CN114195413A - Early warning method for material accumulation and skinning of rotary kiln - Google Patents

Early warning method for material accumulation and skinning of rotary kiln Download PDF

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Publication number
CN114195413A
CN114195413A CN202111650161.1A CN202111650161A CN114195413A CN 114195413 A CN114195413 A CN 114195413A CN 202111650161 A CN202111650161 A CN 202111650161A CN 114195413 A CN114195413 A CN 114195413A
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rotary kiln
time
skinning
carbide slag
lump
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CN114195413B (en
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尹日新
胡继强
葛长健
张凌波
鲍传续
魏国庆
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Anhui Hwasu Corp
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B7/00—Hydraulic cements
    • C04B7/36—Manufacture of hydraulic cements in general
    • C04B7/43—Heat treatment, e.g. precalcining, burning, melting; Cooling
    • C04B7/44—Burning; Melting
    • C04B7/4492—Inhibiting the formation of or eliminating incrustations in the cement kiln
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B7/00—Hydraulic cements
    • C04B7/24—Cements from oil shales, residues or waste other than slag
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B7/00—Rotary-drum furnaces, i.e. horizontal or slightly inclined
    • F27B7/20—Details, accessories, or equipment peculiar to rotary-drum furnaces
    • F27B7/32—Arrangement of devices for charging
    • F27B7/3205—Charging
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Muffle Furnaces And Rotary Kilns (AREA)

Abstract

The invention discloses a rotary kiln material accumulation and skinning early warning method which comprises the steps of block lump detection tool and setting thereof, block lump growth calculation, real-time detection, early warning node determination, skinning improvement test and the like. The method obtains a node value by researching an important phenomenon in the process of skinning growth, namely the growth speed of the lump, and detecting and calculating the pressure, wherein the node value is an early warning time point at which the ring formation is about to come, and indicates that the skinning of the rotary carbide slag kiln needs to be cleaned in time before the node time; the rotary kiln material accumulation and skinning early warning method provided by the invention can obtain more accurate real-time ring formation time and optimal skinning cleaning time; the method can be extended to the determination of each parameter of the skinning improvement test, and can determine the real-time value of parameter change or improper operation, thereby determining the optimal parameter and optimal operation of the carbide slag calcination production and providing a real-time detection early warning tool for the standardized operation of the carbide slag rotary kiln system.

Description

Early warning method for material accumulation and skinning of rotary kiln
Technical Field
The invention relates to the technical field of carbide slag firing treatment, in particular to a rotary kiln material accumulation and skinning early warning method.
Background
Carbide slag (Carbide slag) is waste slag which is obtained by hydrolyzing calcium Carbide to obtain acetylene gas and takes calcium hydroxide as a main component. More than 300 kg of acetylene gas can be generated by adding water into 1t of calcium carbide, and 10t of industrial waste liquid with the solid content of about 12 percent is generated at the same time, and is commonly called as calcium carbide slurry. The carbide slag can replace limestone to prepare cement, produce quicklime to be used as a calcium carbide raw material, produce chemical products, produce building materials, be used for environmental management and the like.
The method for producing cement clinker by using carbide slag is a mature method in carbide slag treatment and utilization, and aims at a large amount of carbide slag generated by carbide-process acetylene in a factory throughout the year, a carbide slag rotary kiln system is introduced in the factory in recent years for solving the problem of overlarge local solid waste.
However, in the operation process of the carbide slag rotary kiln system, the skinning at the inlet of the rotary kiln is serious, so that the materials are accumulated and over-burned and bonded, the temperature near the feeding is overhigh, the melting is accelerated, the materials are quickly condensed after being cooled, the skinning phenomenon is aggravated in turn, and the accumulation and the skinning of the materials are serious vicious circle. In the actual production situation, the skinning weight and the material accumulation situation cannot be expected and observed.
But through many times skinning field test research, and most of skinning is before the complete ring formation and block up the feed pipe, the inner wall skinning of carbide slag calcination rotary kiln forms local fragmental piece in advance, slowly melt the bonding grow up to the lump shape that sticks up gradually, when the area that has 1/3 in the inner wall one end tourus scope all had the lump, skinning speed accelerates by a wide margin, and intermittent type nature leads to the material to pile up, the change of feed rate fluctuation, calcine about one again to two kiln carbide slag, will form the thick ring formation of round, in rotary kiln rotatory in-process, the feed pipe is blockked up completely basically to the ring formation, production fails to this moment, treat to clear up urgently.
Based on this result, the present invention attempts to predict in advance the process of formation of the ring and clogging of the material by detecting the growth of the lump before the ring formation.
Disclosure of Invention
The invention aims to solve the defects in the prior art and provides a rotary kiln material accumulation and skinning early warning method.
In order to achieve the purpose, the invention adopts the following technical scheme:
a rotary kiln material accumulation and skinning early warning method comprises the following steps:
s1, the block lump detection tool and its setting: welding a hoop at the tip of an outlet of a feeding pipe, clamping a vertical ceramic sleeve by the hoop, sleeving a ceramic rod at the bottom end of the ceramic sleeve, enabling two ends of the ceramic rod to be in a circular angle shape, lining an arc-shaped pressure sensing piece on the inner surface of the top wall of the ceramic sleeve, extending the pressure sensing piece out of the rotary kiln through a lead, enabling the ceramic rod to naturally slide down when the inner wall of the rotary kiln is not skinned, enabling the distance between the bottom end of the ceramic rod and the inner wall of the rotary kiln to be 100mm, enabling the skinning to just prop the top end of the ceramic rod against the lowest position of the pressure sensing piece when the inner wall of the rotary kiln is skinned, enabling the pressure sensing piece to be almost zero when the skinning thickness of the inner wall of the rotary kiln is larger than 100mm, enabling the pressure sensing piece to start to transmit an electric signal to be output to the outside of the rotary kiln, processing the electric signal by an amplifier, and outputting the electric signal on an oscilloscope to indicate that a lump with the thickness of more than 100mm is formed;
s2, block lump growth calculation: the rotary kiln rotation speed is omega when calcining, the unit is r/min, an electronic graph on an oscilloscope displays that the ordinate is a voltage value and the unit is mV, the amplified numerical range is 0-10mV, the abscissa is a time value and the unit is ms, the amplified numerical range is 0-10000ms, and the rotary kiln rotation speed is updated and stored after exceeding 10 s;
time t required by one rotation of rotary kiln1=1/(ω/60) × 1000ms =60000/ω ms, from 0 to 10000ms by the baud tester-XBP 1, the total period of time during which the charged signal is scanned is t2The proportion of the total electrification time is as follows:
κgeneral assembly= t2/10000；
With t1The unit time is counted as tnThe proportion of the charged time in each unit time is as follows:
κn= tn/ t1；
statistics of kappanOn the ordinate of the curve of (1) is κnThe abscissa is the number n of the rotary kiln rotation turns, namely the number of the rotary kiln rotation turns is counted, and kappa is obtained after fittingnWhen the slope changes in a power direction, the growth curve marks that the growth area of the lump is larger and the growth rate is higher and higher;
s3, real-time detection: starting the carbide slag rotary kiln, and observing the mV/ms electronic chart and the kappa in real timenThe growth curve of (1), starting from the 7 th or 8 th run of the carbide slag rotary kiln, the mV/ms diagram begins to show intermittent electrical signals, kappanThe growth curve of the block begins to appear at a position close to the abscissa, and the recording point shows that the block lump begins to appear;
starting from the 9 th or 10 th time of the operation of the carbide slag rotary kiln, the mV/ms electronic chart almost connects into a line, and after 100 times of amplification, the mV/ms electronic chart forms a plurality of intermittent short lines or points, namely kappanThe ordinate of the growth curve continuously grows from 0.1 to 0.25, and the included angle between the curve and the abscissa is less than 10 degrees;
from the 11 th operation of the carbide slag rotary kiln, the mV/ms electronic chart electrical signals are completely connected into a line and are amplified by 100 times to form a plurality of intermittent long lines, kappanHas been slowly grown up to 0.31 on the ordinate, up to the node point, κ, of 0.31nThe curve rises rapidly, which shows that the block lump thickness is in a power increasing trend;
by the 12 th end of the carbide slag rotary kiln operation, kappanThe ordinate of the curve grows to 0.95;
a certain time, κ, to 13 th run of the carbide slag rotary kilnnThe ordinate of the curve grows to 1, which indicates that the lump grows completely to form a thicker layer of ring formation, and the pressure sensing piece is possibly damaged completely at the moment, so that the ring formation is judged to be possibly blocked completely by the feeding pipe, and the skinning needs to be cleaned immediately;
s4, determining early warning nodes: screening for kappa from real-time detection in S3nThe value of =0.31 is the node value of the growth of the lump, the area of the lump accounts for about 1/3 of the area of the cylindrical surface, the lump has the tendency of rapid ring formation, and the carbide slag rotary kiln operates at the momentThe method has the advantages that the rotary kiln crusts are immediately cleaned after the rotary kiln is determined to run for 10 times, 50-150s of delay is totally taken into consideration of the response time, the amplification time, the baud scanning time and the calculation time of electric signals, and for the whole production time, the delay is negligible, so that the node value can still be considered to play a role in real-time early warning;
s5, skinning improvement test: screening kappa by improving the proportion of the carbide slag raw material, the rotating speed of the rotary kiln, the temperature control and other parameter improvementsnIn the range of 0.3-0.35 as node value, in particular apparent κnWhether the growth curve of (2) shows a power increase trend or not, namely, the inflection point is a node, so that each optimal parameter is determined, and the optimal parameter is not uniformly expanded due to overlarge statistical value.
Preferably, the ceramic rod is a dumbbell-shaped round rod with two large-diameter ends, and the opening at the bottom end of the ceramic sleeve is sleeved in the middle of the ceramic rod to form a movable sleeving structure.
Preferably, the outer wall of the ceramic sleeve and the outer wall of the lead are covered by aerogel felts for heat insulation.
Preferably, the pressure sensing piece is composed of a semicircular elastic piece with the diameter of 100mm and a pressure sensing patch matrix laid on the bottom surface of the semicircular elastic piece, when the pressure sensing piece is impacted by a ceramic rod, the pressure sensing piece can generate a height which can deform upwards by 80mm to the maximum extent, namely, 100-180mm thick crusts can provide a pressure signal for the pressure sensing piece, the crusts with the thickness exceeding 180mm can cause damage to the pressure sensing piece, but generally, the crusts with the thickness already form a knot ring, and the blanking speed can be seriously influenced.
Compared with the prior art, the invention has the beneficial effects that:
according to the method, an important phenomenon in the process of skinning growth, namely the growth speed of the lump lumps, is researched, and a node value is obtained through pressure detection and calculation, wherein the node value is an early warning time point at which the skinning is about to come, and indicates that the skinning of the carbide slag rotary kiln needs to be cleaned in time before the node time. Therefore, the rotary kiln material accumulation and skinning early warning method provided by the invention can obtain accurate and real-time ring formation time and optimal skinning cleaning time. The method can be extended to the determination of each parameter of the skinning improvement test, and by adopting the early warning method, the real-time value of parameter change or improper operation can be completely determined, so that the skinning caused by improper parameters or improper operation can be determined, and the optimal real-time detection value can be realized by the early warning method, so that a real-time detection early warning tool is provided for the normalized operation in order to determine the optimal parameters and the optimal operation of the carbide slag calcination production.
Detailed Description
The technical solutions in the embodiments of the present invention are clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments.
Taking the rotating speed of the carbide slag rotary kiln as 300r/min as an example, namely omega =300 r/min. Time t required by one rotation of rotary kiln1=1/(300/60)*1000ms=60000/300 ms=200ms；
When the rotary kiln for carbide slag runs for 7 th time for about 0.5h, the mV/ms electronic chart begins to generate intermittent electric signals, the voltage value jumps from 0.5-2.0mV, and kappanBegins to appear as a recorded point near the abscissa, within about 30min,. kappa.nSlow growth of about 0.01 to about 0.05;
in the 9 th operation of the carbide slag rotary kiln for about 1.25h, the mV/ms electronic chart almost connects into a line, and after 100 times of amplification, the electric signals form a plurality of intermittent short lines or points, within about 30min, kappanThe ordinate of the growth curve continuously grows from 0.12 to 0.17, and the included angle between the curve and the abscissa is less than 10 degrees;
within about 30min, kappa is generated when the carbide slag rotary kiln is operated for 10 th time of about 0.5hnThe longitudinal coordinate of the growth curve continuously grows from 0.21 to 0.25, and a Baud scanning result t in a certain mV/ms curve range is intercepted2=2258ms, total charging time ratio κGeneral assembly= t2/10000=0.226；
The 11 th time of the carbide slag rotary kiln operation is about 0.76h, kappanThe growth reached around 0.3, and kappa was observed at 20min before and after observationnBaud scan results of a range of mV/ms curve at 11 th time of about 0.92h for growth curve variation amplitude, the kappanGrowth curve ofNow point of inflection, point of inflection kappan=0.312, n on the abscissa 32, i.e. κ32=0.312, to κ50=0.355, count each kappa within about 10min thereafternGrowth curve up to κn=0.650；
By the 12 th end of the carbide slag rotary kiln operation, kappanThe ordinate of the curve grows to 0.95;
until 13 th time of carbide slag rotary kiln operation, about 0.35h, kappanAnd (3) the ordinate of the curve grows to 1, the production is stopped immediately within the following 30min, the rotary kiln is opened, the ceramic rod is observed after cooling, the lower end of the ceramic rod is embedded in the ring, the test extending depth is about 20mm, and the ceramic rod is not obviously bonded when the ring is removed, so that the ring formation time is determined to be 13 th time of the operation of the carbide slag rotary kiln, and the optimal skinning cleaning time is determined to be 10 th time of the operation of the carbide slag rotary kiln.
If it is only for testing the number of times the rotary kiln for carbide slag is operated, the present invention appears to be somewhat smaller and larger, but considering that the actual ring formation often has some unexpected situations, such as the change of the carbide slag raw material ratio, the rotary kiln rotating speed, the temperature control and other parameters, or the block lumps can be quickly generated due to improper operation, and can quickly grow until the block lumps grow to a certain node value until the block lumps form rings, the time point of the parameter change or the improper operation can not be determined, at the moment, the real-time value of the parameter change or the improper operation can be completely determined by adopting the early warning method of the invention, therefore, the method can determine the improper parameters or the improper operations cause the skinning, and the early warning method of the invention can realize the best real-time detection value at the moment, therefore, a real-time detection early warning tool is provided for standardized operation in order to determine the optimal parameters and the optimal operation of carbide slag calcination production.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention should be equivalent or changed within the scope of the present invention.

Claims (4)

1. A rotary kiln material accumulation and skinning early warning method is characterized by comprising the following steps:
s1, the block lump detection tool and its setting: welding a hoop at the tip of an outlet of a feeding pipe, clamping a vertical ceramic sleeve by the hoop, sleeving a ceramic rod at the bottom end of the ceramic sleeve, enabling two ends of the ceramic rod to be in a circular angle shape, lining an arc-shaped pressure sensing piece on the inner surface of the top wall of the ceramic sleeve, extending the pressure sensing piece out of the rotary kiln through a lead, enabling the ceramic rod to naturally slide down when the inner wall of the rotary kiln is not skinned, enabling the distance between the bottom end of the ceramic rod and the inner wall of the rotary kiln to be 100mm, enabling the skinning to just prop the top end of the ceramic rod against the lowest position of the pressure sensing piece when the inner wall of the rotary kiln is skinned, enabling the pressure sensing piece to be almost zero when the skinning thickness of the inner wall of the rotary kiln is larger than 100mm, enabling the pressure sensing piece to start to transmit an electric signal to be output to the outside of the rotary kiln, processing the electric signal by an amplifier, and outputting the electric signal on an oscilloscope to indicate that a lump with the thickness of more than 100mm is formed;
s2, block lump growth calculation: the rotary kiln rotation speed is omega when calcining, the unit is r/min, an electronic graph on an oscilloscope displays that the ordinate is a voltage value and the unit is mV, the amplified numerical range is 0-10mV, the abscissa is a time value and the unit is ms, the amplified numerical range is 0-10000ms, and the rotary kiln rotation speed is updated and stored after exceeding 10 s;
time t required by one rotation of rotary kiln1=1/(ω/60) × 1000ms =60000/ω ms, from 0 to 10000ms by the baud tester-XBP 1, the total period of time during which the charged signal is scanned is t2The proportion of the total electrification time is as follows:
κgeneral assembly= t2/10000；
With t1The unit time is counted as tnThe proportion of the charged time in each unit time is as follows:
κn= tn/ t1；
statistics of kappanOn the ordinate of the curve of (1) is κnThe abscissa is the number n of the rotary kiln rotation turns, namely the number of the rotary kiln rotation turns is counted, and kappa is obtained after fittingnWhen the slope is raised to the powerWhen the power changes, the growing area of the lump is marked to be larger and larger, and the growing rate is marked to be higher and higher;
s3, real-time detection: starting the carbide slag rotary kiln, and observing the mV/ms electronic chart and the kappa in real timenThe growth curve of (1), starting from the 7 th or 8 th run of the carbide slag rotary kiln, the mV/ms diagram begins to show intermittent electrical signals, kappanThe growth curve of the block begins to appear at a position close to the abscissa, and the recording point shows that the block lump begins to appear;
starting from the 9 th or 10 th time of the operation of the carbide slag rotary kiln, the mV/ms electronic chart almost connects into a line, and after 100 times of amplification, the mV/ms electronic chart forms a plurality of intermittent short lines or points, namely kappanThe ordinate of the growth curve continuously grows from 0.1 to 0.25, and the included angle between the curve and the abscissa is less than 10 degrees;
from the 11 th operation of the carbide slag rotary kiln, the mV/ms electronic chart electrical signals are completely connected into a line and are amplified by 100 times to form a plurality of intermittent long lines, kappanHas been slowly grown up to 0.31 on the ordinate, up to the node point, κ, of 0.31nThe curve rises rapidly, which shows that the block lump thickness is in a power increasing trend;
by the 12 th end of the carbide slag rotary kiln operation, kappanThe ordinate of the curve grows to 0.95;
a certain time, κ, to 13 th run of the carbide slag rotary kilnnThe ordinate of the curve grows to 1, which indicates that the lump grows completely to form a thicker layer of ring formation, and the pressure sensing piece is possibly damaged completely at the moment, so that the ring formation is judged to be possibly blocked completely by the feeding pipe, and the skinning needs to be cleaned immediately;
s4, determining early warning nodes: screening for kappa from real-time detection in S3n=0.31 is a node value of block lump growth, the area of the block lump accounts for about 1/3 of the area of the cylindrical surface, the block lump has a rapid ring formation trend, the carbide slag rotary kiln operates 11 times, therefore, the rotary kiln is determined to be cleaned immediately after operating 10 times, the total time delay of 50-150s is considered in consideration of the response time, the amplification time, the baud scanning time and the calculation time of an electric signal, and the time delay is negligible for the whole production time, and the node can still be considered as the nodeThe value can play a role of real-time early warning;
s5, skinning improvement test: screening kappa by improving the proportion of the carbide slag raw material, the rotating speed of the rotary kiln, the temperature control and other parameter improvementsnIn the range of 0.3-0.35 as node value, in particular apparent κnWhether the growth curve of (2) shows a power increase trend or not, namely, the inflection point is a node, so that each optimal parameter is determined, and the optimal parameter is not uniformly expanded due to overlarge statistical value.
2. The rotary kiln material accumulation and skinning warning method as claimed in claim 1, wherein the ceramic rod is a dumbbell-shaped round rod with two larger end diameters, and the bottom opening of the ceramic sleeve is sleeved in the middle of the ceramic rod to form a movable sleeving structure.
3. The rotary kiln material accumulation and skinning warning method as claimed in claim 1, wherein the outer wall of the ceramic sleeve and the outer wall of the lead are covered with aerogel felt for heat insulation.
4. The rotary kiln material accumulation and skinning warning method as claimed in claim 1, wherein the pressure sensor sheet comprises a semicircular spring sheet with a diameter of 100mm and a pressure sensor patch matrix laid on the bottom surface thereof, when the pressure sensor sheet is impacted by the ceramic rod, the pressure sensor sheet can generate a height capable of being deformed upwards by 80mm to the maximum extent, i.e. 100-180mm skinning can give a pressure signal to the pressure sensor sheet, and skinning with a thickness exceeding 180mm can cause damage to the pressure sensor sheet, but generally the skinning with the thickness forms a ring, which can seriously affect the blanking speed.
CN202111650161.1A 2021-12-31 2021-12-31 Rotary kiln material accumulation and skinning early warning method Active CN114195413B (en)

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN205748000U (en) * 2016-06-13 2016-11-30 山东东华水泥有限公司 Preheater anti-blocking system
CN113465367A (en) * 2021-07-10 2021-10-01 阳泉恒跃兴钙业有限公司 Ring formation detection processing method and device for lime fired by rotary kiln

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN205748000U (en) * 2016-06-13 2016-11-30 山东东华水泥有限公司 Preheater anti-blocking system
CN113465367A (en) * 2021-07-10 2021-10-01 阳泉恒跃兴钙业有限公司 Ring formation detection processing method and device for lime fired by rotary kiln

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