Φ3200自身返碱蒸汽煅烧炉的增产降耗研究与设备改造
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摘要
纯碱是极其重要的基础化工产品之一，重碱煅烧是纯碱生产的重要工序，蒸汽煅烧炉是当今世界上重碱煅烧的高效节能设备。本课题结合自贡鸿鹤化工股份有限公司采用的国内研制的最大规模自身返碱蒸汽煅烧炉在投入生产运行的较长时间内，始终存在着设备运行周期短、产量低、能耗高的重大技术经济难题。分析研究产生上述问题的原因，提出若干增产降耗的措施，对设备进行技术改造。
通过改造返碱进出口结构，增大了返碱量，使断续进碱改为了连续进碱，避免了炉头的结疤刷浆，延长了设备运行周期，同时改变炉头排放不凝气为炉尾排放或取消不凝气系统，利用蒸汽和冷凝水同向流动自动排放不凝气后彻底根除了因排不凝气小管泄漏产生影响设备运行周期的顽疾，使煅烧炉的运行周期由1999年的20天延长到了三个月，现在已能达到连续运行半年以上，设备运转率提高到96％，进入了纯碱行业煅烧炉运转率的先进行列。
针对煅烧炉产量低的难题，提出了对煅烧炉进行三大技术改造的措施。首先是对煅烧炉进行加转提速，把转速由4r／min提高到5r／min。其次是新增煅烧炉的加热面积。使1号煅烧炉的加热面由2670m~2提高到3307m~2。2号煅烧炉的加热面积增加幅度更大，使总加热面积达到3600m~2，同时改原加热蒸汽和冷凝水逆向流动为同向流动，起到了强化传热和强制疏水的作用。第三是补充和完善了1号煅烧炉原1.88m长的预混段，对2号段烧炉通过炉头的改造，增加了预混段的长度，使预混段的总长达到5.32m，这一改造提高了返碱和重碱的预
摘要
混效果。通过上述三大技术改造后，生产能力明显提高，使1号缎烧炉的日产
量由原来的400一450t提高到55Ot，首次达到了设计的生产能力。2号锻烧炉的
日产量达到550一60Ot，超过原设计的生产能力550灯d.台，增产幅度达37.5%。
由于返碱和重碱的预混效果得到改善，纯碱的质量也提高了。吨碱蒸汽消耗由
改前的1530k幼下降到1484k沙，汽耗下降了3%，单台炉全年少消耗8349t，
节约资金达56.8万元。2号锻烧炉的运行电流由过去的220~260A下降到180一
220A，全年节电达12~18万kwh，折算金额5.04一7.56万元。
锻烧炉的密封问题是行业共同关心的一大技术难题。通过对密封机理和结
构的分析对比后，提出了两套密封改造的方案，其共同点都是想把泄漏到机械
密封之前的碱粉返回锻烧炉内，机械密封主要起封气(炉气和空气)的作用。
两套方案实施的结果表明，碱损减少了一些，炉气CO:的浓度变化很小。操作
环境得到一定程度的改善。
锻烧炉保温材料粉化流失造成了环境的污染，同时也破坏了托轮滚圈和大
小传动齿轮的润滑，以及增加了锻烧炉的热损失。在调研的基础上使用复合硅
酸盐保温材料取代传统的超细玻璃棉毡和泡沫石棉毡，完全避免了因材料粉化
流失造成的环境污染和热能的损失。收到了很好的经济效益和环境效益。
本文最后根据对锻烧炉改造的成功和失败的经验，提出了几点操作性较好
的建议，以充分发挥中 3200自身返碱蒸汽锻烧炉的潜能。
关键词纯碱自身返碱蒸汽锻烧设备改造增产降耗
Soda is a very important basal chemical product. The calcination of sodium bicarbonate is the crucial working procedure of soda production. The high-efficiency and energy-saving equipment of calcination is Steam calciner at present. According to the technique and economical problems such as short running period, low production and high consumption that encountered in the running of the largest self return soda ash Steam calciner inland at Honghe Chemcial Inc., this paper analyses the cause of the problems above mentioned and puts forward the solutions to reconstruct the calciner to increase production and to decrease consumption .Via the reconstruction at the entrance of return soda ash of calciner, the quantity of return soda is increased, and this changes the way that soda enter the calciner from discontinuous entering to continuous entering, avoids scaring at the entrance of return soda of calciner, and prolongs the running period of calciner. Meanwhile, we change the discharging approach, which is that from discharging the non-condensable gas out of calciner from its head to the exterior of rear, or to discharge the non-condensable gas automatically without any discharging tubule by utilizing the forward flow between steam and cooling water. As a result, the puzzle, which is that the running period of calciner is affected by the leak of non-condensable gas tubule, gets solved absolutely. The running period of calciner is prolonged from 20 days in 1990 to three month. It can be over half a year now. The running efficiency of self return soda ash Steam calciner is improved to 96%. This comes up to the advanced standard of soda industry.
Aiming at the problem, which is that the production of calciner is low, this paper puts forward three momentous technique-improving measures. One is that improving the rotation numbers of calciner from 4r/min to 5r/min. Another is that increasing the heating area of 1# calciner from 2670 m~2to 3307 m~2. The heating area of 2 calciner increases much bigger, its total heating area is up to 3600 m . And changing the relative flow direction between steam and cooling water from adverse current to forward flow. This enhances heat transfer and forces hydrophobic. And the third is that reinforcing the 1.88-meter- long premixing section of 1# calciner and adding new premixing section to 2# calciner. The total length of the premixing section comes up to 5.32 meters. So the premixing effection gets improved. Via the three large technique improving measures aforesaid , the capability of calciner is improved apparently, the throughput of 1# calciner, with the capability for 400-450t/d before, is improved to 550t/d, it reaches the designed capability for the first time. The throughput of 2# calciner is improved to 550~600t/d, it overpasses the designed capability which is 550t/d, it increases 37.5%. The quality of soda ash also gets improved because of the amelioration of the premix of return soda and sodium bicarbonate. The consumption of steam is reduced from 1530kg/t to 1484kg/f, it reduces 3% and saves 8349t steam in one year, this can save RMB 568,000 yuan. The running current of 2 calciner is reduced from 220-260A before to 180-200A, this saves 120,000- 180,000kwh in one year, that is RMB 50,400-75,600 yuan.The sealing problem of calciner is a big technology puzzle concerned by the whole industry. Two improving solutions for the seal of calciner are represented through analyzing and comparing the principle and the structures of the seal. Their common characteristic is to make the soda ash, which is leaked to the front of mechanical seals, back to the inner calciner. The functing of mechanical seals is to isolate the inner gas and the air outside. The implementing results of the two solutions show that the waste of soda ash is reduced, the density of inner gas(CO2) changes little and the operation environment is ameliorated.The pulverous efflux of insulated material of calciner results in environmental pollution, destroys the lubrication of the rolling ring and supporting wheel and the
inc
通过改造返碱进出口结构，增大了返碱量，使断续进碱改为了连续进碱，避免了炉头的结疤刷浆，延长了设备运行周期，同时改变炉头排放不凝气为炉尾排放或取消不凝气系统，利用蒸汽和冷凝水同向流动自动排放不凝气后彻底根除了因排不凝气小管泄漏产生影响设备运行周期的顽疾，使煅烧炉的运行周期由1999年的20天延长到了三个月，现在已能达到连续运行半年以上，设备运转率提高到96％，进入了纯碱行业煅烧炉运转率的先进行列。
针对煅烧炉产量低的难题，提出了对煅烧炉进行三大技术改造的措施。首先是对煅烧炉进行加转提速，把转速由4r／min提高到5r／min。其次是新增煅烧炉的加热面积。使1号煅烧炉的加热面由2670m~2提高到3307m~2。2号煅烧炉的加热面积增加幅度更大，使总加热面积达到3600m~2，同时改原加热蒸汽和冷凝水逆向流动为同向流动，起到了强化传热和强制疏水的作用。第三是补充和完善了1号煅烧炉原1.88m长的预混段，对2号段烧炉通过炉头的改造，增加了预混段的长度，使预混段的总长达到5.32m，这一改造提高了返碱和重碱的预
摘要
混效果。通过上述三大技术改造后，生产能力明显提高，使1号缎烧炉的日产
量由原来的400一450t提高到55Ot，首次达到了设计的生产能力。2号锻烧炉的
日产量达到550一60Ot，超过原设计的生产能力550灯d.台，增产幅度达37.5%。
由于返碱和重碱的预混效果得到改善，纯碱的质量也提高了。吨碱蒸汽消耗由
改前的1530k幼下降到1484k沙，汽耗下降了3%，单台炉全年少消耗8349t，
节约资金达56.8万元。2号锻烧炉的运行电流由过去的220~260A下降到180一
220A，全年节电达12~18万kwh，折算金额5.04一7.56万元。
锻烧炉的密封问题是行业共同关心的一大技术难题。通过对密封机理和结
构的分析对比后，提出了两套密封改造的方案，其共同点都是想把泄漏到机械
密封之前的碱粉返回锻烧炉内，机械密封主要起封气(炉气和空气)的作用。
两套方案实施的结果表明，碱损减少了一些，炉气CO:的浓度变化很小。操作
环境得到一定程度的改善。
锻烧炉保温材料粉化流失造成了环境的污染，同时也破坏了托轮滚圈和大
小传动齿轮的润滑，以及增加了锻烧炉的热损失。在调研的基础上使用复合硅
酸盐保温材料取代传统的超细玻璃棉毡和泡沫石棉毡，完全避免了因材料粉化
流失造成的环境污染和热能的损失。收到了很好的经济效益和环境效益。
本文最后根据对锻烧炉改造的成功和失败的经验，提出了几点操作性较好
的建议，以充分发挥中 3200自身返碱蒸汽锻烧炉的潜能。
关键词纯碱自身返碱蒸汽锻烧设备改造增产降耗
Soda is a very important basal chemical product. The calcination of sodium bicarbonate is the crucial working procedure of soda production. The high-efficiency and energy-saving equipment of calcination is Steam calciner at present. According to the technique and economical problems such as short running period, low production and high consumption that encountered in the running of the largest self return soda ash Steam calciner inland at Honghe Chemcial Inc., this paper analyses the cause of the problems above mentioned and puts forward the solutions to reconstruct the calciner to increase production and to decrease consumption .Via the reconstruction at the entrance of return soda ash of calciner, the quantity of return soda is increased, and this changes the way that soda enter the calciner from discontinuous entering to continuous entering, avoids scaring at the entrance of return soda of calciner, and prolongs the running period of calciner. Meanwhile, we change the discharging approach, which is that from discharging the non-condensable gas out of calciner from its head to the exterior of rear, or to discharge the non-condensable gas automatically without any discharging tubule by utilizing the forward flow between steam and cooling water. As a result, the puzzle, which is that the running period of calciner is affected by the leak of non-condensable gas tubule, gets solved absolutely. The running period of calciner is prolonged from 20 days in 1990 to three month. It can be over half a year now. The running efficiency of self return soda ash Steam calciner is improved to 96%. This comes up to the advanced standard of soda industry.
Aiming at the problem, which is that the production of calciner is low, this paper puts forward three momentous technique-improving measures. One is that improving the rotation numbers of calciner from 4r/min to 5r/min. Another is that increasing the heating area of 1# calciner from 2670 m~2to 3307 m~2. The heating area of 2 calciner increases much bigger, its total heating area is up to 3600 m . And changing the relative flow direction between steam and cooling water from adverse current to forward flow. This enhances heat transfer and forces hydrophobic. And the third is that reinforcing the 1.88-meter- long premixing section of 1# calciner and adding new premixing section to 2# calciner. The total length of the premixing section comes up to 5.32 meters. So the premixing effection gets improved. Via the three large technique improving measures aforesaid , the capability of calciner is improved apparently, the throughput of 1# calciner, with the capability for 400-450t/d before, is improved to 550t/d, it reaches the designed capability for the first time. The throughput of 2# calciner is improved to 550~600t/d, it overpasses the designed capability which is 550t/d, it increases 37.5%. The quality of soda ash also gets improved because of the amelioration of the premix of return soda and sodium bicarbonate. The consumption of steam is reduced from 1530kg/t to 1484kg/f, it reduces 3% and saves 8349t steam in one year, this can save RMB 568,000 yuan. The running current of 2 calciner is reduced from 220-260A before to 180-200A, this saves 120,000- 180,000kwh in one year, that is RMB 50,400-75,600 yuan.The sealing problem of calciner is a big technology puzzle concerned by the whole industry. Two improving solutions for the seal of calciner are represented through analyzing and comparing the principle and the structures of the seal. Their common characteristic is to make the soda ash, which is leaked to the front of mechanical seals, back to the inner calciner. The functing of mechanical seals is to isolate the inner gas and the air outside. The implementing results of the two solutions show that the waste of soda ash is reduced, the density of inner gas(CO2) changes little and the operation environment is ameliorated.The pulverous efflux of insulated material of calciner results in environmental pollution, destroys the lubrication of the rolling ring and supporting wheel and the
inc
引文
[1] 中国纯碱工业协会．纯碱工学．北京化学工业出版社．1990
[2] 戎寿昌．刍议煅烧炉的预混装置．纯碱工业 1984．5：28～30
[3] 程迈．钱华明．郑敏秀．唐锁云．煅烧炉前预混装置的研究与应用纯碱工业．1989．5：13～16
[4] 王楚．纯碱生产工艺与设备计算．北京化学工业出版社．1995
[5] 钱志奎．近几年我国纯碱生产技术的进展及发展前景．纯碱工业 2001．1：10
[6] 李远松．纯碱蒸汽煅烧炉工程设计中几个问题的探讨．纯碱工业 1999．3：6～23
[7] 许昌犁．φ3200自身返碱蒸汽煅烧炉的改进．纯碱工业．1993．1：18～23
[8] 李正明．王首娥．一种新型的保温材料—复合硅酸盐节能保温涂料．纯碱工业．1994．1：11～14
[9] 湖南冷水江制碱厂．殚精竭虑．不断完善变换气制碱．纯碱工业 1990．2：15～18
[10] 赵根庆．刘军．魏浩源．唐环荣．取消蒸汽煅烧炉不凝气管的可行性纯碱工业．1992．5：34～36
[11] 刘惠凤．韩光琨．对蒸汽煅烧炉不凝气体释放问题的浅见．纯碱工业． 1997．4：33～34
[12] 高志刚．侯景琪．φ3.6×30轻灰炉改造．纯碱工业．1998．5：48～52
[13] 毛希澜．化工设备设计全书．换热器设计．上海科学技术出版社．1989
[14] 侯亮平．鸿化纯碱工艺操作规程．1998．1：50～160
[2] 戎寿昌．刍议煅烧炉的预混装置．纯碱工业 1984．5：28～30
[3] 程迈．钱华明．郑敏秀．唐锁云．煅烧炉前预混装置的研究与应用纯碱工业．1989．5：13～16
[4] 王楚．纯碱生产工艺与设备计算．北京化学工业出版社．1995
[5] 钱志奎．近几年我国纯碱生产技术的进展及发展前景．纯碱工业 2001．1：10
[6] 李远松．纯碱蒸汽煅烧炉工程设计中几个问题的探讨．纯碱工业 1999．3：6～23
[7] 许昌犁．φ3200自身返碱蒸汽煅烧炉的改进．纯碱工业．1993．1：18～23
[8] 李正明．王首娥．一种新型的保温材料—复合硅酸盐节能保温涂料．纯碱工业．1994．1：11～14
[9] 湖南冷水江制碱厂．殚精竭虑．不断完善变换气制碱．纯碱工业 1990．2：15～18
[10] 赵根庆．刘军．魏浩源．唐环荣．取消蒸汽煅烧炉不凝气管的可行性纯碱工业．1992．5：34～36
[11] 刘惠凤．韩光琨．对蒸汽煅烧炉不凝气体释放问题的浅见．纯碱工业． 1997．4：33～34
[12] 高志刚．侯景琪．φ3.6×30轻灰炉改造．纯碱工业．1998．5：48～52
[13] 毛希澜．化工设备设计全书．换热器设计．上海科学技术出版社．1989
[14] 侯亮平．鸿化纯碱工艺操作规程．1998．1：50～160