧结成水泥熟料。
The decomposed hot material powder separated from a C6 cyclone follows a discharging slope to be fed into the rotary kilns(437 KL1/438 KL1), and relying on the rotation of a rotary kiln, slowly move toward the kiln outlet. During the period of the movement, the powder is going on with exchanging heat with the hot fumes inside the kiln, realizing the serial chemical reactions in the kiln, and finally, at a burning zone, the combustion heat provided by the kiln outlet burners makes the powder sintered into cement clinker.
Φ6.2×92m的回转窑，斜度为 4%，三档支撑，窑尾配有汽缸压紧式密封装置，并配有两台空压 机（437CP1，CP2/438CP1，CP2），一用一备；还配有多点式干油泵（437LQ1/438LQ1），用于 密封装置的润滑。窑头配有钢片式密封装置，并配有冷却风机（437FN1/438FN1）。该窑配置有双 传动，主电机（437MM1，MM2/438MM1，MM2）功率 1050kW，变频调速，调速范围：0.4~3.98~5r/min。 除主电机外，还设有辅助传动电机（437AM1，AM2/438AM1，AM2）和柴油发电机（437DE1， DE2/438DE1，DE2），供特殊情况下使用。该窑还配置有双液压挡轮系统，分别设在窑的第三档和 第 二 档 。 液 压 挡 轮 共 用 一 套 挡 轮 油 泵 站 （ 437HD1/438HD1 ）。 正 常 情 况 下 使 用 窑 尾 挡 （437KT1/438KT1），该档故障时可用窑中挡（437KT2/438KT2）替代。液压挡轮系统用于限制调 节筒体上、下窜动。各托轮、轴瓦为油润滑和水冷却，并设有温度监测。小齿轮设有喷雾润滑系统 （437LQ4/438LQ4）以满足窑的传动齿面的润滑。窑的筒体配置有筒体扫描温度监测系统，可随时 监测烧成过程中烧成带及前后的筒体表面的温度变化情况。在烧成带及后部设有 16 台筒体冷却风机 （437FN6~L/438FN6~L），以用于筒体表面的冷却，该系列风机设有轨道可根据需要调整其位置。 一、二号轮带两侧设有 4 台冷却风（437FN2~5/437FN2~5）机用于冷却轮带的垫板和间隙。 For the Φ6.2×92m rotary kiln, the gradient is 4%, with three supports, the kiln inlet has a cylinder compression type sealing apparatus and two air compressors(437 CP1, CP2/438 CP1, CP2), one in use and one on standby, multipoint grease pumps (437 LQ1/438 LQ1) are also provided, used for the lubrication of a sealing apparatus. The kiln outlet has steel sheets sealing apparatuses and cooling fans (437 FN1/438 FN1).The kiln is equipped with twin drive. For the main motors (437 MM1, MM2/438 MM1, MM2), power: 1050 kW, with frequency control. Speed adjustable range: 0.4~3.98~5 r/min. In addition to the main motors, there are also auxiliary motors (437 AM1,
AM2/438 AM1, AM2) and diesel generators (437 DE1, DE2/438 DE1, DE2), to be used under a special circumstance. The kiln is also equipped with double hydraulic thrust roller systems, respectively established in the third and second supports of the kiln. The hydraulic thrust rollers share a set of thrust roller oil pump stations (437 HD1/438 HD1). Under a normal circumstance, the kiln inlet shelves (437 KT1/438 KT1) are used. If the shelves malfunction, the kiln middle shelves (437 KT2/438 KT2) may be used instead. The hydraulic thrust roller system is used for restricting and adjusting the upward or downward movement of the kiln. Each supporting roller or axle bush is lubricated by oil and cooled by water, with temperature monitoring. A pinion has fog lubrication systems(437 LQ4/438 LQ4) to satisfy the lubrication of a drive flank. The body of a kiln is equipped with a kiln body surface scanning temperature monitoring system, which can at any time monitor the temperature change of the firing zone and its front and rear cylinder surfaces in the process of calcination. The burning zone and its back have 16 cylinder body cooling axial fan (437 FN 6~ L/438FN 6~ L), used for cooling a cylinder body surface. The serial axial fan have tracks, whose positions can be adjusted according to demands. The two sides of No. 1 or No.2 tyre have 4 cooling fans ( 437 FN 2~5/437 FN 2~5), used for cooling the liner plate and clearance of a tyre.
2.4 熟料冷却与废气处理和窑头燃烧系统（烧成窑头）Clinker cooling, exhaust treatment and
kiln outlet calcining system(Calcinating kiln outlet)
窑内煅烧所需的燃料主要是原油和天然气。原油由专供窑头的双联高压泵（L37FP2/ L38FP2） 送至窑头原油控制阀组（447VT1/448VT1），通过调节阀组上的流量阀来调节燃烧器的喷油量，再 结合对燃烧器一次风的调节，使窑内火焰满足窑内熟料的烧成要求。燃气时由天燃气阀组 （447VT2/448VT2）控制。窑头燃烧器（447BU1/448BU1）与分解炉燃烧器一样为Pillard提供。窑 头燃烧器为多通道燃油、燃气燃烧装置，含有三个空气通道分别为轴向风（外圈）、旋流风（次外圈）、 中心风（第4圈），一个燃气通道（第3圈）），一个燃油通道（内圈油枪），一个点火通道（内圈）。燃 烧器喷出的燃料与一次风机（447FNG/448FNG）的冷风和来自冷却机的二次风一起进入窑内充分 混合燃烧，为熟料的烧成提供所需的热量。与一次风机并联的还有一台备用风机（447FNH/448FNH） 和事故风机（447FNI/448FNI）。事故风机用于在一次风机、备用风机停车时，及时吹风冷却，保护 燃烧器而不被损坏。燃烧器悬挂在电动移动小车支架上，移动小车由悬吊的轨道梁支撑，燃烧器可 在一定范围内上下、左右调节、前后移动以满足煅烧要求。
The main fuels that calcination needs inside a kiln are crude oil and natural gas. Crude oil is sent from the duplex high-pressure pumps ( L37 FP2/L38 FP2) provided particularly for the kiln outlet to the kiln outlet crude oil control valve train (447 VT1/448 VT1). Adjusting the flow rate valve of the valve train to control the amount of oil injection of a burner plus the accommodation of primary air to the burner can make the flame inside a kiln satisfy the requirements for clinker calcination. Burning gas is controlled by the natural gas valve train (447 VT2/448 VT2). The kiln outlet burners (447 BU1/448 BU1) as well as precalciner burners were provided by Pillard. The kiln outlet burner is a multichannel oil-burning and gas-burning combustion train, containing three air channels for axial wind(outer ring), spiral-flow wind (second outer ring) and center wind(fourth ring)respectively, one gas-burning channel(third ring), one oil-burning channel(inner ring oil gun) and one ignition channel(inner ring).The fuel a burner ejects, the cold air from the primary air fans and the secondary air from the coolers enter the kiln together for sufficient mixture and calcination, providing heat needed for the calcination of clinker. Together with a primary fan are a standby fan(447 FNH/448 FNH) and an emergency fan(447 FNI/448 FNI).The emergency fan is used for
timely blowing and cooling when the primary fan and standby fan stop so that the burner is protected from damage. The burner is suspended on the support of an electric moving cart. The cart is shored by a suspended track beam. In a certain range, the burner can be adjusted up and down, left and right, and move to and fro to satisfy the calcination requirements.
烧结后的高温熟料出窑落入推动篦式冷却机的篦床上。篦冷机（447GQ1/448GQ1）由IKN公 司供货，能力：11000t/d，篦床有效面积：250m2。冷却机分为前后两段冷却，两段篦床均分为固 定篦床和活动篦床两区域。固定篦床区域均采用梁供风形式，活动篦床区域采用室供风形式。前后 两 段 活 动 篦 床 均 采 用 液 压 传 动 ， 分 属 液 压 油 泵 站 （ 447HD1/448HD1 ） 的 两 个 传 动 装 置 （447MD1,MD2/448MD1,MD2），篦床速度可根据篦下压力调节以保持一定的熟料层厚度，篦下风 室，各配有单独的风机，各室间隔密封，风量、风压均可单独调节，从而确保冷风能克服相应区段 的篦板及料层阻力，均匀穿透物料层，使篦床上熟料得到有效的冷却。冷却机分为前后两段，两段 之间设有辊式破碎机（447CR1/448CR1），出窑熟料温度为 1400℃,经前段的冷却，然后经过辊式 破碎机的破碎，95%以上的熟料粒度小于 25mm。破碎机的型号：6×4.8m，辊直径Φ490mm，辊长 度：4800mm，装机：6×18kW，辊速：3~5 r / min，辊的工作温度约 150~200℃。破碎后的熟料在 经后段篦床的冷却，出冷却机熟料温度可降至环境温度+65℃以下，经冷却机末端的卸料口卸到熟 料链斗输送机（457DP1/458DP1）上，由链斗输送机送入熟料库。前端固定床的端部,设有 9 台空 气炮（447BQ1~9/448BQ1~9），通过循环工作，帮助推动此处的熟料运动。熟料在通过篦板的往复 推动中，偶尔通过篦孔落入风室的小颗粒收集在灰斗中，前段篦床灰斗中的细熟料颗粒由灰斗的气 力输送系统(简称PHD系统)（447PC1/448PC1）送入熟料的链斗输送机上，后段篦床灰斗中的细熟 料颗粒由灰斗的气动锁风阀（447FV1~FV6/448FV1~FV6）在料位和时间控制器的控制下,直接送到 熟料链斗输送机上。前段篦床固定床和活动床前部通过物料层换热后的气体可分别作为二次风直接 入窑和作为三次风抽往窑尾分解炉锥部入炉。后部多余的废气（约 250～300℃）将通过窑头电收尘 器（447EP1/448EP1）净化后，由窑头排风机（447FNF/448FNF）导入烟囱（447SK1/448SK1） 排入大气。电收尘器的气体处理量：1100,000m3/h，收尘面积：361m2，净化后的气体含尘浓度： ≤20mg/Nm3，高压硅整流器的电压：66kV，额定功率：66kW。熟料电收尘器捕集的粉尘由分别由 4台熟料拉链机（447CV1~4/448CV1~4）和叶轮喂料机（447RF1~4/448RF1~4）送到汇总的熟料 拉链机（447CV5/448CV5）中，再送至熟料链斗输送机。窑头排风机的风量：1150,000m3/h，风 压：2000Pa，装机功率：1050kW，可变频调速调节风量。
After leaving the kiln, the sintered high-temperature clinker falls onto the grate bed of a pendulum grate cooler. The grate cooler (447 GQ1/448 GQ1) is provided by the IKN company, with a capacity: 11000 t/d, grate bed effective area: 250m2. The cooler is divided into two sections, front and rear, for cooling. Each of the two grate bed sections is divided into two areas of a fixed grate bed and a movable grate bed. The fixed grate bed area uses the beam-providing-wind form, while the movable grate bed area involves the chamber-providing-wind form. The two front and rear movable grate bed sections use hydraulic drive, belonging to the two drive units(447 MD1, MD2/448 MD1s, MD2) of the hydraulic oil pump station(447 HD1/448 HD1).The speed of a grate bed can be adjusted according to the pressure under the grate so as to retain a certain clinker layer thickness. Each under-grate wind chamber is equipped with a single fan. Each chamber is airtight, with its air volume and air pressure adjustable alone, thus ensuring that cold air can overcome a corresponding section’s grate plate and material layer resistance and evenly penetrate a material layer, making the clinker on the grate bed receive effective cooling. A cooler is divided into two sections, front and rear, and between them, there is a roll crusher (447 CR1/448 CR1).The temperature of the kiln-leaving clinker is 1,400 ℃. The clinker is cooled by the front
section and crushed by a roll crusher so that the fineness of more than 95% of the clinker is less than 25 mm. The type of the crusher:6 × 4.8 m, roller diameter Φ 490 mm, roller length:4800 mm, loader:6 × 18 kW, roller speed:3~5 r/ min, working temperature of the roller: about 150~ 200 ℃. After the crushed clinker is cooled by the rear grate bed, the temperature for the clinker to leave the cooler can decline to an ambient temperature below +65 ℃. Through the unloading mouth at the end of the cooler, the clinker is unloaded to the clinker chain bucket conveyor (457 DP1/458 DP1), which sends the clinker to a clinker storage. The end of the front fixed bed is equipped with 9 air cannons (447 BQ 1~9/448 BQ 1~9), whose duty-cycle operation helps push the movement of clinker here. While clinker is passing a grate plate in reciprocating push, the small particles occasionally passing grate holes and falling into a wind chamber are collected in an ash bucket. The fine clinker particles in the front grate bed ash bucket are sent to a clinker chain bucket by pendulum (briefly called PHD system) (447 PC1s/448 PC1s). The fine clinker particles in the rear-section grate bed ash bucket are sent directly to the chain conveyors by ash bucket air-lock valves (447FV1~FV6/448FV1~FV6) under the control of material level and time controllers. The gas after the heat exchange of the material layers at the front grate fixed bed and in front of the movable bed may directly enter a kiln as secondary air and may be discharged to the conic section of the kiln inlet precalciner to enter the furnace. The rear exhaust (about 250-300 ℃) is purified by the kiln outlet electrostatic precipitator (EP) (447 EP1/448 EP1) (447 FNF/448 FNF) and guided to the chimney(447 SK1/448 SK1) and into the atmosphere by the kiln outlet fan (447FNF/448FNF). Air flow of an EP: 1,100,000 m 3/h, Cross area: 361 m2, dust concentration after gas purification: ≤ 20 mg/Nm3, voltage of high-voltage silicon rectifier: 66 kV, rated power: 66 kW. The dust caught by the clinker EP is sent to the general clinker chain conveyor (447CV5/448CV5) by 4 clinker chain conveyor (447CV1~4/448CV1~4) and rotary valve feeders (447RF1~4/448RF1~4) respectively and then sent to the clinker chain bucket conveyor. The air flow of the kiln outlet vent air fan: 1,150,000 m3/h, air pressure: 2,000 Pa, installed power: 1050 kW, with adjustable frequency control air volume.
2.5 熟料输送 2.5 Clinker Conveyance 熟料经链斗输送机（457DP1/458DP1）经分料溜子分别由开关阀（457SG1/458SG1）经熟料 链斗输送机（457DP2/458DP2）进熟料散装库，开关阀（457SG2/458SG2）控制进熟料储存库。 在熟料储存库内还建有中心库专门存放次熟料，可通过选择电动开关阀（457SG4/458SG4）进中心 次熟料库区和选择电动开关阀（457SG3/458SG3）进熟料储存库的合格熟料区。
After being conveyed by bucket conveyer (457DP1/458DP1) and divided by the diversion chute, the clinker will go into the clinker bulk silo after being controlled by the switch valve (457SG1/458SG1) and conveyed by the clinker bucket conveyer (457DP2/458DP2), and the clinker storage silo after being controlled by the switch valve (457SG2/458SG2) respectively. A central silo has been set up in the clinker storage silo for storage of unqualified clinker. People could send the clinker to the central unqualified clinker silo by selecting the electric switch valve (457SG4/ 458SG4) or the qualified clinker silo by selecting the electric switch valve (457SG3/458SG).
2.6 Bypass and Returned Ash Conveyance
由于该厂原料中氯含量超标，会给预分解系统造成结皮堵塞，因此在窑尾上升烟道上设有旁路 放风口，可实施旁路放风，减少有害气体的循环富集。
Due to over-standard chlorine content of the raw material used by this plant, the precalcining system will be crusted and blocked. Therefore, the bypass air outlet is set up on the uptake at the kiln inlet in order to carry out the bypass and decrease the circulation and concentration of harmful gases. 当需要开启旁路放风系统时，窑尾高温废气由旁路放风口抽出经旁路放风装置时与一次冷却风 机（417FN2/418FN2）掺入的冷风混合，再与二次冷却风机（417FN3/418FN3）掺入的冷风混合 成 200℃左右的废气，经系统袋收尘器（427BF1/428BF1）净化后由旁路放风系统的排风机 （427FN1/428FN1）经烟囱（427SK1/428SK1）排入大气。旁路系统的放风量通过调节排风机的 转速和调节阀（417DA3/418DA3）的开度实现。旁路放风量小，可开启冷风阀（417DA6/418DA6） 来替代二次冷却风机。系统故障时，也是优先开启冷风阀作为短暂保护。一次冷却风机的风量： 300,000m3/h，风压：2100Pa，功率：280kW；二次冷却风机的风量：300,000m3/h，风压：1800Pa， 功率：250kW，变频调速。一次冷却风机不可调，正常情况下一次冷却风机全负荷操作, 二次冷却 风机可根据袋收尘器进口的温度调节供风量。袋收尘器的处理风量: 900000m3/h，出口含尘浓 度:≤20mg/Nm3，气体温度: 正常 180℃~220℃，袋收尘器的阻力: ≤ 1700 Pa。系统的排风机的风 量: 920000 m3/h，风压: 3800Pa，功率: 1450kW，可变频调速。
When the bypass system is started, the hot gas of the kiln inlet will be drawn out through the bypass air outlet, and then become the waste gas of about 200 ℃ after being mixed with the cool air from the primary cooling fan (417FN2/418FN2) and the cool air for the secondary cooling fan (417FN3/418FN3); and then, the waste gas will be purified by the system bag filter (427BF1/428BF1) and exhausted to atmosphere by the exhaust fan (427FN1/428FN1) of the bypass system through the chimney (427SK1/ 428SK1).Regulation of the air volume of the bypass system could be realized through adjustment of the rotation speed of the exhaust fan and opening degree of the adjusting valve (417DA3/418DA3). When the air volume of the bypass system is small, the cold-air valve (417DA 6/418DA6) could be opened to work instead of the secondary cooling fan. When the system failure occurs, the cold-air valve will also be opened first as temporary protection. The air volume of the primary cooling fan:300,000m3/h, wind pressure: 2100Pa, power efficiency:280 kW; the air volume of the secondary cooling fan: 300,000m3/h, wind pressure: 1800 Pa, power efficiency: 250 kW, frequency control. The primary cooling fan is not adjustable. Under normal circumstances, the primary cooling fan will be operated with full load, and the air supply volume of the secondary cooling fan could be adjusted according to the inlet temperature of the bag filter. Air volume the bag filter: 900000m3 /h, outlet dust concentration:≤20 mg /Nm3, gas temperature:180℃～ 220℃normally, resistance of the bag filter:≤1700Pa.Air flow of the exhaust fan of the system: 920000 m3 / h, wind pressure: 3800 Pa, power efficiency: 1450 kW, frequency control. 由袋收尘收集的粉尘，经过拉链机（427CV1，CV2/428CV1，CV2）、叶轮给料机（427RF1， RF2/428RF1，RF2）、转运拉链机（427CV3，CV4/428CV3，CV4）、提升机（427BE1/428BE1） 被送入散装仓（427BI1/428BI1）。因富含氯、碱等有害成分不能返回烧成系统，故需经过仓底的螺 旋闸门（427SG1/428SG1）、叶轮给料机（427RF4/428RF4）、散装头（427BS1/428BS1）卸入散 装罐车外运。
After being conveyed by the drag chain conveyor (427CV1,CV2/428CV1,CV2), revolving plow
rotary feeder (427RF1,RF2/428RF1, RF2), transfer drag chain conveyor
(427CV3,CV4/428CV3,CV4) and the elevator (427BE 1/428BE1), the dust collected by the bag filer will be fed into the bulk bin (427BI1/428BI1).The dust could not be returned to the burning system due to rich contents of noxious constituents such as chlorine and alkaline, so it will be discharged to the bulk tanker for transportation to other places through the bulk loading machine (427 BS1/428BS1) after being controlled by the screw gate valve (427SG1/428SG1) under the bin and conveyed by the rotary feeder(427RF4/428RF4).
3．烧成系统主要设备单元的操作规程
3. Operation Instructions of Major Equipment Units of the Burning system 3.1概述
3.1 General Description
本节只对烧成系统主要设备单元的操作、维护作一介绍，更为详尽的设备性能、配置情况以及 操作要求，请参见工艺设备表和设备说明书，如与供货厂商提供的说明书不一致，则以供货厂商的 说明书为准。
This section only introduces the operation and maintenance of major equipment units of the burning system. For detailed equipment performance, configuration situation and operation requirements please refer to the process equipments table and equipment instruction manuals. If unconformity between the manuals provided by us and those provided by the manufacturers occurs, the manufacturers' manual should be taken as final.
3.2 范围 3.2 Scope
本规程适应于烧成系统主要设备单元的操作、维护，即从生料充气卸料到熟料入库之间的设备。 This regulation is applicable to the operation and maintenance of major equipment units of the burning system , that is, the equipments used from raw meal aeration and discharging to clinker warehousing. 3.3 目的 3.3 Objective 本规程旨在规范操作巡检制度，提升工作质量，对主要设备单元的操作、维护需要注意的方面 提供正确的信息，以帮助操作人员准确判断设备故障及采取正确、有效的处理方法，树立安全生产、 质量第一的观念，保证设备长期、安全、高效的运行。
Objective of this regulation is to standardize the operation and patrol system, improve working quality and provide accurate information on operation and maintenance matters of major equipment units that require attention, in order to help operating personnel determine equipment failures correctly and take correct and effective treatment measures, establish the concept of " safe production and quality first” and guarantee the long-term, safe and efficient operation of equipments.
3.4 Operation Mode
各设备控制均有“集中程控”、“机旁控制”两种状态，现场有“开”、“停”、“闭锁”开关，正常生产时 各设备都处于 “集中控制” 状态；现场进行单机试机时，设备处于“机旁控制”状态，开单机时设备不 参与联锁控制，但停单机时，设备受联锁控制，主要是考虑设备的安全操作、防止设备内积料过多 而导致故障等方面因素，从而达到安全、可靠生产的目的。
All of the equipments have two control modes, namely, the "centralized program control" and "local control". There are "Start", "Stop" and "Lock" switches at the field. During regular production, all of the equipments are in the mode of "centralized control"; during single unit test run at the field, the equipment is in the mode of "local control". When a single unit is started, the equipments will not participate in the interconnected control; when a single unit is stopped, the equipments will be controlled by the interconnected control in order to guarantee the safe operation of equipments and prevent equipment failures due to material deposits in the equipments, thus realizing the objective of safe and reliable production.
3.5 主要设备单元的操作规程 Operating Instructions of Main Equipment Units 3.5.1 回转窑 Rotary kiln
3.5.1.1设备概述 Equipment Summary
回转窑是烧成系统的主要热工设备之一，主要由窑筒体、传动装置、支承装置、挡轮装置、窑 头密封装置、窑尾密封装置、窑头罩等部分组成。The rotary kiln is one piece of the main thermal technical equipment of a burning system , consisting mainly of a kiln cylinder, drive unit, supporting apparatus, thrust roller device, kiln outlet sealing apparatus, kiln inlet sealing apparatus, kiln hood, etc.
3.5.1.2主要技术性能 Main Technical Performances
规格 Specification（m）: Φ6.2×92m 有效内径 Effective inside diameter（m）: Φ5.7 斜度 Gradient（%）: 4（正弦）(sine) 支座数（档）Number of support abutments: 3 产量 Output（t/d）: 10000
窑转速 Kiln revolving speed （r/min）:
用主传动时调速范围 Speed adjustable range at main drive:0.4~3.98~5
用辅助传动时 At auxiliary drive:0.105
传动型式 Drive type: 双传动 Twin drive
挡轮型式 Thrust roller type: 双液压挡轮 Double hydraulic thrust roller 窑 头 密 封 形 式 Kiln outlet
sealing form:
钢片密封 Sealed by sheet steel 窑 头 冷 却 方 式 Kiln outlet
cooling mode:
风冷 Air cooling 窑 尾 密 封 形 式 Kiln inlet
sealing form:
汽缸压紧端面密封 Sealed by pneumatic cylinder pressing end surface
3.5.1.3主要结构和控制元器件概述 Summary of Main Structures and Control Components 1）窑筒体Kiln shell 窑筒体是回转窑的躯干，窑筒体倾斜地安装在三对托轮上，在窑筒体低端装有耐高温耐磨损的 窑口护板并组成套筒空间，设有专用风机对窑口部分进行冷却。沿窑筒体长度方向上套有三个轮带， 轮带下采用浮动垫板，可根据运转后的间隙进行调整或更换，以获得最佳间隙，垫板起到增加窑筒 体刚度、避免由于轮带与窑筒体有圆周方向的相对滑动而使窑筒体遭受磨损和降低轮带内外表面温 差的作用。
The kiln shell is the trunk of the rotary kiln and has been slantwise installed on three pairs of supporting rollers. The lower end of the cylinder is equipped with thermostable and abrasion-proof kiln outlet guard boards, constituting a casing space, and with exclusive-use fans to cool the kiln outlet. Along the length of the kiln cylinder, there are three tyres, under which there are floating liner plates. They may be adjusted or replaced according to the clearance after operation to acquire the best clearance. The liner plates have the functions to increase kiln cylinder rigidity, prevent the kiln cylinder from abrasion because of the relative slip of the tyres and the kiln cylinder in the circumferential direction and lower the surface temperature range inside and outside a tyre. 窑筒体内设有3道挡砖圈，并在长度方向按温度、作用不同砌有性能不同的耐火砖保护筒体。为 了帮助筒体表面冷却，在烧成带及后部设有14台冷却风机，风机的位置可以根据需要适当调整。为 了监测筒体表面温度，设置了在线筒体温度扫描仪，可时时监测筒体的温度变化，并在中控室显示 曲线和图像。
The kiln cylinder inside has 3 brick-blocking circles, and along the length direction and according to different temperatures and functions, there are firebricks with different performances to protect the shell. For the sake of helping the cylinder surface cool, the burning zone and its rear are equipped with 14 cooling fans, whose positions may be properly adjusted as required. For the sake of monitoring the cylinder surface temperature, an on-line shell temperature scanner has been set. It can always monitor the temperature change of the cylinder and display curves and pictures in the central control room.
2）传动装置 Drive unit
传动系统采用双传动，每边各有一台主传动电动机驱动一台主减速器和一个小齿轮,共同通过一个大 齿轮带动窑筒体转动。每台主减速器配有一套主减速器稀油站。为保证主电源中断时仍能盘窑操作， 防止窑筒体弯曲，便利检修，设有辅助传动装置。
The drive system uses twin drive. Each side has a main drive motor to drive a main reducer and a pinion, arousing the rotation of the kiln cylinder by jointly using a gearwheel. Each main reducer has one main reducer thin oil station. For the purpose of ensuring that the main power supply can still control the working of the kiln at power failure, preventing the kiln cylinder from being bent and facilitating an overhaul, an ancillary drive unit has been installed.
传动电动机Driving motor：
主 传 动 Main drive 辅 助 传 动 Auxiliary drive
型 号 Model 额定 功率 Rated power (kW) 额定 转速 Rated rotary speed (r/min) 调速 范围 Speed adjustable range (r/min) 型 号 Model 额定 功率 Rated power (kW) 额定 转速 Rated rotary speed (r/min) 1PQ4560-6CM90-Z 1050 1197 120~1197~1504 1LG4223-4AA 54 1770 减速器Reducer：
主 传 动 Main drive 辅 助 传 动 Auxiliary drive
型 号 Model 总中心距 Total center distance 公称速比 Nominal speed ratio 型号 Model 总中心距 Total center distance 公称速比 Nominal speed ratio H3SH24-31.5 1570 31.5 H3SH9-56 580 56 主传动电动机与辅助传动电动机的电源设有连锁装置，当辅助传动电动机电源接通时，主传动 电动机的电源会自动切断；当主传动电动机电源接通时，辅助传动电动机的电源会自动切断，并窑 中传动与中控室设置有联络讯号。
The power supply for the main drive motor and auxiliary drive motor is equipped with an interlocking device. When the power supply for the auxiliary drive motor is switched on, the power supply for the main drive motor will be automatically switched off and vice versa. The local drive in the kiln and the central control room are furnished with communication signals.
为安全可靠的实现主传动电动机与辅助传动电动机的转换，系统设置有电磁式制动器。电磁式 制动器的电源随辅助电动机同时开或关,即辅助电动机接通电源的同时,制动器也接通电源使之松开, 辅助电动机断开电源的同时,制动器也断开电源,使之即刻制动。
For the safe and reliable implementation of the switchover of a main drive motor and auxiliary drive motor, the system is equipped with an electromagnetic brake. The power supply of the electromagnetic brake is switched on or off simultaneously with the auxiliary motor, that is, the moment the auxiliary motor is powered on, the brake will be powered on and unclenched, while the moment the auxiliary motor is powered off, the brake is powered off, arresting motion instantly. 为安全可靠地实现主、辅减速器的转换，辅助减速器带超越离合器,其作用；在使用辅助传动时, 离合器啮合，辅助传动的动力通过辅助减速器传到主减速器上,再进一步带动窑旋转。当使用主传动 时，离合器处于脱开状态，主传动的动力不能传到辅助减速器上。
For the safe and reliable implementation of the switchover of a main reducer and an auxiliary reducer, the latter is equipped with an overrunning clutch. Its action lies in that while using auxiliary drive, the clutch is engaged. The dynamic force that auxiliary drive passes an auxiliary reducer and spreads to a main reducer, further arousing the rotation of a kiln. While using main drive, the clutch is disengaged and the dynamic force of the main drive can not spread to an auxiliary reducer.
主减速器高速轴端带有3个Pt100轴承测温传感器和1个Pt100测油温传感器,此外还带2个测振传 感器。温度、振动超限会发出报警。主减速器稀油站配有水冷却系统。
The high-speed shaft end of a main reducer has 3 Pt100 bearing temperature measuring sensors and one Pt100 oil temperature measuring sensor as well as 2 vibration measuring sensors. Temperature or vibration exceeding a limit will send out an alarm. A main reducer’s thin oil station has a water cooling system.
由于采用了双传动，因此还需考虑同步性要求，传动系统控制中设有自动跟踪控制。
关于传动齿轮的润滑方面，在小齿轮的齿面配有喷雾润滑系统。间歇供油，间隙时间的设定可根据 实际使用情况调整。喷头发生堵塞时，油路分配器上的传感器会发出报警信号并报警。中控室会显 示报警信号。
As twin drive is adopted, it is also necessary to consider the synchronization requirements. There is automatic tracking in the drive system’s control.
Concerning the lubrication of the drive gears, a fog lubrication system has been provided on the tooth face of a pinion. Oil is provided intermittently and the setting of the interval time may be adjusted pursuant to an actual employment circumstance. When a spray nozzle is jammed, a sensor on the oil route distributor will send out an alarm signal. The central control room will display an alarm signal.
3）支承装置 Supporting Unit
支承装置承受着窑筒体的全部重量，并对窑筒体起定位作用，使其能安全平稳地进行运转。支 承装置为调心式滑动轴承结构，轴承的瓦、油配置有测温报警装置。每个轴承配有齿轮泵，窑启动 初期提供润滑。还为托轮的轴承配有水冷却系统。
The supporting unit bears the complete weight of the kiln cylinder, and have the positioning action to the kiln cylinder, making it operate safely and steadfastly. The supporting unit is of core-adjusting sliding bearing structure. The bearing bush and oil are equipped with a temperature measuring alarm. Each bearing has a gear pump, providing lubrication at the early stage of kiln starting. The bearings of a supporting roller have a water cooling system.
4）液压挡轮装置 Hydraulic thrust roller unit
液压挡轮设置在回转窑中部支承装置及窑尾部支承装置轮带的下侧。通过液压挡轮迫使轮带和 窑筒体一起按一定的速度和行程沿窑中心线方向在托轮上往复移动，使轮带和托轮在全宽上能均匀 磨损，以延长使用寿命。正常情况下使用窑尾的主控挡，该挡故障时可把窑中备用挡设为主控挡。 Hydraulic thrust rollers are installed at the downside of tyres of bearing sets at the middle part and charging side of the rotary kiln. The hydraulic thrust roller forces the tyre and the kiln shell to reciprocate on the supporting roller in the direction of kiln center line at the certain speed and distance together, in order to make the tyre and the supporting roller worn evenly at the full width, so as to increase their service lives. Under normal circumstances, the main control thrust roller at the charging side of the kiln will be used. When the failure of this thrust roller occurs, the standby thrust roller at the middle of the kiln could be set as the main control thrust roller.
开关，双挡轮共配置 10 只。窑运转时只能是一档上的行程开关起作用，即正常生产时窑尾档是主控 挡轮，此时它上面的 5 个行程开关接通，控制挡轮油泵站的动作，而窑中档的行程开关全部断开； 异常情况当将窑中档液压挡轮作主控挡轮时，则其上的行程开关接通而窑尾档的行程开关全部断开。 This pair of thrust rollers shares a set of oil pump station of thrust roller. Each of the hydraulic thrust rollers is equipped with the oil temperature alarm unit. Each hydraulic thrust roller is equipped with 5 travel switches, so, this pair of thrust rollers are equipped with 10 travel switches. During running of the kiln, only one set of the travel switches could work, that is, during regular production, the thrust roller at the charging side of the kiln is used as the main control thrust roller, and the 5 travel switches on which are switched in to control actions of oil pump station of the thrust roller, while all of travel switches at the middle of the kiln are switched off; Under abnormal situations, when the hydraulic thrust roller at the middle of the kiln is used as the main control thrust roller, then the travel switches on it will be switched in while all of the travel switches at the charging end of the kiln will be switched off.
5个行程开关的的动作分别代表窑的 5 个位置，由 5 个行程开关的信号分别控制挡轮油泵站的
油泵和电磁换向阀的动作，从而调整窑体上行或下行，如此循环。若窑偏离正常情况向上窜或向下 窜，行程开关的信号会指挥发出报警信号，若窑继续偏离正常情况向上窜，行程开关的信号会跳停 主电机。
Actions of the 5 travel switches stand for 5 parts of the kiln respectively. Signals of the 5 travel switches control actions of oil pump and electromagnetic directional valve of the oil pump station of the thrust roller respectively, in order to adjust the kiln body to go up or down, and then circulate in this way. If the kiln and goes up or down deviating from normal condition, the signal of the travel switch will direct to issue alarm signals, and if the kiln continues to goes up deviating from the normal condition, the signal of the travel switch will lead to trip of the primary motor.
挡轮油泵站还配有磁感式电接点压力表 用于监控液压系统的压力，当系统压力超过其上限设定 值和下限设定值（此压力值现场调定）时，分别发出报警信号。通知巡检工查明原因，排除故障， 使系统恢复到正常工作。
The oil pump station of thrust roller is also equipped with magnetic-induction type electro connecting pressure gauge for monitoring of the pressure of the hydraulic system. When the system pressure exceeds the setting value (the value of the pressure could be set up at the field) of its upper limit or lower limit, the alarm signals will be issued respectively to notify the patrol personnel to find out the reason, clear the fault and restore the system to normal operations.
挡轮油泵站在油箱中装有热电阻，用于测定油液温度并在中控室监控,当油温高于 55℃时,发出 报警信号,通知工人打开油冷却器冷却水球阀. 当油温低于 35℃时发出报警信号,通知工人关闭油冷 却器冷却水球阀。
The resistance temperature sensor is installed in the oil tank of oil pump station of the thrust roller, in order to measure the temperature of the liquid oil and monitor it in the central control room. When the oil temperature is over 55℃, the alarm signal will be issued to notify the worker to open the cooling water ball valve of the oil cooler. When the oil temperature is lower than 35 ℃, the alarm signal will be issued to notify the work to close the cooling water ball valve of the oil cooler.
或更换滤芯。
The filter is equipped in the oil pump station of thrust roller. When blocking occurs in this system, the pressure difference signal sender will issue alarm signals. The worker should be notified to wash and replace the filter element.
5）窑头密封装置
5) Sealing Device of the Kiln Outlet
窑头密封装置采用GP型(钢片式)径向接触式的密封形式，能自动补偿窑筒体运转时的偏摆和 运转中沿轴向的往复窜动，有良好的密封性能。与窑头罩的结合部位有风冷套，并配有冷却风机。 为防止罩壳内积存熟料细颗粒，下部设有灰斗，灰斗经导料溜子直接与篦冷机连接，将熟料细颗 粒直接送入篦冷机的篦床上部，并配有两个空气炮帮助送料。
The sealing device of the kiln outlet adopts the GP (sheet steel) radial contact sealing method, which could automatically compensate the deflection and axial reciprocating motion of the kiln shell during running, and has favorable sealing property. The wind cooling cover is used at the combining part of the kiln outlet and the kiln hood, and the cooling fan is installed there. In order to prevent accumulation of fine particles of clinkers in the hood casing, the ash hopper is installed at the bottom. The ash hopper is directly connected with the grate cooler through the material-guiding chute. The fine particles of clinker will be sent onto the grate bed of the grate cooler directly. Two air cannons have been equipped to help transport the materials.
6）窑尾密封装置
6) Sealing Device of the Kiln inlet
窑尾密封装置采用QD型气缸压紧端面接触式，整个密封圈受力均匀，能消除由于安装和窑筒体 挠度产生的不良影响。为窑尾密封配置了两台空压机，一用一备，为汽缸提供动力。此外还配置有 一台电动多点干油脂泵，可将润滑脂注入摩擦圈接触面进行润滑，以减小摩擦阻力，减少磨损。干 油泵设定为定时间歇供油，间歇时间可调。
The sealing device of the kiln inlet adopts QD type of air cylinder pressing end-surface contact type. The entire sealing ring is under even stress, and it could eliminate the adverse effect generated by installation and deflection of the kiln shell. Two air compressors have been equipped for sealing of the kiln inlet, one for use and one standby, to provide power for the cylinder. Moreover, an electric multipoint consistent grease pump has been equipped. It could feed the lubricating grease into the contact surface of the friction ring for lubrication in order to reduce the frictional resistance and decrease abrasion. The grease pump is set as interrupted oil supply at fixed time, and the pause time is adjustable.
7） 窑头罩 7）Kiln hood 窑头罩是将窑和冷却机密封连接的罩形装置，两侧的支腿座落在窑头操作平台上。窑头罩内砌 筑耐火砖或浇灌耐热浇注料，窑头罩的外端面设有二扇悬挂移动式窑门，以便进入窑内检修及窑衬 砌筑等工作。窑门上设有观察孔和电视探头，可现场借助工具和远程观察窑内的烧成情况；窑门上 还设有温度探头，可监测烧成带温度。窑头罩侧面设有温度、压力测点，可监测窑头气体的温度、
压力。另外窑门上还开有窑燃烧器的进出孔。
The kiln hood is hood-shape equipment connecting the kiln and the cooling machine tightly. The legs on the two sides of the kiln hood are located on the operating platform of the kiln outlet. The firebricks or castables are laid or poured in the kiln hood. A pair hanging and movable kiln Door is installed at the outer end surface of the kiln hood, so that workers could enter into the kiln to do works such as overhaul and laying of the kiln lining and so on. The sight window and TV probe have been set on the kiln door. People could observe the calcinating situation in the kiln by using the tools at the field or remotely; the temperature probe is also installed on the kiln door for monitoring of the temperature of the calcinating zone. Measuring points of temperature and pressure are set on the side of the kiln hood, in order to monitor the temperature and pressure of the gas at the kiln outlet. In addition, the entry & exit hole of kiln burner is opened on the kiln door. 3.5.1.4 开机前的准备 Preparations before Startup
1）窑体 Kiln body
a、确认窑出入口处密封护板及窑口护铁的安装螺栓是否松动;
a, Confirm whether an erection bolt of a kiln access sealing guard board or a kiln outlet cover iron is loose or not;
b、确认轮带与垫板间是否加足石墨锂基脂。
b, Confirm whether sufficient graphite lithium based grease has been added to the space between a tyre and a liner plate.
c、确认轮带与托轮接触面之间有无异物。
C, Confirm whether there is foreign matter on the interface between a tyre and a supporting roller.
d、确认轮带与托轮在旋转时是否碰到其它物体。
d, Confirm whether a tyre and supporting roller run into other bodies while revolving.
e、确认窑内耐火砖完好，耐火砖厚度可满足开机要求。
e, Make sure that the firebricks inside the kiln are intact and their thickness can satisfy the startup requirements.
2）托轮 Supporting roller a、确认各部位螺栓有无松动。
a, Confirm whether each part’s bolts are loose or not.
b、托轮轴温检测装置是否完好。
b, Confirm whether a shaft temperature detection apparatus is intact or not.
c、确认润滑油位，冷却水阀是否打开。
3）传动装置 Drive unit
a、检查大齿轮与小齿轮的啮合、磨损与润滑情况。
a, Check the engagement, abrasion and lubrication circumstances of a gearwheel or a pinion. b、小齿轮轴承润滑油路是否畅通，齿面喷油装置是否正常。
b. Check whether the lub oil route of the pinion bearings is unimpeded or not and the tooth face oil injection apparatus is normal or not.
c、检查油箱油量；
c, Check the oil amount of an oil tank;
d、确认各部位螺栓有无松动。
d, Confirm whether each part’s bolts are loose or not. e、稀油站冷却水是否畅通。
e. Check whether the thin oil station’s cooling water is unimpeded or not. f、各测量元件是否完好，报警系统是否正常。
f Check whether each measuring element is intact and each alarm system is normal. g、检查主、辅离合器是否能正常离合，是否在正确的位置，限位开关是否能动作准确。 g. Check whether a main or auxiliary clutch can work normally and is in an exact position, and
whether a limit switch can act accurately. h、检查各阀门、管道是否正常，有无渗、漏油。
h Check whether each valve or pipeline is normal and leaks oil. 4）液压挡轮 Hydraulic thrust roller
a、检查液压挡轮轴承和油箱油质，油量是否满足要求；
a, Check a hydraulic thrust roller bearing, oil tank and oil quantity and whether the oil quantity can satisfy the requirements;
b、泵吸入侧阀是否全部打开，送油管路内气体是否全部排出；
b Check whether all the pump suction side valves are unbolted and whether the gas inside the oil delivery pipe route is all discharged;
c、确认各过滤器的指标是否处于正常位置；
c, Confirm whether the indexes of each filter are placed in normal positions or not;
d、检查泵安全阀设定压力是否在规定值；
d, Check whether the set pressure of a pump safety valve is a rated value;
e, Check whether the motion of each hand operated valve is flexible and whether there is a leakage or damage phenomenon. If there is, replace the valve immediately.
f、检查液压挡轮的石墨润滑情况，保持石墨块与挡轮接触面接触良好。
f, Check the black lead lubrication circumstance of a hydraulic thrust roller, and maintain the good interface of a black lead cake and a thrust roller.
g、检查电接点压力表有无损坏及异常现象，指针是否放在设定的控制点上。
g, Check whether a pressure gauge with electric contact has a damage and abnormal phenomena and whether a needle pointer is put on the stated control point.
h、检查各测量元件是否完好，报警系统是否正常。
h, Check whether each measuring element is intact and an alarm system is normal. 5）窑头罩 Kiln hood
a、确认耐火材料是否符合砌筑要求，燃烧器入窑孔周围密封是否添加。
a, Confirm whether a refractory material meets laying requirements and the sealing of a burner going into the kiln is affixed.
b、窑头罩是否与旋转部件摩擦。
b Check whether the kiln hood rubs with a revolving part.
3.5.1.5开停机顺序及注意事项 Startup and Shutdown Sequence and Matters Need Attention 1）开停机顺序遵循的原则 Principles to be followed for startup and closedown sequences
开机时遵循的原则是：a）开保护系统的设备，如冷却水、润滑系统等；b）启动尾部设备；c） 启动主体传动设备；d）筒体冷却设备。而关机时遵循的原则是：a）停主体传动设备；b）停尾部设 备；c）停润滑设备；d）停筒体冷却设备；e）停保护系统的设备如冷却水系统。1) Principles to be followed for startup and closedown sequences
Principles to be followed for startup are: a) turning on the equipment of a protecting system, such as cooling water, lubricating system, etc.; b)starting tail equipment; c) starting master drive equipment; d)cylinder cooling equipment Principles to be followed for closedown are: a)stopping the master drive equipment; b)stopping tail equipment; c)stopping the lubrication equipment; d)stopping the cylinder cooling equipment; e)stopping the equipment of a protecting system, such as a cooling water system.
2）开停机顺序 Sequences for Startup and Closedown
开停机顺序在集中控制系统中已有设置，并有启动的顺序的时间控制和联锁关系。此处的简单介 绍是为了更充分地了解其中的关系。
The sequences for startup and closedown have already been set up in the centralized control system, and there are startup sequence control and interlocking relations. The simple introduction here is for understanding their relations more adequately.