Modularized installation process for low-energy-consumption and high-efficiency calcium carbide production line

Abstract

The invention relates to the technical field of calcium carbide installation operation, in particular to a low-energy-consumption and high-efficiency calcium carbide production line modular installation process which comprises furnace body installation, a raw material storage and transportation module, a carbon material drying module, a screening and batching module, a furnace gas purification module, a raw material conveying module, an electric furnace feeding module, an electrode paste feeding module and a calcium carbide production module. According to the raw material storage and transportation module, lime is fed through a vibrating feeder, switched to be distributed through an electro-hydraulic three-way distributor and conveyed to a batching station through a belt conveyor. The other part of lime enters a lime shed for temporary storage through a conveyor, materials are unloaded to an underground material receiving pit through a wheel loader, are fed through a vibrating feeder and are conveyed to a screening and batching station through a belt conveyor; according to the calcium carbide production process, through scientific process improvement, the production efficiency of a calcium carbide production line is effectively improved, the production environment pollution of the production line is reduced, meanwhile, the production energy consumption of the production line is reduced, and the production and use requirements of enterprises are effectively met.

Description

Technical Field

[0001] This invention relates to the field of calcium carbide production technology, specifically to a modular installation process for a low-energy-consumption, high-efficiency calcium carbide production line. Background Technology

[0002] Electrolytic stone, commonly known as calcium carbide, is an inorganic compound. Pure electrolytic stone is a colorless crystal (high-purity electrolytic stone is purple), while industrial grade electrolytic stone is often a yellowish-brown or black lumpy solid with a density of 2.22 g / cm³ and a melting point of 447℃. It is chemically reactive, reacting rapidly with water to produce acetylene gas and calcium hydroxide, releasing heat in the process. Industrial production primarily utilizes an electric furnace smelting method, reacting coke with calcium oxide at approximately 2200℃. The oxythermal method employs an oxygen-enriched blast furnace process to improve resource utilization. Electrolytic stone is widely used in acetylene welding, organic synthesis, and polyvinyl chloride (PVC) production. While the reaction product acetylene can be used as fuel, impurities can produce toxic gases such as arsine and phosphine, requiring purification with sulfuric acid and potassium dichromate. This substance is flammable when wet and reacts violently with acids; strict protective measures are required during handling, and leaks must be safely recovered with sand or dry lime. After more than 60 years of development, my country's domestic calcium carbide industry has become an important basic chemical raw material industry. It mainly uses the electrothermal method to produce calcium carbide, with electric furnaces including open furnaces and semi-closed furnaces. However, these calcium carbide production lines suffer from complex installation processes, high energy consumption, harsh working environments, and severe environmental pollution, which greatly restrict the development of my country's calcium carbide industry. Therefore, designing a low-energy-consumption, high-efficiency calcium carbide production line installation and operating system is extremely urgent. Summary of the Invention

[0003] The purpose of this invention is to provide a modular installation process for a low-energy-consumption, high-efficiency calcium carbide production line. This calcium carbide production process, through scientific process improvement, effectively increases the production efficiency of the calcium carbide production line, reduces environmental pollution during production, and reduces energy consumption, thus effectively meeting the production and usage needs of enterprises.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: A modular installation process for a low-energy-consumption, high-efficiency calcium carbide production line includes a furnace body installation module, a raw material storage and transportation module, a carbon material drying module, a screening and distributing module, a furnace gas purification module, a raw material conveying module, an electric furnace feeding module, an electrode paste feeding module, and a calcium carbide production module. The raw material storage and transportation module: lime is fed by a vibrating feeder, and the electro-hydraulic three-way distributor switches the distribution. The belt conveyor transports the lime to the batching station. Another part of the lime is temporarily stored in the lime shed by a conveyor. The material is unloaded into the underground receiving pit by a wheel loader, fed by a vibrating feeder, and transported to the screening and batching station by a belt conveyor. The charcoal drying module: qualified semi-coke material is conveyed to the top of the vertical drying kiln via a vibrating feeder, a steep-angle belt conveyor, a feed tee, and a reversible belt conveyor. Simultaneously, a hot air furnace supplies hot air into the kiln, ensuring full contact between the hot air and the material, removing moisture. Inside the vertical dryer, the moisture content of the semi-coke is reduced from ~15% to below 1%. The raw material conveying module: Semi-coke is conveyed to the silo via a belt conveyor, and then falls from the silo by gravity, and is evenly added to the weighing hopper by a vibrating feeder for weighing; Lime is conveyed to the silo via a belt conveyor, and then falls from the silo by gravity, and is evenly added to the weighing hopper by a vibrating feeder for weighing; The two raw materials are weighed in a ratio of 56:100, and the motor feeder adopts frequency conversion speed regulation control to ensure accurate weighing and proportioning of materials; The electric furnace feeding module: qualified lime and semi-coke are sent to the calcium carbide production workshop by the mixed material conveyor, and enter the furnace top silo through the ring feeder of the calcium carbide furnace. The mixed material in the silo enters the calcium carbide furnace continuously by gravity through the downward extending material pipe and the feed port on the furnace cover. The electrode paste feeding module: The electrode paste, which is installed in the electrode paste hopper, is lifted from the ground to the top of each electrode cylinder by a monorail and poured into the electrode cylinder; The calcium carbide production module: After the raw materials are added into the furnace according to the formula, electrical energy is input into the calcium carbide furnace through the transformer, short grid, combined holder and electrodes to generate a high temperature of about 2000℃~2200℃. The molten raw materials react to produce calcium carbide. Liquid calcium carbide is intermittently put into the calcium carbide pot from the furnace outlet. The calcium carbide pot is placed on the calcium carbide trolley and pulled to the calcium carbide cooling workshop by the winch for cooling.

[0005] Furthermore, in the raw material storage and transportation module, the carbon material comes from two sources: externally supplied coke and semi-coke. A carbon material storage shed is set up. The incoming material is first unloaded into the carbon material storage shed by truck, and then piled into the receiving hopper by a loader. The material is then sent to the carbon material drying system for drying by the vibrating feeder at the bottom of the hopper and the belt conveyor.

[0006] Furthermore, in the charcoal drying module, the exhaust gas from the vertical drying kiln is filtered by a bag filter system before being discharged into the atmosphere, ensuring ultra-low emission standards for environmental protection. The vertical drying kiln is equipped with an electro-hydraulic gate valve and a four-way material distribution valve. Qualified dried materials can be transported to the batching station via a finished product belt conveyor and a finished product inclined conveyor. Unqualified materials are sent to the return silo via a return material belt conveyor.

[0007] Furthermore, in the screening and distribution module, the module consists of a lime transfer conveyor belt, a lime screening and distribution station conveyor belt, a charcoal transfer conveyor belt, a charcoal screening and distribution station conveyor belt, a screening and distribution station, a transfer station, and a storage and transportation station. The screening and distribution station completes the screening of lime and charcoal, and the storage of lime, charcoal lumps and powders. It is equipped with 4 lime lump silos and 4 charcoal lump silos, and the storage of lime and charcoal lumps must meet the needs of the two electric furnaces in this project for at least 12 hours. It is equipped with 2 lime powder silos and 2 charcoal powder silos, which can meet the needs of at least two days. The station is equipped with 2 lime screens and 2 charcoal screens. The screened lumps are distributed to the silos via short conveyor belts. The screening and distribution station is equipped with a weighing device at the bottom to complete the accurate measurement of raw materials.

[0008] Furthermore, in the furnace gas purification module, the calcium carbide furnace gas collects some dust through a settling device to reduce the load on subsequent subsystems. After further dust removal by a cyclone dust collector and cooling by a cooler, the gas is pressurized by a coarse air blower and then filtered by a bag filter. The filtered gas is then transported to the furnace gas pipeline network by a clean air blower and finally connected to the gas holder. The filtered dust is transported to the furnace gas purification ash hopper by a sealed scraper conveyor. Each ash discharge port is strictly calculated based on the angle of repose of the dust to ensure that the inclination angle of the ash hopper is not less than 60 degrees and there are no internal angles, so as to avoid ash accumulation and blockage and ensure smooth ash discharge. The pressure relief and explosion protection of the entire furnace gas purification module are automatically controlled by a computer to ensure reliable system operation.

[0009] Furthermore, in the raw material conveying module, the weighed materials are released from the weighing hopper and fed onto the belt conveyor by the motor vibrating feeder. Then, the belt conveyor delivers the mixed raw materials to the ring feeder of each calcium carbide furnace, and then unloads them into the furnace charge silo. The conveying, metering, and belt alignment of the raw materials are all automatically controlled by the computer system.

[0010] Furthermore, in the calcium carbide production module, the calcium carbide production steps are as follows: S1. After the raw materials are added into the furnace according to a certain ratio, electrical energy is input into the calcium carbide furnace through a transformer, short grid, combined holder, and electrodes to generate a high temperature of about 2000℃~2200℃. The molten raw materials react to produce calcium carbide. Liquid calcium carbide is intermittently poured from the furnace outlet into the calcium carbide pot, which is placed on a calcium carbide trolley and pulled by a winch to the calcium carbide cooling workshop for cooling. The by-product, calcium carbide furnace gas, is treated by a purification device and used as fuel for lime kilns to calcine lime production. S2. During the calcium carbide production process, the electrodes are gradually consumed, so it is necessary to extend the electrode shell. The process of extending the electrode shell and adding electrode paste is as follows: Use the predetermined jacket → Place the electrode shell to be extended on the electrode column to be extended, so as to maintain good concentricity → Weld the two circular steel cylinders and the inner stiffeners firmly → Complete the electrode shell extension operation. S3. The smelted liquid calcium carbide is removed from the furnace once per hour. The liquid calcium carbide flows into the calcium carbide pot on the calcium carbide trolley and is pulled to the cooling plant by a winch. The calcium carbide pot is lifted off the trolley by a bridge crane and placed in the "hot pot pre-cooling zone" for cooling. S4. After 2 hours, the solidified calcium carbide is lifted out of the pot and placed in the cooling zone to continue cooling. After cooling, the entire calcium carbide is lifted out of the pot by a crane using special clamps and sold as a finished product.

[0011] The furnace body installation includes the following operations: Installing the furnace shell, furnace cover, and electrode posts: First, determine the center of the calcium carbide furnace and the center of the electrodes, and lay out the lines according to the process drawings. Then, use the furnace center and the electrode center as reference points to determine the relative positions of each piece of equipment. Check whether the positions of the foundations, reserved holes, and embedded parts of each piece of equipment meet the requirements of the drawings. Installing the furnace shell: First, lay the bottom row of the furnace shell, and then install the furnace shell on this basis. Note that you should first find the position of the furnace core, and then weld the furnace shell on this basis. The roundness error of the furnace shell should be less than 10mm. Furnace cover installation: First, assemble the six sector-shaped sections, then install the center section of the furnace cover, followed by the hanging device, ensuring alignment with the furnace core and electrode center. Finally, install the water-cooled sealing sleeve and water-cooled piping on the furnace cover; this part should be done after the electrode columns are installed. Since all six sector-shaped sections and the center section of the furnace cover are water-cooled, a water pressure test of 0.46 MPa should be performed before installation. Installation can proceed only after confirming there are no leaks.

[0012] Furthermore, the electrode posts are installed from top to bottom: a. First, lower the two lifting cylinders to their lowest positions, place the pressing platform between the two cylinders, and connect the auxiliary hanging device to the pressing platform; then, adjust the center of the pressing platform according to the plumb line so that it is aligned with the center of the electrode; and adjust the cylinder support on the pressing platform to be horizontal. After achieving the above requirements, connect the pressing platform to the cylinder. b. Installation of the holding cylinder: The holding cylinder consists of two parts, upper and lower. The upper holding cylinder is connected to the lower flange of the pressing platform, and the lower holding cylinder is connected to the secondary busbar hanger and water-cooled hanger. Contact elements, water-cooled protective sleeves, bottom rings, etc. are all installed on the lower holding cylinder. After the upper holding cylinder is installed, raise the lifting cylinder to the highest position and support it firmly with a steel frame. Then install the lower holding cylinder. Before connecting the lower holding cylinder to the upper holding cylinder, the connecting bolts, insulating gaskets, insulating sleeves, and flange surfaces should be cleaned. c. Measure whether the plumb line is centered at the bottom of the holding tube and align it accordingly; d. Hoist the bottom rings. Assemble the five bottom rings and their hanging devices. Using the plumb line as the baseline, find the center of the bottom rings. Measure the alignment of the electrode clamps of the pressing device and the semicircle of the bottom rings. Measure in sequence to ensure strict alignment. After completing the above connection steps, tighten the connecting bolts of each part. e. Before installing the contact element, make an auxiliary electrode shell according to the size of the electrode shell. The auxiliary electrode shell can be used as an auxiliary tool when installing the contact element. The height of the auxiliary electrode shell is about 400mm. f. Installing the contact element: First install the hanging device for the contact element, then install the contact element itself. The contact element is soldered to the vertical conductive copper pipe and the connectors using silver brazing. The upper part of the vertical conductive copper pipe is temporarily fixed while awaiting silver brazing. g. Install the water-cooled piping for the electrode post section, install the bottom ring support piping, and then connect the bottom ring inlet and outlet to the cooling water vertical pipe; during installation, pay attention to the silver solder joints at each connection point and do not damage them; h. When installing the conductive copper pipe, pay attention to cooling protection when welding the upper connector of the horizontal conductive copper pipe and the vertical conductive copper pipe to prevent the silver brazing joint between the connector and the vertical pipe from melting.

[0013] The beneficial effects of this invention are as follows: The modular installation process for a low-energy-consumption, high-efficiency calcium carbide production line, through scientific process improvements, effectively increases the production efficiency of the calcium carbide production line, reduces environmental pollution, and lowers energy consumption, effectively meeting the production needs of enterprises. Specifically, the low-energy-consumption, high-efficiency calcium carbide production system of this invention incorporates innovative structural improvements in the raw material storage and transportation module, carbon material drying module, screening and distribution module, furnace gas purification module, raw material conveying module, electric furnace feeding module, electrode paste feeding module, and calcium carbide production module. For example, it improves the feeding process by introducing hot blast stoves into the kiln... Internal hot air supply ensures full contact between the hot air and the material, removing moisture and reducing the moisture content of semi-coke from ~15% to below 1% within the vertical dryer. The exhaust gas from the vertical drying kiln is filtered by a bag filter system before being discharged into the atmosphere, effectively ensuring ultra-low emission standards. A portion of the dust from the calcium carbide furnace gas is collected by a settling device to reduce the load on downstream subsystems. The filtered dust is then transported to the furnace gas purification ash silo by a sealed scraper conveyor. Each ash discharge port is rigorously calculated based on the dust's angle of repose to ensure an inclination angle of no less than 60 degrees and no internal angles, preventing ash accumulation and blockage, and ensuring smooth ash discharge. Attached Figure Description

[0014] Figure 1 This is an overall structural block diagram of the modular installation process for the low-energy-consumption, high-efficiency calcium carbide production line of the present invention; Figure 2 This is a flowchart of the calcium carbide production process in this invention; Figure 3 This is a diagram of the physical and chemical properties of lime used in the modular installation process of this invention; Figure 4 This is a diagram showing the physicochemical properties of the carbon material used in the modular installation process of this invention. Figure 5 This is a physicochemical index diagram of the electrode paste in this invention. Detailed Implementation

[0015] The technical solutions of the present invention will be clearly and completely described below with reference to embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. It should be noted that, unless otherwise specified, all embodiments and preferred methods mentioned herein can be combined to form new technical solutions. Unless otherwise specified, all technical features and preferred features mentioned herein can be combined to form new technical solutions. Unless otherwise stated, the professional and scientific terms used herein have the same meaning as those familiar with the art. Furthermore, any methods or materials similar to or equivalent to the described content can also be applied to the present invention.

[0016] Specific Embodiment 1: As per the appendix to the specification of this invention Figure 1-5 As shown, the modular installation process of a low-energy-consumption, high-efficiency calcium carbide production line provided in this embodiment includes a furnace body installation, a raw material storage and transportation module, a carbon material drying module, a screening and distributing module, a furnace gas purification module, a raw material conveying module, an electric furnace feeding module, an electrode paste feeding module, and a calcium carbide production module. The raw material storage and transportation module: Lime is fed by a vibrating feeder, and the feed is switched by an electro-hydraulic three-way distributor. Belt conveyors then transport the lime to the respective batching stations. Another portion of lime is conveyed to a lime shed for temporary storage, then unloaded into an underground receiving pit by a wheel loader, fed by a vibrating feeder, and conveyed by a belt conveyor to the screening and batching station. The charcoal sources are externally supplied coke and semi-coke. A charcoal storage shed is provided. Incoming materials are first unloaded into the charcoal storage shed by trucks, then piled into a receiving hopper by a loader, and finally transported to the charcoal drying system for drying via a vibrating feeder at the bottom of the hopper and a belt conveyor.

[0017] The charcoal drying module: The charcoal drying module consists of a drying body, a heating system, a feeding system, a discharging system, a dust removal system, and an automated control system. Meticulously sized semi-coke from the self-wet semi-coke silo is conveyed to the top of the vertical drying kiln via a vibrating feeder, a steep-angle belt conveyor, a feed tee, and a reversible belt conveyor. Simultaneously, a hot air furnace supplies hot air into the kiln, ensuring full contact between the hot air and the material, removing moisture. Inside the vertical dryer, the moisture content of the semi-coke is reduced from ~15% to below 1%. The fluidized bed furnace uses drying dust ash as fuel; this ash is pneumatically conveyed from under the drying dust collector scraper to the semi-coke powder storage silo, and then pneumatically conveyed to the fluidized bed furnace dust ash conveying and combustion system. The exhaust gas from the vertical drying kiln is filtered by a bag filter system before being discharged into the atmosphere, ensuring ultra-low emission standards. The vertical drying kiln is equipped with an electro-hydraulic gate valve and a four-way material distribution valve. Qualified dried materials can be transported to the batching station via a finished product belt conveyor and a finished product inclined conveyor; unqualified materials are sent to the return silo via a return material belt conveyor. The drying system adopts a manual-automatic mixed control mode. Under normal circumstances, it is controlled automatically. In special needs, the manual-automatic mode can be switched via the manual / automatic knob on the on-site control box (cabinet), and then operated via the start / stop button on the control cabinet.

[0018] The screening and distributing module: The screening and distribution module consists of a lime transfer conveyor, a storage and transportation belt conveyor, a lime screening and distribution station belt conveyor, a charcoal transfer conveyor, a charcoal screening and distribution station belt conveyor, a screening and distribution station, a transfer station, and a storage and transportation station. The screening and distribution station completes the screening of lime and charcoal, and the storage of lime, charcoal lumps and powders. It has four lime lump silos and four charcoal lump silos, with the storage capacity sufficient to meet the needs of the two electric furnaces for at least 12 hours. It also has two lime powder silos and two charcoal powder silos, sufficient for at least two days' worth of storage. The station has two lime screens and two charcoal screens; the screened lumps are distributed to silos via short conveyor belts. A weighing device is installed at the bottom of the station for accurate measurement of raw materials. Dust collection devices are installed at each dust-generating point in the screening and distribution station. The dust collectors are designed to be located on the ground outside the screening and distribution station. Dust collection points above the mixing conveyor at the bottom of the station use separate dust collection for lime and charcoal; the mixing conveyor at the bottom of the station and subsequent conveyors have separate dust collectors. The charcoal drying process and distribution station utilizes steeply inclined belt conveyors. The lime transfer station to the lime storage and transportation station employs double-line, flat belt conveyors. The lime storage and transportation station to the screening and distribution station uses a single-line flat belt conveyor. The screening and distribution station connects to the main workshop using double-line flat belt conveyors. After reaching the main workshop, two short flat belt conveyors separate the raw materials for electric furnace one and electric furnace two.

[0019] The raw material conveying module: Semi-coke is conveyed to the silo via belt conveyor, then falls from the silo by gravity and is evenly added to the weighing hopper by a vibrating feeder for weighing. Lime is also conveyed to the silo via belt conveyor, then falls from the silo by gravity and is evenly added to the weighing hopper by a vibrating feeder for weighing. The two raw materials are weighed at a ratio of 56:100. The motor feeder uses frequency conversion speed control to ensure accurate weighing and proportioning. After weighing, the materials are released from the weighing hopper and fed onto the belt conveyor via the motor vibrating feeder. The belt conveyor then delivers the mixed raw materials to the annular feeder of each calcium carbide furnace, and finally unloads them into the furnace charge silo. The conveying, metering, and belt alignment of the raw materials are all automatically controlled by a computer system.

[0020] The calcium carbide furnace feeding module: Lime and semi-coke of qualified particle size are sent to the calcium carbide production workshop by a mixed material conveyor. They are then fed into the furnace top silo by the ring feeder of the calcium carbide furnace. The mixed materials in the silo are continuously fed into the calcium carbide furnace by gravity through the downward-extending material pipe and the feed port on the furnace cover.

[0021] The electrode paste feeding module: The electrode paste, which is installed in the electrode paste hopper, is lifted from the ground by a monorail crane to the top of each electrode cylinder and poured into the electrode cylinder.

[0022] The furnace installation includes the following operations: Installing the furnace shell, furnace cover, and electrode columns: First, determine the center of the calcium carbide furnace and the electrode center, and lay out the lines according to the process drawings. Then, using the furnace center and electrode center as reference points, determine the relative positions of each piece of equipment. Check whether the foundations, reserved holes, and embedded parts of each piece of equipment meet the requirements of the drawings. Installing the furnace shell: First, lay the bottom row of the furnace shell, and then install the furnace shell on this basis. Note that you should first find the position of the furnace core, and then weld the furnace shell on this basis. The roundness error of the furnace shell should be less than 10mm. Installing the furnace cover: First, assemble the six sector-shaped sections, then install the center section of the furnace cover, and then install the hanging device, making sure to align it with the furnace core and electrode center. Finally, install the water-cooled sealing sleeve and the water-cooled pipes on the furnace cover. This part should be done after the electrode columns are installed. Since the six sector-shaped sections and the center section of the furnace cover are all water-cooled structures, a water pressure test should be performed before installation. The test pressure is 0.46MPa. Installation can only proceed if there is no leakage.

[0023] The electrode posts are installed from top to bottom: a. First, lower the two lifting cylinders to their lowest positions, place the pressing platform between the two cylinders, and connect the auxiliary hanging device to the pressing platform; then, adjust the center of the pressing platform according to the plumb line so that it is aligned with the center of the electrode; and adjust the cylinder support on the pressing platform to be horizontal. After achieving the above requirements, connect the pressing platform to the cylinder. b. Installation of the holding cylinder: The holding cylinder consists of two parts, upper and lower. The upper holding cylinder is connected to the lower flange of the pressing platform, and the lower holding cylinder is connected to the secondary busbar hanger and water-cooled hanger. Contact elements, water-cooled protective sleeves, bottom rings, etc. are all installed on the lower holding cylinder. After the upper holding cylinder is installed, raise the lifting cylinder to the highest position and support it firmly with a steel frame. Then install the lower holding cylinder. Before connecting the lower holding cylinder to the upper holding cylinder, the connecting bolts, insulating gaskets, insulating sleeves, and flange surfaces should be cleaned. c. Measure whether the plumb line is centered at the bottom of the holding tube and align it accordingly; d. Hoist the bottom rings. Assemble the five bottom rings and their hanging devices. Using the plumb line as the baseline, find the center of the bottom rings. Measure the alignment of the electrode clamps of the pressing device and the semicircle of the bottom rings. Measure in sequence to ensure strict alignment. After completing the above connection steps, tighten the connecting bolts of each part. e. Before installing the contact element, make an auxiliary electrode shell according to the size of the electrode shell. The auxiliary electrode shell can be used as an auxiliary tool when installing the contact element. The height of the auxiliary electrode shell is about 400mm. f. Installing the contact element: First install the hanging device for the contact element, then install the contact element itself. The contact element is soldered to the vertical conductive copper pipe and the connectors using silver brazing. The upper part of the vertical conductive copper pipe is temporarily fixed while awaiting silver brazing. g. Install the water-cooled piping for the electrode post section, install the bottom ring support piping, and then connect the bottom ring inlet and outlet to the cooling water vertical pipe; during installation, pay attention to the silver solder joints at each connection point and do not damage them; h. When installing the conductive copper pipe, pay attention to cooling protection when welding the upper connector of the horizontal conductive copper pipe and the vertical conductive copper pipe to prevent the silver brazing joint between the connector and the vertical pipe from melting.

[0024] The process of the furnace gas purification module is as follows: The furnace gas produced by a closed calcium carbide furnace normally reaches a temperature of 550–700℃, and can instantaneously reach 800–1000℃. Its main components are carbon monoxide (70–80% V), hydrogen (2–10% V), carbon dioxide (5–8% V), and dust (100–150 g / Nm³). 3 It contains small amounts of coal tar (1.5~2 V%), oxygen (~0.5 V%), and nitrogen (1.5~2 V%). The calcium carbide furnace gas undergoes cooling and dust removal treatment via water-cooled pipes, a settling tank, and a cooler (or cyclone dust collector) to control the furnace gas temperature between 225℃ and 260℃. At this temperature, the dust concentration in the furnace gas is controlled to 50 mg / Nm³ after filtration by a bag filter. 3Within the specified range. The calcium carbide furnace gas first passes through a settling device to collect some dust, reducing the load on subsequent subsystems. After further dust removal by a cyclone dust collector and cooling by a cooler, it is pressurized by a coarse air blower and enters a bag filter for filtration. The filtered gas is then transported to the furnace gas pipeline network by a clean air blower and finally integrated into the gas holder. The filtered dust is then transported to the furnace gas purification ash hopper by a sealed submerged scraper conveyor. Each ash discharge port is strictly calculated based on the dust's angle of repose to ensure the ash hopper's inclination angle is not less than 60 degrees, with no internal angles, preventing ash accumulation and blockage, and ensuring smooth ash discharge. The entire system's pressure relief and explosion-proof features are automatically controlled by a computer to ensure reliable system operation. When the furnace gas purification device is working, the high-temperature calcium carbide furnace gas is cooled to approximately 600℃ through water-cooled pipes. After passing through a settling device (or cyclone dust collector), the furnace gas temperature drops to approximately 240℃. The furnace gas enters the bag filter at a temperature of 225~240℃. The aforementioned cooling stages, in addition to controlling the temperature of the furnace gas entering the baghouse dust collector, also possess a certain dust removal capacity of approximately 30% (conservative value), primarily targeting coarse particles, which is crucial for extending the lifespan of the filter bags. The baghouse dust collector is equipped with a cleaning device, and the filter bags are cleaned by backflushing with purified furnace gas. The nitrogen supply system is used for purging the gas seals of each furnace gas purification device, system start-up and shutdown, and maintenance, playing a vital role in equipment, personnel, and safety.

[0025] The operation process of the modular installation technology for a low-energy-consumption, high-efficiency calcium carbide production line of the present invention is as follows: Calcium carbide is a product of carbon reduction using quicklime and semi-coke as raw materials in an electrically heated submerged arc furnace. It is an electrothermal process with continuous feeding and intermittent tapping. Calcium carbide is produced by melting and reacting lime and semi-coke at a high temperature of 2000℃~2200℃ in a calcium carbide furnace. The reaction to produce CaC2 is endothermic and requires a large amount of electrical energy. Its chemical reaction formula is: CaO+3C→CaC2+CO ↑ - 466kJ / mol After the raw materials are added to the furnace according to a certain ratio, electrical energy is input into the calcium carbide furnace through a transformer, short grid, combined holder, and electrodes, generating a high temperature of about 2000℃~2200℃. The molten raw materials react to produce calcium carbide. Liquid calcium carbide is intermittently poured from the furnace outlet into a calcium carbide pot, which is placed on a calcium carbide cart and pulled by a winch to the calcium carbide cooling workshop for cooling. The by-product, calcium carbide furnace gas, is treated by a purification device and used as fuel for lime kilns to produce lime. During the calcium carbide production process, the electrodes are gradually consumed, so it is necessary to extend the electrode shell. The process of extending the electrode shell and adding electrode paste is as follows: Using a predetermined jacket → Fitting the electrode shell to be extended onto the electrode column to be extended, ensuring good concentricity (which needs to be measured) → Firmly welding the two circular steel cylinders and the inner stiffeners → Completing the electrode shell extension operation. Electrode paste, contained in a hopper, is hoisted from the ground to a feeding platform by an electric hoist. The paste is then poured into an electrode cylinder, ensuring a smooth surface. The smelted liquid calcium carbide is removed from the furnace once per hour, flowing into a calcium carbide pot on a trolley and then being transported to a cooling plant by a winch. A bridge crane lifts the calcium carbide pot from the trolley and places it in a "hot pot pre-cooling zone" for cooling. After 2 hours, the solidified calcium carbide is removed from the pot and placed in the cooling zone for further cooling. Once cooled, the entire calcium carbide is lifted from the pot by a crane using specialized clamps and sold as a finished product. The above describes the basic principles, main features, and advantages of this invention. Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made without departing from the spirit and scope of the invention, and all such changes and modifications fall within the scope of the invention as claimed.

Claims

1. A low energy consumption, high efficiency calcium carbide production line modular installation process characterized by, The furnace body installation, raw material storage and transportation module, carbon material drying module, screening and distribution module, furnace gas purification module, raw material conveying module, electric furnace feeding module, electrode paste feeding module and calcium carbide production module are included. The furnace body installation includes the following operations: installing the furnace shell, furnace cover and electrode column; first, the center of the calcium carbide furnace and the center of the electrode are determined, and then the relative positions of various devices are determined based on the process drawing requirements; and the positions of the foundations and reserved holes, embedded parts of various devices are checked to see whether they meet the drawing requirements. The furnace shell is installed on the basis of the furnace shell bottom row, and the furnace core position is found first, and then the furnace shell is welded based on this; the roundness error of the furnace shell is less than 10 mm. The furnace cover is installed: first, six fan-shaped segments are assembled, then the center segment of the furnace cover is installed, and then the hanging device is installed, paying attention to aligning the furnace core and the electrode center; finally, the water-cooled sealing sleeve and the water-cooled pipe line on the furnace cover are installed, which is performed after the electrode column installation is completed; since the six fan-shaped segments and the center segment of the furnace cover are water-cooled structures, a water pressure test is performed before installation, and the test pressure is 0.46 Mpa, and the installation is performed after it is determined that there is no leakage. The raw material storage and transportation module: lime is fed by a vibrating feeder, and a belt conveyor is used to convey it to the distribution station; lime is fed into the lime shed by a conveyor for temporary storage, and a wheel loader is used to unload the material into the underground receiving pit, a vibrating feeder is used to feed the material, and a belt conveyor is used to convey it to the screening and distribution station. The carbon material drying module: the qualified grain size of the semi-coke is conveyed to the top of the vertical drying kiln through the vibrating feeder, large-angle belt conveyor, feed three-way valve and reversible belt conveyor; at the same time, the hot blast stove sends hot air into the kiln, so that the hot air and the material are in full contact, and the water in the material is removed; the moisture content of the semi-coke in the vertical drying kiln is reduced from 15% to below 1%. The raw material conveying module: the semi-coke is sent to the stock bin by the belt conveyor, then falls from the stock bin by gravity, and is uniformly added to the weighing hopper by the vibrating feeder for weighing; the lime is sent to the stock bin by the belt conveyor, then falls from the stock bin by gravity, and is uniformly added to the weighing hopper by the vibrating feeder for weighing; the two raw materials are weighed in a ratio of 56:

100. The electric furnace feeding module: the qualified grain size of the lime and semi-coke is sent to the calcium carbide production workshop by the mixed material conveyor, and then enters the furnace top bin through the ring feeder of the calcium carbide furnace; the mixed material in the storage bin enters the calcium carbide furnace continuously through the downwardly extending material pipe and the feed port on the furnace cover by gravity.

2. A low energy consumption, high efficiency modular installation process for a calcium carbide production line according to claim 1, characterized in that, In the raw material storage and transportation module, the carbon material is sourced from two sources: externally supplied coke and semi-coke; a carbon material storage shed is provided, and the incoming material is first unloaded into the carbon material storage shed by a truck, then the material is piled into the receiving hopper by a loader, and then the material is sent to the carbon material drying system for drying by the hopper bottom vibrating feeder and belt conveyor.

3. A low energy, high efficiency modular installation process for a calcium carbide production line according to claim 2, characterized in that, In the carbon material drying module, the exhaust gas of the vertical drying kiln is dusted by the bag dust removal system and then discharged to the atmosphere to ensure that the environmental protection ultra-low emission standard is met; the vertical drying kiln is provided with an electro-hydraulic gate valve and a four-way distribution valve below, and the qualified material after drying can be conveyed to the distribution station by the finished product belt conveyor and the finished product large-angle conveyor; the unqualified material is conveyed to the return bin by the return belt conveyor.

4. A low energy, high efficiency modular installation process for a calcium carbide production line according to claim 3, characterized in that, In the screening distribution module, the screening distribution module is composed of lime transfer, storage and transportation belt, lime upper screening distribution station belt, carbon material transfer belt, carbon material upper screening distribution station belt, screening distribution station, transfer station and storage station; the screening distribution station completes screening of lime and carbon material, and storage of lime, carbon material block and powder.

5. A low energy, high efficiency modular installation process for a calcium carbide production line according to claim 4, characterized in that, In the furnace gas purification module, calcium carbide furnace gas collects part of dust through a settler to reduce the load of the following subsystem, and after dust removal through a cyclone dust collector and cooling through a cooler, the calcium carbide furnace gas is pressurized into a bag-type dust collector through a coarse gas fan, and the filtered gas is transported to a furnace gas pipe network through a clean gas fan and finally connected to a gas tank; the filtered dust is transported to a calcium carbide furnace gas purification ash bin by a sealed en masse scraper conveyor, each dust outlet is strictly calculated according to the repose angle of the dust to ensure that the inclination angle of the ash bucket is not less than 60 degrees, there is no included angle inside, and the dust is not accumulated and the dust is not blocked, so that the whole dust discharge is smooth.

6. A low energy, high efficiency modular installation process for a calcium carbide production line as claimed in claim 1, wherein, In the raw material conveying module, the weighed materials are discharged from the weighing hopper, added to the belt conveyor through the motor vibration feeder, and then conveyed to the ring-type feeder of each calcium carbide furnace through the belt conveyor.

7. A low energy consumption, high efficiency modular installation process for a calcium carbide production line according to claim 1 characterized in that, In the calcium carbide production module, the calcium carbide production steps are as follows: S1, after the raw materials are added into the furnace according to a certain ratio, electric energy is input into the calcium carbide furnace through the transformer, short network, combined holder and electrode to generate a high temperature of about 2000-2200℃, and the molten raw materials react to generate calcium carbide; the liquid calcium carbide is intermittently discharged from the furnace outlet into the calcium carbide pot, which is placed on the calcium carbide trolley and pulled to the calcium carbide cooling workshop by the winch for cooling; the byproduct calcium carbide furnace gas is treated by the purification device and used as fuel for the lime kiln for calcination to produce lime; S2, during the production of calcium carbide, the electrode is gradually consumed, so the electrode shell needs to be lengthened, and the process of lengthening the electrode shell and adding electrode paste is as follows: using a predetermined jacket → wrapping the electrode shell to be lengthened on the electrode column that needs to be lengthened to maintain good concentricity → firmly welding the circular steel cylinder and the rib plate inside the cylinder → completing the lengthening of the electrode shell operation; S3, the smelted liquid calcium carbide is discharged from the furnace once an hour, and the liquid calcium carbide flows into the calcium carbide pot on the calcium carbide trolley and is sent to the cooling workshop by the winch; the calcium carbide pot is lifted out of the trolley by the bridge crane with a lifting tool and placed in the "hot pot pre-cooling area" for cooling; S4, after 2h, the solidified calcium carbide is lifted out of the pot and placed in the cooling area for further cooling; after cooling, the whole calcium carbide is lifted out of the pot by the crane through a special clamp and sold as calcium carbide product.

8. A low energy, high efficiency modular installation process for a calcium carbide production line according to claim 7, characterized in that, The calcium carbide production module: after the raw materials are added into the furnace according to a certain ratio, electric energy is input into the calcium carbide furnace through the transformer, short network, combined holder and electrode to generate a high temperature of about 2000-2200℃, and the molten raw materials react to generate calcium carbide; the liquid calcium carbide is intermittently discharged from the furnace outlet into the calcium carbide pot, which is placed on the calcium carbide trolley and pulled to the calcium carbide cooling workshop by the winch for cooling.

9. A low energy, high efficiency modular installation process for a calcium carbide production line according to claim 1, characterized in that, The installation of the electrode column is carried out from top to bottom. a. First, put the two lifting oil cylinders to the lowest position, put the pressure platform between the two oil cylinders, connect the auxiliary hanging device to the pressure platform; then adjust the center of the pressure platform according to the plumb line, and make it align with the electrode center; and adjust the oil cylinder support on the pressure platform to be horizontal, after meeting the above requirements, connect the pressure platform with the oil cylinder; b. Install the holding cylinder, which is divided into upper and lower parts, the upper part is connected with the lower flange of the pressure platform, and the lower part is connected with the secondary bus hanging frame and water cooling hanging frame, the contact element, water cooling protection sleeve, bottom ring, etc. are all installed on the lower part; after the upper part is installed, lift the lifting oil cylinder to the highest position, support it with a steel frame, and then install the lower part; c. Measure whether the plumb line is in the center of the lower holding cylinder, and find the center; d. Hoist the bottom ring, assemble the five bottom rings and their hanging devices, find the center of the bottom ring according to the plumb line, measure the centering of the electrode clamp and the bottom ring semicircle of the pressure device, and measure in turn to ensure strict centering, and tighten the connecting bolts after the above connection steps are completed; e. Before installing the contact element, first make an auxiliary electrode shell according to the size of the electrode shell, which can be used as an auxiliary tool for installing the contact element, and the height of the auxiliary electrode shell is about 400mm; f. Install the contact element: first install the hanging device of the contact element, and then install the contact element, which is connected with the vertical conductive copper pipe and the connecting piece by silver brazing; temporarily fix the upper part of the vertical conductive copper pipe, and wait for silver brazing; g. Install the electrode column part of the water cooling pipeline, install the bottom ring support pipeline, and then connect the bottom ring water inlet and outlet with the vertical pipe of cooling water; pay attention to the silver welding port of each connection point during installation, and do not damage it; h. Install the conductive copper pipe, pay attention to the cooling protection when welding the upper connecting body of the horizontal conductive copper pipe and the vertical conductive copper pipe, to prevent the silver brazing port between the connecting body and the vertical pipe from melting.

Images