熱耗十大原則

10GoldenRules

forHeatConsumptionMastery

熱耗管理十大原則DPCOctober2009–V1DIVISIONORACTIVITY10GoldenRulesforHeatConsumptionMastery

熱耗管理十大原則Prepareaconsistentrawmix

穩(wěn)定入窯生料Controloxygenlevelinkilnandpre-heater

控制窯內(nèi)及預(yù)熱器氧含量

Optimizefuelcombustion優(yōu)化燃燒Masterkilnstability穩(wěn)定窯況Optimizecoolerefficiency優(yōu)化冷卻機Masterpre-heaterandcalcineroperation控制預(yù)熱器及分解爐操作Optimizekilnthroughput優(yōu)化窯產(chǎn)量Maximizereliabilityfactor最大化RFMinimizecementkilndustorkilndustloss最小化窯灰損失Applyoperatingprocedureswithskilledoperators熟練的操作員執(zhí)行標(biāo)準(zhǔn)操作程序Notesonspecificprocesses

備注:關(guān)于特殊生產(chǎn)工藝2RULE1:Prepareaconsistentraw

mixWhatistheKFUIlevelinyourplant?

你們工廠的KFUI如何？Canyouimprovetherawmixburnability?

能否改善生料的易燒性？IstheclinkerC3Stargetoptimized?C3S目標(biāo)值是否已經(jīng)優(yōu)化？準(zhǔn)備穩(wěn)定的入窯生料3Rawmixislinkedtospecificheatconsumption

生料對熱耗的影響

RawmixuniformityaffectsprocessstabilitythusSHC(Alsohaspositiveeffectsonproducts)

入窯生料的均勻性影響工藝穩(wěn)定性，以及熱耗，產(chǎn)品（質(zhì)量）ClinkerLSFaffectsclinkeringtemperature,oversaturationhastobeavoided

熟料的LSF影響燒成溫度，應(yīng)避免過飽和LSFClinkeringtemperaturedegCRule1預(yù)均化效果礦山原料變化入窯生料穩(wěn)定性取樣及質(zhì)控取樣誤差控制策略及頻次分析儀校準(zhǔn);儀器故障時窯灰管理

開停生料磨時數(shù)量/質(zhì)量變化均化庫的效率粉磨細度及大小分布配料倉中料的變化卸料均勻性計量精度4RawmixImpactsspecificheatconsumption生料對熱耗的影響

TheburnabiltyindexofrawmixhasadirectimpactonSHC.(MeasuredusingLafargeK1450index)生料的易燒性系數(shù)對熱耗有直接影響（用K1450評估）

Source:ETC2008rawmixannualsurvey

來源：ETC2008生料年度調(diào)查ImpactonSHCdependsonK1450level:K1450對熱耗的影響Mainsfactorsaffectingburnability:

易燒性的主要影響因素ImpactonK1450

對K1450的影響

Rawmixfineness

生料細度+1%res100mm-1.6Quartz

石英+1%-10Aluminaratio

鋁率+0.14MgO+0.1%+2.6Na2O+0.1%-12S+0.1%+3.8NotanegativeimpactifS/A>2.5

如果S/A>2.5

會產(chǎn)生負面影響Rule15Prepareaconsistentrawmix

準(zhǔn)備穩(wěn)定的生料Prerequisite

前提條件Teamwork-Quarry,Lab,ProductionandProcess

團隊工作－礦山，化驗室，生產(chǎn)，工藝Actions行動Settargetfor設(shè)定目標(biāo)值 Typicalvalue典型值 KFUI <14 ClinkerC3S熟料C3S 60%MonitorK1450evolution

監(jiān)測K1450

HaveaweeklyreviewofC3SandKFUIduringperformancemeeting;emergencyactionplantobeimplementedifKFUI>30

每周業(yè)績會上回顧審視C3S及KFUI：如果KFUI>30

，需采取緊急措施Implementregularfollowupofburnabilityindex(minimumonceayearduringrawmixandclinkermappingexercise);actionplanifK1450<50.

執(zhí)行定期檢查易燒性系數(shù)（最少一年一次），若K1450<50則采取行動Reviewtheselectionofrawmaterialsinthescopeofburnabilityimprovement(slag,puzzolana,quartzreduction)onceayear每年檢查回顧一次原料選擇對易燒性的影響(礦渣，火山灰，石英減量等）Performarawmixlineauditevery3years,usingrawmixauditgrid采用生料審計表格，每三年進行一次生料系統(tǒng)的審計Measurementmethods

測量方法KFUI:dailymeasurement每天檢查K1450:Testofburnabilityforcementplantrawmeal,doneinTClabonly

生料易燒性試驗：僅在TC實驗室做。Support支持文件Rawmixpreparationtrainingmaterial

生料制備培訓(xùn)資料TechnicaldoctrineRawmix

生料相關(guān)技術(shù)文件

Rule1K14506RULE2

Controloxygenlevelsinkilnandpre-heater

控制窯及預(yù)熱器的氧含量Whatistheoptimumoxygenlevelforyourkilnsystem?

你們工廠窯系統(tǒng)的優(yōu)化的氧含量是多少?Isyourfalseairundercontrol?

工廠的漏風(fēng)量在控制范圍內(nèi)嗎？Canyouroperatorsrelyonyourgasanalysissystems?

工廠的操作員是否能依靠氣體分析儀系統(tǒng)？7Manageexcessairatkilninletandcalcineroutlet管理窯尾煙室及分解爐出口過?？諝饬縋rerequisite前提條件Teamwork–Process,MaintenanceandProduction團隊協(xié)作－工藝，維修和生產(chǎn)Actions行動SettargetO2levels設(shè)定目標(biāo)O2含量Typicalvalue典型值

Kilninlet窯尾煙室2-3%(accordingtokilnandfuels依據(jù)窯及燃料)KeepkilnInlettargetoxygenshouldbesetaslowaspossible,whilstmaintainingCO<100ppm(andSO2<3000ppm)

窯尾煙室O2含量盡量低，同時CO<100ppm(SO2<3000ppm)

NotebulkyAF&ARMmaycauseCOhigherthan100ppm(seePost-SevillaCombustionmanual)注意塊狀替代燃料或原料可能導(dǎo)致CO含量高于100ppm（見Post-SevillaCombustionmanual）Investigatecombustionparametersforvaluessignificantlyhigherorlowerthantarget,tofinditemstoimprove

審視工藝參數(shù)是否有明顯的高于或低于目標(biāo)值，找出并改進。Maintainreliableandaccurategasanalyzersandsamplingsystems維護好氣體分析儀和取樣系統(tǒng):可靠,準(zhǔn)確。Ensurecorrectlocationofprobes-samplethemainprocessgasstreamwithoutcontaminationbyfalseair.

確保探頭在正確的位置－對主要氣流取樣，避免受漏風(fēng)的影響。Weeklycalibration(minimum)byinstrumentdepartment

由自動化部門每周（至少）進行校準(zhǔn)。Frequentprobecleaningasrequired(automaticandmanual)byproduction生產(chǎn)單位按需求頻次清理探頭（自動或手動）Withairseparatesystems,ensureproperfunctioningoftertiaryairdamper(orcalcinerdiaphragm)

帶三次風(fēng)管的窯型，應(yīng)保證三次風(fēng)門（或）縮口閥門功能正常。Measurementmethods測量方法Continuousmonitoringbygasanalyzers氣體分析儀連續(xù)測量CrosscheckO2accuracyreadingwithportableanalyzers

用便攜式分析儀校對O2準(zhǔn)確性。Support支持文件SeeprocedurePRPYRP0845:“Measuregascompositionbygasanalyzer”

見程序PRPYRP0845:“用氣體分析儀測量氣體成分”

Rule28ManageFalseAir管理漏風(fēng)Prerequisite前提條件Teamwork團隊協(xié)作–Process,MaintenanceandProduction

工藝，維修及生產(chǎn)Actions行動Settargetfalseairlevels設(shè)定漏風(fēng)目標(biāo) TypicalValues典型值Preheater預(yù)熱器 <5%Coolerexhaust 窯頭余風(fēng) <10%Developinspectionplan

編制檢查計劃Conductregularoverallmeasurements,inspectionsandrepairs(minimummonthly)

例行整體測量，檢查和維修（每月至少一次）Re-designrepeatedproblemareas重新設(shè)計（改進）頻繁故障區(qū)域Performdetailedmeasurementoversystem(minimumannually)每年至少一次全面測量Measurementmethods

測量方法Byoxygendifferencewherepossible

條件允許時測量O2差異Bytemperaturedifferenceonmillsandfilters

磨機及收塵器測量溫度差Directmeasurementbyvolumeflowdifference

直接測量風(fēng)量變化Support支持文件SeeprocedurePRPYRP0609:“Controlfalseairinthepre-heater”

見程序PRPYRP0609:“控制預(yù)熱器漏風(fēng)”SeeprocedurePRPYRP0610:“Measurefalseair”

見程序PRPYRP0610:“測量漏風(fēng)”

Rule29TypicalSourcesofFalseAir典型漏風(fēng)點

Missingbolts

法蘭FanSeals

軸封Doors

孔，門Doors孔，門FlapSeals

翻板閥軸封KilnInletSeal

窯尾密封ClinkerChute

熟料溜子ExpansionJoints膨脹節(jié)ClassifierSeal

軸封FeedingPoint

喂料點FeedingPoint

喂料點Doors

孔，門Doors

孔，門FanSeals

風(fēng)機軸封PokeHoles

捅料孔FlangesTieRodSeals拉拉桿KilnHoodSeals

窯頭密封FanSeals

軸封Seals

鎖風(fēng)，密封Seals

鎖風(fēng)設(shè)備Casingcracks

殼體開裂Casingwear&corrosion

殼體腐蝕，摩擦Isolationdampers

隔離閥ExpansionJoints

膨脹節(jié)

Lookforgaps/cracks/missing

bolts/missing

packing

etc…查找：裂紋，間隙，螺栓脫落,盤根脫落

Listenforwhistlingair聽：風(fēng)哨的聲音Lookfordust

blowingoutduring

startup看(找)：啟動時冒灰Rule210RULE3OptimizefuelcombustionWhattypeofburner,whichset-upandwhatmonitoring?何種煤管?設(shè)定值?怎樣監(jiān)測？Doyouhaveanoxidisingatmosphereinthekiln?你們窯內(nèi)是否為氧化氣氛？優(yōu)化燃料燃燒11Setupandmonitorawelldesignedburner

安裝和監(jiān)測-設(shè)計良好的噴煤管:Prerequisite前提條件Teamwork:Production,ProcessandMaintenance團隊協(xié)作：生產(chǎn)，工藝及維修Recommendedhighmomentumburner(1stchoice:Lafargetype/AlternativeUnithermM.A.S/others)

推薦高推力噴煤管（首選：拉法基煤管/或者UnithermM.A.S/其他）Actions

行動Burnerset-ups

噴煤管安裝：(swirlanglesuchthatswirlrotationinsamedirectionaskilnrotation內(nèi)風(fēng)旋向應(yīng)與窯旋向相同)

Lafargetype

拉法基煤管

Gas氣Oil油Coal煙煤

Petcoke

無煙煤

Alternativefuels

替代燃料recommendation

設(shè)計值（建議）Specificimpulse

推力比[Is][Nh/GJ]1,21,21,51,81,82,2Swirl

旋流比[-]0,050,08-0,150,150,150,150,15Alignburnerorflamewithkilnaxis(especiallywhenusingAF)噴煤管(或火焰)方向與窯同軸（尤其使用替代燃料時）UseLafargeburnerspreadsheettomonitormomentumandswirl,tobeadaptedtofuelpropertiesandkilnphysicalandoperatingconditions使用拉法基計算表格來監(jiān)測推力和旋流比時，要根據(jù)燃料性質(zhì)以及窯況來決定。Avoidexcessiveprimaryairandcontroltransportair,especiallywhenaddingseveralfuels(transportvelocityat25/30m/s,fuel/airratioat4/6kg/Nm3)避免出現(xiàn)過剩一次風(fēng)（控制送煤風(fēng)），尤其在使用多種燃料時（送煤風(fēng)風(fēng)速25/30m/s，燃料/空氣為4/6kg/Nm3）Lookforchangesinpressureforagivenflow,whichcouldindicatemechanicalchangesinburnerandothercomponents(eg:blowerdustfilters)當(dāng)風(fēng)量給定時，檢查壓力變化，其變化可能意味著噴煤管的一些機械問題或其他部分的故障（如：風(fēng)機濾網(wǎng)等）Support

支持文件SeeTA“Fuelflexibility”

見技術(shù)文件“燃料多樣性”SeeprocedurePRPYRP0602:“Startup&optimizeaburner”

見技術(shù)文件PRPYRP0602:“噴煤管使用與優(yōu)化”SeetoolPRPYRT09-05:“Lafargeburnerspreadsheet”

見計算工具PRPYRT09-05:“拉法基噴煤管計算表格”Rule312Operatethekilnwithanoxidisingatmosphere

在氧化氣氛下操作窯Prerequisite前提條件Teamwork:Production,ProcessandMaintenance,Quality

團隊合作：生產(chǎn)，工藝，維修，質(zhì)控部門Reliablekilnbackendanalyzer,withCO/SO2*/NO,withresultsinppm,andO2可靠的窯尾氣體分析儀:CO/NO（單位為ppm）O2/SO2*

Actions行動Setgasanalysislevels設(shè)定目標(biāo)值 TypicalValues典型值CO(inppm) <100SO2(inppm) <3000O2(in%):ifS/A<1,2 1.2–3

ifS/A>1.2 2–3.5Avoidlocallyreducingconditions(e.g.:withcoarsealternativefuelsSSW,animalmeal);forlowVolatileMatterssolidfossilfuels,respectthefollowingrules:避免局部還原氣氛（例如：粗的替代燃料SSW，動物骨料等）對于低揮發(fā)固體化石燃料，遵循如下原則：rejectsat200μm<0.1%200μm篩余<0.1%

rejectsat90μm<?VolatileMatters90μm篩余<?揮發(fā)物Asrequired,measureFeOonclinkertoqualifyqualityofburning

如需要，測量熟料中的FeO含量，以評價燃燒控制的水平Support支持文件SeeprocedurePRPRYP0845:“Measuregascompositionbygasanalyzer”

見程序PRPRYP0845:“如何用氣體分析儀測量氣體成分”“FeOmeasurement”proceduresetupwithTechnicalCentre

按TC程序“FeO的測量”

*ifS/A>1.2Rule313RULE4:MasterkilnstabilityWhatisthefreelimetargetandvariation?

你們工廠的游離氧化鈣目標(biāo)?波動情況？Doyouminimizekilnfeedandfueldosingvariability?

你們工廠控制入窯生料秤及煤秤的波動(最小)么？Doyoumanageconsistencyoffuels?你們廠控制燃料的穩(wěn)定性么?Ifyouhaveaprocesscontrolsystem,doyouoptimizecontrolloopsandmonitorperformanceregularly?如果有過程控制系統(tǒng)，你們廠是否優(yōu)化了控制回路，是否經(jīng)常檢查回路的效果呢？穩(wěn)定窯況14Monitorfreelimevariation

監(jiān)測f-CaO波動Prerequisite前提條件Teamwork–Process,Production,LaboratoryandMaintenance團隊協(xié)作－工藝，生產(chǎn)，化驗室和維修部門KFUIC3S<14Actions行動

SettargetFreeLimelevels設(shè)定f-CaO目標(biāo)TypicalValue典型值Clinkercooleroutlet 冷卻機出口熟料1

to1.5%(0.5to1%

長窯)FreeLimeUniformityIndex游離鈣均勻指數(shù)

<1Minimisekilnfeedvariationbymasteringrawmixuniformity(seerule1)

通過控制生料的均勻性，使窯喂料波動最?。ㄒ娫瓌t1）Minimizefueldosingvariationsandavoidreducingconditions(seerule3)

減小喂煤波動，避免還原氣氛出現(xiàn)（見原則3）Maintaincalcinationontarget(seerule6)

穩(wěn)定分解率（見原則6）OptimisecooleroperationforgoodandstableSecondaryandTertiaryAirT°C(seerule5)

優(yōu)化篦冷機操作，獲得穩(wěn)定二次及三次風(fēng)溫（原則5）Adjustkilnfeed/speedratiotooptimisekilnbeddepthandallowshorterburningzone

調(diào)整窯喂料/窯速(料速比)，以優(yōu)化窯填充率，縮短燒成帶。Measurementmethods

測量方法RegularFLUIreviews

定期檢視FLUISupport

支持文件SeeLQTSonFreeLimeAnalysisbycomplexometrymethod

參見LQTs“滴定法游離鈣分析”O(jiān)nLineFreeLimeAnalysis(OFLA)

在線游離鈣分析（OFLA）

Rule415Minimisekilnfeedandfueldosingvariability

煤秤及生料秤波動最小化Prerequisite前提條件Teamwork–Process,ProductionandMaintenance團隊合作－工藝，生產(chǎn)和維修KFUIC3S<14Actions行動SettargetKilnFeedandFuelDosinglevels設(shè)定目標(biāo)值TypicalValues典型值Kilnfeedfineness

窯喂料細度dependsonburnability

依據(jù)易燒性Kilnfeedflowrate窯喂料量 ±1%Solidfuelflowrate喂煤量 ±1%Maintainequipmenttoensureaccuracyaspertarget

維護設(shè)備，以保證計量精度Managereturnofdusttokilnfeedinordertominimizeimpactofrawmillstops控制窯灰循環(huán)以使生料磨停機產(chǎn)生的影響減至最低Ensurepropermixingofsolidfuelsbeforegrinding確保固體燃料在粉磨前經(jīng)過恰當(dāng)?shù)幕旌螩heckfueltransporttohaveadequatevelocityandfuel/airconcentration

檢查燃料輸送管線具有合適的速度和固比;UseLuciefuelmanager(ifavailable)whenstartingaprogressiveAFprogram在開始使用AF時，應(yīng)使用Lucie（若有）中的燃料管理器。Measurementmethods:測量方法：Regularlabanalysis

常規(guī)化驗室分析Processparameters

工藝參數(shù)Support文件支持SeeCombustionmanual(PostSevilla1997)

見燃燒手冊（PostSevilla1997）Seetechnicalagenda“FuelFlexibility”

見技術(shù)文件“燃料多樣性”

Rule416Optimizecontrolloopsofprocesscontrolsystem優(yōu)化控制回路Prerequisite前提條件Teamwork–Process,ProductionandMaintenance

團隊合作－工藝，生產(chǎn)和維修ProcesscontrolsystemorPIDControlLoops（withoperatingrequiredsensors)過程控制系統(tǒng)或PID控制回路（需要的傳感器）Actions行動SettargetProcessControlLevels設(shè)定目標(biāo)值 TypicalValues典型值Calcination(kilnwithcalciner)分解率90.0to92.0%KilnHoodPressure 窯頭罩壓力 -2/-5mmH2OOperatecalcinerfuelrateinterlockedwithbottomstagecyclonegasexitT°C

分解爐喂燃料量與末級筒出口溫度形成控制。MaintainconstantO2inexcessatkilnbackendwithpreheaterfan,avoidCOformationandminimizeSO3volatilisation(seerule3)

用ID風(fēng)機控制窯尾穩(wěn)定氧氣，避免CO形成，最小化SO3揮發(fā)。（原則3）Maintainconstantslightlynegativekilnhoodpressure,withcoolerexhaustfan(seerule5)用頭排風(fēng)機控制窯頭罩微負壓（原則5）Maintainrestoftheprocessvariablesasconstantaspossibletomasterkilnoperationatrequiredproduction(seerules2and6)穩(wěn)定其他工藝參數(shù)，控制好窯穩(wěn)產(chǎn)。（原則2和3）Support支持文件SeeKilnOperationGuidelinesSeptember2006(TCEA)

見“窯操作指南”2006.09（TCEA)

Rule417RULE5:

Optimizecoolerefficiency優(yōu)化篦冷機效率Doyouoptimizeairflowdistribution?

你們工廠優(yōu)化風(fēng)量分布么？Doyouhaveagoodclinkerdistributionandsize?你們廠熟料顆粒分布好么?熟料料床分布好么？Doyoumaximizeclinkerbeddepth?

你們廠是否最大化熟料料床厚度？Howdoyoucontrolthecooleroperation?

你們廠如何控制冷卻機的操作？18Adjustblownairflowdistribution調(diào)整風(fēng)量分布

Prerequisites前提條件Requiredsensorstomeasurefanairflowsandvalvestoadjustvolumes

風(fēng)量測量所需的傳感器和調(diào)節(jié)風(fēng)量的閥門Actions行動Intherecuperationzone,maximizeheatrecoveredincombustionair(AS,AT);coolerfanvolumeflowdensitymustbeconstantaccordingto:

在熱回收段，應(yīng)最大化回收熱氣（二次風(fēng)，三次風(fēng)）；鼓風(fēng)密度應(yīng)恒定（依據(jù)下表）：Specificvaluesdependoncoolerdesignandare“startingpoints”foroptimization(seeairdistributioncalculation)

具體數(shù)值要根據(jù)冷卻機設(shè)計型式而定，且僅僅為優(yōu)化的初始點（參見計算表格）Inthecoolingzone,coolerfanvolumesareproportionaltoclinkerproductionrate;makespecificairflow(Nm3/kgclinker)adjustmentsandminimizeair/clinkerratioaccordingtomaximumacceptableoutletclinkertemperature

在冷卻段，風(fēng)量與產(chǎn)量成比例關(guān)系；進行風(fēng)量(Nm3/kg熟料)調(diào)整，依據(jù)熟料允許的最高溫度來最小化空氣用量。Atnominalkilnproduction,keeptotalair/clinkerratioconstant:1.8to2.2Nm3/kgclinker(formostcoolertypes):

正常產(chǎn)量情況下，對多數(shù)篦冷機類型，保持空氣/熟料比例穩(wěn)定：1.8to2.2Nm3/kg熟料。Measurementmethods測量方法Continuousmonitoringbypiezometricflowmetersandregularairflowchecksbyfieldmeasurements

用環(huán)形流量計來連續(xù)監(jiān)控空氣流量，并定期用現(xiàn)場測量來標(biāo)定。Visualinsidecoolerchecks(throughwindow)toensurethatnovolcanoescreatedduetoexcessiveairblowingdensity

現(xiàn)場肉眼觀察（透過觀察窗）篦冷機內(nèi)部，確保不會出現(xiàn)通風(fēng)過量引起的噴泉。Support支持文件SeeprocedurePRPYRP0607:“Checkthecalibrationofcoolingfanairflows”

見標(biāo)準(zhǔn)程序PRPYRP0607：“校對冷卻風(fēng)量”SeeprocedurePRPYRP0608:“Adjustthecoolingairlevelanddistribution”

見標(biāo)準(zhǔn)程序PRPYRP0608；“調(diào)整冷卻風(fēng)量分布”SeetoolPRPYRT0702:“Airdistributioncalculation”

見標(biāo)準(zhǔn)計算工具PRPYRT0702:“風(fēng)量分布計算表“Chamber#風(fēng)室123Airflowdensity鼓風(fēng)密度(Nm3/m2/.s)1,5to1,71,2to1,51,0

Rule519Adjustclinkerdistribution

andsize

調(diào)整料床分布和熟料顆粒Prerequisite前提條件Goodclinkerchemistrycontrol(sampling,frequency,labaccuracy)

良好的熟料化學(xué)控制（取樣，頻次，化驗準(zhǔn)確性）Backandsidewindowstobeabletolookinside

尾部或側(cè)面觀察窗：觀察篦冷機內(nèi)部Actions行動Masterclinkerchemistry(minimizingvariationsinrawmixandfuels)andanalyzechemistryvs.events(snowmen,lumps,redrivers,fineclinker)掌控熟料化學(xué)（生料和燃料穩(wěn)定），對異常問題（雪人，大塊，紅河，飛砂）進行化學(xué)分析Operateburningzoneascoolaspossible(seerule4)

盡量降低燒成帶溫度（原則4）Usedeadgratestostopredrivers(Clinkerfinestendtofluidizemoreeasily)使用固定蓖板制止紅河（尤其細料易流化）Install,optimizeandmaintainaircanonsatcoolerinlettoremovesnowmen篦冷機入口安裝/維護/優(yōu)化空氣炮并，以清除雪人。Adjustblowingdensitylaterally(ifdesignallowsandspreadairaccordingtolateralgradientofparticlesizeandclinkerdropout

若有側(cè)部調(diào)風(fēng)裝置，應(yīng)優(yōu)先邊側(cè)充氣（根據(jù)邊側(cè)粒度及漏料）Usedirectaeratedplates(ifdesignallows)toadjustairbeamdistribution

使用局部充氣蓖板（如設(shè)計允許）優(yōu)化空氣梁配風(fēng)Forfixedinletcoolers(clinkerhastobegranulatedandnotsticky):

對于進口固定篦床（熟料顆粒狀，不發(fā)粘）：Implementhorseshoedesignandinstallairbeampressuresensorinordertodetectsnowmen

安裝馬蹄型澆注料，空氣梁上安裝壓力傳感器以監(jiān)測雪人。Firstfansmayneedsignificantlymorepressurecapacitytomovelumps

第一臺風(fēng)機的風(fēng)壓應(yīng)足以以移動大塊料。Measurementmethods測量方法Clinkersizedistribution

熟料粒度分布Dailyclinkerbedvisualchecks

每日熟料料床目視檢查Pressureinfixedinletchecks

固定進口處的壓力檢查。Support

支持文件See“PriorityStudyCoolerTechnologies”參見“篦冷機技術(shù)”

Rule520Maximizeclinkerbeddepth

最大化料床厚度Prerequisite前提條件Teamwork–Process,ProductionandMaintenance

團隊協(xié)作－工藝，生產(chǎn)，維修Adequatestaticpressuresensors

合適的靜壓傳感器Actions行動Usepressureindicationinmonitoredcompartmentasacontrolloopsetpoint

使用壓力作為控制回路參數(shù)來監(jiān)控相關(guān)風(fēng)室Adjustgratespeedtocontroltheundergratepressure調(diào)整篦速來控制蓖下壓力Controlspeedof1stsectioninmultiplegratesections;remainingsectionsfollowbyfixedratio(preferred)

對于多段篦床，控制第一段的篦速，其余篦床篦速按固定比例調(diào)節(jié)（推薦）Ifairflowchangesarerequiredduetoseasonalreasons,changesetpointaccordingly如果因為季節(jié)原因需調(diào)整風(fēng)量，相應(yīng)的需調(diào)整設(shè)定值（壓力）Measureclinkerbeddepth(closetocoolerinlet,whereclinkerbedisstable):測量篦床厚度（在篦冷機入口附近，料面穩(wěn)定后）Maximizingclinkerdepthmeansmaximizingfansoutletstaticpressure,butkeepingamarginfornormaloperation最大化料床厚度意味著最大化風(fēng)機出口靜壓，但是需留有一定操作余量Measurementmethods測量方法Visualchecksthroughwindowwithheightreferencemarkedoncoolerwallorbyweightedchain

料床厚度：通過觀察窗觀察篦冷機壁上的高度參照標(biāo)記或通過重錘鏈條;Continuousmonitoringbypressuresensorinunder-gratecompartment,orinfanoutletduct用傳感器連續(xù)監(jiān)測蓖下壓力或者風(fēng)機出口風(fēng)管壓力Regularpressurechecks,withamanometer

定期用便攜式壓力表校對壓力顯示Support支持文件SeeprocedurePRPYRP0620:“Howtooptimizeaclinkercooler”見程序“如何優(yōu)化篦冷機”

OldGrateCooler舊式篦冷機NewerCoolers

新型篦冷機clinkerbeddepth料床厚度200mm500–700mm(*

特例達1000MM)Rule521Controlcooleroperation

篦冷機操作控制Prerequisite前提條件Teamwork–Process,ProductionandMaintenance團隊工作－工藝，生產(chǎn)和維修Goodclinkerchemistrycontrol(sampling,frequency,labaccuracy)好的熟料化學(xué)控制（取樣，頻次，化驗準(zhǔn)確性）Sensorsingoodoperativecondition

傳感器狀態(tài)良好Actions行動Settargetlevels設(shè)定目標(biāo)值Stabilityofsecondary(&tertiary)airtemperature

穩(wěn)定二次、三次風(fēng)溫Stabilityofcoolerexitclinkertemperature(alsoventairtemperature)穩(wěn)定出篦冷機熟料溫度（以及排氣溫度）Control

KilnHoodPressurebycoolerexhaustfan:通過頭排風(fēng)機控制窯頭罩負壓Setpoint:–2/–5mmWG(dependingonitsstability)設(shè)定值：:–2/–5mmWG

（依其穩(wěn)定性）Controlclinkerbeddepthandcoolerfanairflowdistribution

控制熟料料床厚度及篦冷機風(fēng)量分布Ensurekilnoutletsealingoodconditions

保證窯頭密封良好Ensuretightnessofcoolercomponents(betweenplates,betweenplatesandsidecastings,betweenchambers,atleveloffinesevacuation)保證篦冷機組件密封良好（蓖板之間，側(cè)封板密封，倉間密封，漏料粒度）Measurementmethods測量方法Coolerinspectionduringkilnshutdowns

停窯時檢查篦冷機Othermethodsasseenpreviously

其他方法參見前面Support支持文件SeeprocedurePRPYRP0620:“Howtooptimizeaclinkercooler”

參見標(biāo)準(zhǔn)程序PRPYRP0620:“如何優(yōu)化篦冷機”。

Rule522RULE6:

Masterpre-heaterandcalcineroperation掌控預(yù)熱器和分解爐操作Doyouminimizegasby-pass(flapvalves)andoptimizemealdistribution(splashboxes)?

你們工廠是否最小化氣體短路（翻板閥）？撒料箱撒料效果是否已優(yōu)化？Doyouhaveagoodmaterial/gasdistribution(diptubeincyclones)?

你們工廠是否有好的料氣分布？內(nèi)筒效果如何？Doyoumanagebuild-ups(mealcurtain,airblasters,pokingaccesses

你們是否管理好結(jié)皮？（料幕，空氣炮，捅料作業(yè)）23Controlpreheatercalcineroperation控制預(yù)熱塔操作Prerequisite前提條件Teamwork–Process,MaintenanceProductionandQuality

團隊工作－工藝，維修，生產(chǎn)和質(zhì)控Actions行動Settargetlevels

設(shè)定目標(biāo)值TypicalValues典型值PreheatercalcinationrateSP窯分解率 55–70%PrecalcinercalcinationratePC窯分解率 90–92%O2/COpreheaterexit

預(yù)熱器出口O2/CO

O2:3–5%;CO<100ppFuelpreparation燃料準(zhǔn)備Refertotechnicalagenda”Fuelflexibility參見技術(shù)文件“燃料多樣性”

Adjustfuelaccordingtocalcinationtarget(throughatemperaturesetpoint)根據(jù)分解率目標(biāo)（參考設(shè)定溫度）調(diào)整燃料用量Adjustpreheaterdraughtaccordingly相應(yīng)調(diào)整預(yù)熱器通風(fēng)PerformregularcontrolsofaboveKPIsandimplementcorrectiveactions

定期檢查以上KPIs，同時進行必要的行動Measurementmethods:測量方法：Regularcalcinationmeasurements

定期分解率測量Stabilityofgasanalysisandtemperatures

穩(wěn)定性（氣體分析和溫度）Support支持文件SeeprocedurePRPYRP0845:“Measuregascompositionbygasanalyzer”

參見程序PRPYRP0845：“用氣體分析儀測量氣體成分”SeeprocedurePRPYRP0603:“Howtosamplehotmeal”

參見程序PRPYRP0603：“怎樣進行熱生料取樣”SeeprocedurePRPYRP0611:“Howtocontrolhotmeal”

參見程序PRPYRP0611：“怎樣控制熱生料”Seetechnicalagenda“fuelflexibility”參見技術(shù)文件“燃料多樣性”

Rule624Reducegasbypassandcontrolmealdistribution

減小氣體短路，控制生料撒料Prerequisite前提條件Teamwork–Process,MaintenanceProductionandQuality

團隊合作－工藝，維修，生產(chǎn)和質(zhì)控Actions行動Settargetlevels(aspersupplierdesign)

設(shè)定目標(biāo)值（按照廠商設(shè)計）Gascycloneinletandoutletandmaterialcycloneoutlettemperatures

旋風(fēng)筒進口/出口氣體溫度和旋風(fēng)筒出口料溫Optimizemealdistributionbyinstallingsplashboxesinplaceofsplashplates

優(yōu)化生料撒料效果（用撒料箱而不是撒料板）Checkmealpipesdesign(splashboxtypically1mabovecycloneroof,mealpipeangle>60°,flapvalvemin.2mabovesplashbox)檢查下料管設(shè)計（撒料箱一般高于旋風(fēng)筒頂部1m，下料管傾斜角度>60°,

翻板閥在撒料箱以上最少2m）Minimisegasbypassbyensuringproperfunctioningofflapvalvesincyclonemealpipes(checkflapdesignwithyourTC)盡量減小氣體短路，保證下料管上翻板閥的功能（與TC一起檢查翻板閥設(shè)計）Checkcycloneefficiency(vortexfinderandgasinletdesignsneedtobeanalyzed)andinspectthemfordamagesandbuild-upsduringkilnstops檢查旋風(fēng)筒效率（分析內(nèi)筒及進風(fēng)口設(shè)計）停窯時檢查是否損壞，有積料等。Measurementmethods:測量方法：Temperatureprofilesinriserductorcyclonegasducts,aboveandbelowmealfeed測量上升煙道或旋風(fēng)筒換熱管道的溫度分布（喂料點上下）Temperatureprofilesincyclonemealducts

料管內(nèi)溫度分布Support支持文件SeewithyourTChowtomeasuregasprofileinariserduct連續(xù)你的TC如何測量氣體分布（煙道內(nèi)）SeewithyourTChowtomeasurecycloneefficiency

聯(lián)系你的TC如何測旋風(fēng)筒效率

Rule625Managebuildups

控制結(jié)皮Prerequisite

前提條件Teamwork–Process,MaintenanceProductionandQuality

團隊工作－工藝，維修，生產(chǎn)和質(zhì)控Pressureandtemperaturesensorsingoodoperationalconditions良好的壓力和溫度傳感器Actions行動Frequentlycheckpreheatertoensurenoairin-leakages(patroller)

崗位工經(jīng)常檢查預(yù)熱器確保無漏風(fēng)Ensureproperworkingofblockagedetectorsandflapvalves

確保堵料探測儀及翻板閥工作正常Closelymonitorpreheateroutletpressureandcyclonepressuresandtemperatures

密切關(guān)注預(yù)熱器出口壓力，旋風(fēng)筒壓力及溫度ManagehotmealSO3+Clconcentrationinbottomcyclonemeal

控制末級旋風(fēng)筒熱料中的SO3＋Cl。Usethermo-camera(ifavailable)tolocateareasofthickbuild-ups

用熱像儀（如果可能）探測厚結(jié)皮的區(qū)域Reviewinstallationofairblastersaccordingtobuild-upslocationandensurecorrectoperationofairblasters

根據(jù)結(jié)皮積料位置，評估空氣炮位置，保證空氣炮的正確使用Irrequired,implementmealcurtainanduse“non-stick”refractory

如果需要，安裝料幕，使用抗結(jié)皮澆注料。Ensureregularcleaningoperationsofkilnhearthandriserduct,byqualifiedoperators,instrictcompliancewithsafetyprocedures

由合格人員在嚴(yán)格安全程序下，定期清理煙室，煙道。Support支持文件SeeprocedurePRPYRP0603“Howtosamplehotmeal”

參見標(biāo)準(zhǔn)程序PRPYRP0603：“如何取熱生料”SeeprocedurePRPYRP0611:“Howtocontrolhotmeal”“參見標(biāo)準(zhǔn)程序PRPYRP0611：”如何控制熱生料“SeeprocedurePRPYRP0614:“Howtocleanapluggedcyclone”

參見標(biāo)準(zhǔn)程序PRPYRP0614：”如何處理旋風(fēng)筒堵料“SeeprocedurePRPYRP0625:“Howtomeasurewalllossesbyinfraredpyrometer

參見標(biāo)準(zhǔn)程序PRPYRP0625：”如何用紅外高溫儀測量墻體熱損失“Setupsafetyproceduresforcleaningbuild-upsinpreheaterwithTCandOH&Sorganisation與TC和OH&S組織一起建立預(yù)熱器結(jié)皮清理的安全程序。

Rule626RULE7:

Optimizekilnthroughput優(yōu)化窯產(chǎn)量Doyouoperatekilnatmaximumstablethroughput?你們工廠是否運轉(zhuǎn)在最大穩(wěn)定產(chǎn)量嗎？Doyouknowwhatisyourcurrentbottlenecktoincreaseoutput?

你知道你們工廠的影響提產(chǎn)的生產(chǎn)瓶頸嗎？Doyouhaveamarginforcontrol?

你們工廠有操作的富余嗎？*Inanonsoldoutplant,optimumcostobjectivesmightleadtoanoperationbelowmaximumstablethroughput

在非售罄的工廠，優(yōu)化成本的目標(biāo)也許會使窯在低于最大穩(wěn)定產(chǎn)量下運行27Permanentlyreviewkilnthroughput

堅持關(guān)注窯產(chǎn)量Prerequisite前提條件Teamwork:Production,ProcessandMaintenance,Kilncoach團隊合作：生產(chǎn)，工藝，維修和窯教練Propersensors/actuators+ReliabilityFactorandMTBFhighenoughtoenterinto“optimization”approach合適的傳感器/執(zhí)行器＋RF＋高的MTBF

FLPoperatorperformancedailytracking窯況評估看板Rule7ActionsRegularlychallengethekilnoperatoronwhatpreventshimfromincreasingfeedrate:經(jīng)常挑戰(zhàn)窯操作員什么阻止他不能提高喂料Trackshiftperformanceandid