Application case 15: Cement two stage ignition combustion control system
1. Process Description
The technical program is used for Fuel System energy-saving projects of East Hope Cement Co., Ltd., Chongqing. The supplier provide the system’s safe use of all the technology such as process design, functional design, structure, installation, testing and commissioning and so on, the system must comply with the 2 × 150t / h fluidized bed boiler and 3 × 4800t / d cement kiln production line ignition fuel system engineering of Chongqing East Hope Cement Co., Ltd., after system transformation they have to meet the switch combustion of diesel and methanol.
2. Design basis
Fuel system energy saving design, manufacture, CIMAC-3001 methanol burner, both for 2 × 150t / h fluidized bed boiler and also meet 3 × 4800t / d cement kiln production line ignition fuel system.
Three main technical parameters and characteristics:
1) CIMAC-3001 type ignition combustion system:
A. Methanol ignition fuel system should also meet the demand side, 2 × 150t / h fluidized bed boiler and 3×4800t/d cement kiln production line operation. Methanol and diesel fuel to ensure simple switching operation. This system is necessary to meet the combustion of methanol, but also to meet the combustion of diesel. Conversion of methanol tanks and accessories can continue to use (breathing valve, safety valve, gauge steel, etc.), the system is 76 mm diameter per hour can be achieved 250T, enough to use.
B. Energy-saving systems designed by provider fully meet the safe storage and safe use of methanol. In the course of the demand side should meet process requirements and safety reliability. Ensure that the boiler furnace process temperature at the point needs time to achieve the rated cast coal (or coal) temperatures. In the boiler fueled with methanol assurance can reach more than 30% of rated load.
C. The entire device selected controllers, instrumentation, control components configured for branded products, explosion-proof grade dⅡCT4.
D. Blast furnace fuel pressure: 0.65-0 .85 Mpa
E. Blast furnace atomizing medium pressure: 0.40-0 .70 Mpa
F. Each gun burner ignition system capacity 4500000 -2160 Wan kcal / h; combustion heat value of fuel oil and methanol ratio of 2.1:1 , or methanol fuel switching is simple, stable flame burning , combustion, no black smoke , burning is atomized oil gun than the mechanical efficiency of 20% , wherein the water content of the crude alcohol 7% to incandescent flame . High point guns can automatically retractable, enabling electronic ignition function.
G. Methanol system regulator using the original system equipment or Self- regulating valve, pressure oil system to ensure stability.
H. Each boiler and cements lines with a local operating units to meet the DCS control box and remote control requirements.
I. When methanol and diesel combustion exchanged with 0.4MPa normal purge piping on it. Ensure that the fuel is completely blown to waste oil tank.
J. Compressed air blast furnace can be maintained between 0.4 ~ 0.7MPa.
K. Taking into account the methanol pump output, the original maximum flow is 15m ³ / and now the pipe line length 1500m than the original 800m long 400m, the level difference 32m than the original 20m high 12m, while the ignition cement lines also increased a in order to ensure three cement lines and two boilers running simultaneously, shield pump parameter Q = 25m³/h, H=195m, medium: methanol, temperature: room temperature power 25 KW.
2) The technical parameters
A. The gun output: Output of vulcanized sheets gun only 1000-1700KG/h, cement production line output of single gun 4800Kg/h, output is adjustable.
B. Spray angle: 60°-140°,flame center temperature:1900℃; flame length: 1m-3m
C. Air atomizing medium flow: single gun 0.1 cubic meters / minute
3. Of methanol and energy saving effect of the gun
Methanol gun atomization mechanism not only in its scientific nature , but also in its design, layout methanol guns scientific, methanol flame gun ejected angle 60°-140゜and methanol flame gun with a strong rotation, temperature up to 1400-1900℃. Methanol nozzle atomization effect is good, combustion is stable, after ignition methanol can immediately put into operation, no black smoke, thus increasing the boiler efficiency and reduce the emissions of incomplete combustion, is conducive to energy conservation and environmental protection. Methanol 1:4 gun flow adjustment, adjustment range is very wide, both for direct point of light diesel oil coal, ignition combustion, but also for no coal (such as cold ignition) satiation with load, so that the fuel system can be greatly simplified.
4. Blast furnace fuel methanol system
(1) Electric furnace control system：
Figure 2 CIMAC-3001HFM probe wiring wire 4 ~ 20mA standard output
Figure 3 CIMAC-3001HFM1 probe three-wire connection mode 4 ~ 20mA standard output
(2) Thermal control functions:
A. All access control system DCS system.
B. Left in situ cabinets communication interface with other systems, Yingjie point capacity AC220V 3A.
(3) Programmable ignition control section:
DCS process control to achieve at a time when local control cabinet control is invalid. Process control I / O points are as follows:
A. Control output: boiler controlled device through any corner angle control cabinet accepts DCS system sends the following command (passive contact):
Point guns control commands (forward, back)
Valve control command (ON, OFF)
Atomizing valve control commands (ON, OFF)
Purge valve control command (ON, OFF)
Ignition control command (ignition, stop)
B. Boiler controlled device through any corner to corner cabinet DCS control system provides the following status signals (passive contact):
Manual / programmed switch in the “programmable " bit
Point guns thruster back in place
Point guns pusher into place
Methanol valve off place
Methanol valve opening position
Atomizing valve off place
Atomizing valve opening position
Purge valve off place
Purge valve opening position
C. Local ignition control section
The first step requires manual control controls cabinet in the corner on the operator panel select "Manual”, then the corresponding corner point guns, oil guns, oil valve and steam valve separate forward, back, open and close and hit the igniter fire operations.
D. OFT action to provide protection setting value , OFT interlock logic settings and OFT reset conditions ; start the burner purge conditions , sequential , logical , time setting ; achieve sequential automatic ignition control .
5. Scope of supply
(1) Fluidized bed boiler combustion system: (one furnace)
(2) Cement production line combustion system: 3 lines
|
|
Name |
Number |
Units |
|
Air atomizing gun methanol |
3 |
Root |
|
|
2 |
Metal hose |
6 |
Root |
|
3 |
Valve |
6 |
|
|
4 |
Valve |
18 |
|
|
5 |
Check Valve |
6 |
|
|
6 |
Electric valve |
9 |
|
|
7 |
Self-regulating valve |
3 |
|
|
8 |
Local control cabinet |
3 |
|
|
9 |
High-energy ignition (including pole cable) |
3 |
Set |
|
10 |
Gauge |
9 |
|
|
11 |
Point guns thruster |
3 |
|
|
12 |
Fire detection |
3 |
Set |
|
13 |
Flowmeter |
3 |
|
|
14 |
Filter |
6 |
|
|
15 |
DPM |
1 |
Batch |
(3) Methanol pump
Guaranteed three cement lines and two boilers running simultaneously shield pump parameter Q = 25m³/h, H=195m, medium: methanol, temperature: normal temperature, power=25KW. Operate with a control cabinet may meet DCS remote control operation.