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Common accidents and treatment measures in cement plant

Date:2019-08-22 15:54 Source:cementepcViews:

Major equipment accidents and process accidents may occur at any time in the production process of cement factory. Every factory should set up emergency plan as soon as possible to prevent further expansion of the accident.In case of accident, it is necessary to deal with the problem correctly and effectively, so as to minimize the loss and injury of the factory and employees.
 

1. Raw material feeding scale is out of order


(1) increase the rotation speed of the high-temperature fan to prevent the preheater from collapsing and blocking due to the sudden increase or decrease of the material quantity.

(2) reduce kiln speed to prevent running raw materials.

(3) increase the amount of coal fed to the kiln head, increase the temperature of the firing zone, leave the fire to wait for the material, and ensure the quality of the clinker is not affected.

(4) when the electrical personnel go to the equipment warehouse to look for solenoid valve spare parts, and the valve opening of pneumatic valve reaches 100%, the pneumatic valve inlet pipe shall be pulled out quickly to reduce the fluctuation of raw material feeding quantity into the kiln.

(5) replace the solenoid valve, connect the air inlet pipe of the pneumatic valve, and resume normal production.

Feeding scale

2. The preheater is blocked


Most of the time of preheater blockage occurs shortly after feeding, when the kiln operation is abnormal, the thermal system is unstable, the system accidents are many, which leads to the frequent opening and stopping of the kiln, skilling and falling, serious air leakage, and mechanical failure.

After the preheater block, if found not timely, it is possible to block from the feeding pipe to the preheater cone, or even block the whole cyclone tube, bring great difficulty to the preheater block.Some manufacturers have to adopt the blasting method with hidden safety risks to clear the blockage, improper operation of the blockage will cause serious accidents of casualties.Therefore, it is of great significance to formulate and strictly operate in accordance with the pre-heater blocking plan to prevent casualties and restore normal production of the blocked parts as soon as possible.

Preparation before plugging removal: prepare plugging removal tools, such as 6 pieces of steel pipe (5m~7m), rubber pipe, protective mirror, asbestos clothes, gloves, wire, pliers, etc.Organize personnel and unified command to ensure safety.

 

The central control operation shall be adjusted as follows:


(1) after confirming that the preheater is blocked, stop the coal feeding in the decomposition furnace and the raw material feeding in the kiln immediately.

(2) inform the waste heat generation operator to make corresponding adjustments.

(3) reduce the high temperature fan draft, pay attention to control the kiln head negative pressure, grate cooler cooling fan inlet valve can be gradually reduced from the low temperature section to the high temperature section, to ensure normal clinker cooling.

(4) open the ignition chimney cap so that the outlet temperature of C1 Jane does not exceed 400C.

(5) appropriately reduce the kiln speed and the amount of coal used in kiln head according to the temperature in the kiln.

(6) stop the main drive of the kiln and use auxiliary motor to intermittently rotate the kiln on the site if the blockage removal cannot be completed within 30min;If the blockage is serious, stop the kiln head to feed coal, stop the kiln treatment, can be cleaned in a short time, can be treated as kiln insulation.

(7) control the negative pressure of the one-stage cyclone tube to ensure the safety of the on-site plugging personnel.

(8) it is forbidden to fire air cannon during blocking removal to prevent high-temperature gas or materials from shooting out and burning blocking personnel.

(9) it is strictly forbidden to stand in the pit of kiln head, grate cooler and clinker conveying when blocking is cleared, so as to prevent fresh materials from pouring out and injuring people.The gush of raw material should be promptly cleaned to prevent personnel from being burned.

preheater

3. High temperature fan air inlet collapse material


(1) in order to prevent the preheater from clogging due to material collapse, the amount of raw material feeding into the kiln shall be appropriately reduced as the case may be;

(2) in order to prevent the high-temperature fan from tripping and stopping due to the current exceeding the limit for a long time, properly close the inlet valve, and return to normal after the collapse;

(3) the inspection personnel of kiln head should stay away from the kiln mouth and grate cooler to prevent burns;

(4) as the amount of hot air into the mill decreases, the raw material vertical mill should reduce the amount of feeding, appropriately reduce the speed of the separator, avoid excessive vibration and stop.After the high temperature fan collapse ends, restore the speed of the separator in time to prevent the coarse fineness of raw material from grinding from affecting the calcining of the kiln.

 

4.High temperature fan trip


In normal production, high temperature air may be shut down because of electrical failure, fan oil supply system failure or kiln tail exhaust fan trip.After the high-temperature fan tripping, the kiln tail preheater system will soon show positive pressure, and then the kiln head will return to fire with positive pressure, and the gas temperature into the electric dust collector of the kiln head will rise sharply, seriously endangering the personal safety and equipment safety of field inspection personnel.At this time, if the effective measures are not taken, the preheater will be blocked, the electric dust collector of the kiln head will be burned, and the accident of the burn inspector will be caused.
 

In case of high temperature fan trip accident, the central control operation shall promptly take the following measures according to the accident treatment plan:


(1) through the intercom, inform the site inspection personnel to take an emergency risk, and leave the preheater, the ramming hole and manhole door of the smoke room as soon as possible, and no one is allowed to stand in front of the kiln head and grate cooler to ensure personal safety;

(2) stop feeding coal in the decomposing furnace and raw material into the kiln to prevent clogging of the preheater;

(3) open the ignition bacon cap, close the fan inlet valve in the low temperature section of the grate cooler, increase the opening of the inlet valve of the kiln head exhaust fan, and ensure the abnormal pressure of the kiln head.

(4) inform the waste heat generation operator to make corresponding adjustments;

(5) reduce kiln speed appropriately to prevent running raw materials;

(6) reduce the amount of coal used in kiln head and stop coal when necessary;

(7) according to the inlet temperature of electric dust collector of kiln head, open the cold air valve in the inlet pipe appropriately to protect the dust collector from being burned;

(8) find out the cause of tripping and contact relevant personnel to deal with it. Close the high temperature fan inlet valve and get ready for starting.

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