Installation method for complete equipment of bgl gasifier

Abstract

The application discloses a BGL gasifier complete equipment installation construction method, after checking the frame civil construction, arranging hoisting machine rigging, then hoisting the gasifier, after completing hoisting, assembling the gasifier support beam, water cooling wall slag port, slag pool, and testing the water cooling wall slag pool pipe pressure; after the gasifier is in place, installing the remaining steel structure, installing the connecting short section, then installing the gasifier internal special inner part water cooling wall; after installing the gasifier internal special inner part water cooling wall, building the furnace and baking the furnace; installing the gasifier internal stirrer and coal distribution disc, and linkage trial operation. The application leads the fixed pulley set to the lower part of the frame main structure beam, reduces the reserved amount of the frame structure, reduces the secondary construction frame structure, once arranges the hoisting machine, hoists multiple gasifiers, is high in mechanical utilization rate, speeds up the construction progress, shortens the planned construction period of the key line, and reduces the engineering cost.

Description

Technical Field

[0001] This invention relates to the field of gasifier installation technology, specifically to an installation process method for a complete set of BGL gasifier equipment. Background Technology

[0002] Coal gasification units are the core equipment in coal chemical industry. Currently, there are nearly 10 typical gasifier types in China. The BGL pulverized coal slag gasifier is a new type of coal gasification equipment developed by the German company ZEMAG, based on Lurgi fixed-bed pressurized gasifier technology. BGL gasification technology combines the characteristics of fixed-bed and fluidized-bed gasification. Lump coal enters the gasifier intermittently from the top through a coal lock, passing sequentially through a drying zone, a dry distillation zone, a reduction zone, and an oxidation zone (i.e., a combustion zone). The ash and slag in the coal become molten and enter the slag pool, then are intermittently discharged into the quench chamber through connecting short sections, and finally intermittently discharged into the slag flushing ditch from the slag lock. However, the existing BGL gasifier, as the core equipment of the gasification unit, has disadvantages such as high oxygen consumption, low conversion rate, and high emissions. It is necessary to set up equipment to complement the BGL to overcome these defects.

[0003] Therefore, developing installation processes for complete BGL gasifier equipment is a critical issue that urgently needs to be addressed in the field of gasifier technology. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method for the installation and construction of a complete set of BGL gasifier equipment, which helps to speed up the construction progress, ensure the quality of equipment installation, and shorten the installation period.

[0005] To solve the above technical problems, the technical solution adopted by the present invention is as follows:

[0006] A method for installing a complete set of BGL gasifier equipment includes the following steps:

[0007] S1. After the frame civil construction is accepted, the hoisting machine rigging is arranged, and then the gasifier is hoisted. After the gasifier is hoisted, the gasifier support beam is welded, the slag inlet and slag pool of the internal water-cooled wall are assembled, and the slag pool piping of the internal water-cooled wall is pressure tested.

[0008] S2. After the gasifier is in place, install the remaining steel structure and the connecting short section, and then install the internal water-cooled wall of the gasifier.

[0009] S3, after the water-cooled wall of the internal components inside the gasifier is installed, the furnace is built and baked.

[0010] S4. Install the agitator and coal distribution plate inside the gasifier and conduct a trial run.

[0011] Furthermore, in step S1, during the hoisting of the gasifier, a suspended hoisting point lowering method is adopted, that is, steel wire ropes are added to guide the tethering pulley point from the steel structure box-type hoisting beam to below the concrete beam, and a pulley block and matching winch are hung at the rope below the concrete beam to complete the hoisting of the gasifier.

[0012] Furthermore, in step S2, the installation of the internal water-cooled wall of the gasifier includes:

[0013] S21, Recheck the dimensions and pre-assembly of the upper and lower slag pits;

[0014] S22, remove the internal parts of the connecting short section, install the slag outlet quench water pipe and the annular burner gas source pipe, and install the slag outlet and the annular burner.

[0015] S23, flip the connecting short section again so that its upper flange faces upward, install the two sections of the slag pool, the slag port and the slag pool piping and pressure test;

[0016] S24, install the connecting short section into the lower inlet of the gasifier, and attach the slag inlet slag pool;

[0017] S25, Construction of ramming material for water-cooled wall of slag discharge pool;

[0018] S26, slag pool inside the gasifier;

[0019] S27, Welding of slag pool support components, piping, and water pressure test;

[0020] S28, Construction of ramming material for water-cooled wall of slag discharge pool.

[0021] Furthermore, in step S3, after the furnace is built, the quench chamber, slag lock, pumps and furnace drying equipment are installed. Then, the jacket water and high-pressure cooling water pipelines are installed. After the individual pumps of the furnace drying water system are tested, the furnace is dried.

[0022] Further, in step S4, the installation of the agitator and coal distribution plate inside the gasifier includes the following steps:

[0023] S411, Install the mixing tank, including hoisting the lower cone of the mixing tank and hoisting the mixing arm;

[0024] S412, hoisting of the upper part of the shaft;

[0025] S413, hoisting of the coal distribution tray;

[0026] S414, installation of coal retaining cover, radial bearing and protective cover;

[0027] S415, Welding of the circumferential weld of the mixing tank;

[0028] S416, Installation of tar distributor;

[0029] S417, installation of large gear support plate, positioning ring and support cap;

[0030] S418, large gear hoisting;

[0031] S419, thrust bearing, upper radial bearing of agitator;

[0032] S420, guide sleeve installation;

[0033] S421, the entire mixer is hoisted;

[0034] S422, Installation of mixer scraper, scraper blade, and support plate;

[0035] S423, filler filling;

[0036] S424, Transmission system installation.

[0037] Furthermore, in step S411,

[0038] The steps for hoisting the lower cone of the mixing tank are as follows:

[0039] First, use a 16T electric hoist to lift the lower cone of the mixing tank to the furnace opening. Then, use two 3T slings to pass through the water outlet holes of the lower cone of the mixing tank. Hang the two slings on the guide chain of the winch. Raise the winch and lower the 16T electric hoist until the hook on the 16T electric hoist is removed. Slowly send the lower cone of the mixing tank to the bottom of the furnace and adjust it to place the lower cone of the mixing tank into the tooling.

[0040] The steps for hoisting the mixing arm are:

[0041] The agitator arms include a small agitator arm, a large agitator arm I, and a large agitator arm II. Before hoisting, the PTFE rings should be installed in the cooling water pipe groove of the small agitator arm. First, use a 6m long 5T sling, with one end wrapped around one blade of the small agitator arm and the other end connected with a snap ring. Then, use two 3m long 3T slings to hold the blades of the two agitator arms. Use a 16T electric hoist to lift the two 3T slings and move them to the furnace opening. Use a 3T chain hoist on the winch to suspend one end of the 5T slings. Raise the hoist and lower it until the two 3T slings can be removed, making the small agitator arm vertical. Slowly lower the small agitator arm to the vicinity of the lower cone of the mixing tank. Hang another 3T chain on the wire rope, suspending the 3T sling on the other blade. Adjust the two chains to make the small agitator arm horizontal, and insert the cooling water pipe of the small agitator arm into the cooling water pipe of the lower cone of the mixing tank. Loosen the slings and spot weld them in place. The hoisting method for the large agitator arm I and large agitator arm II is the same as that for the small agitator arm.

[0042] Further, in step S412, the upper part of the shaft is moved to the gasifier opening using a 16T electric hoist. A 3T sling is tied to the coal distributor fixing plate on the upper part of the shaft, and another 3T sling is tied to the hollow shaft. A 3T winch is used to hook the 3T sling on the hollow shaft, and the upper part of the shaft is raised using the 16T electric hoist. After being raised, the 16T hook is removed, and the upper part of the shaft is slowly lowered using the winch.

[0043] Further, in step S413, firstly, two 3T, 3m lifting straps are tied to the left and right lifting lugs of the right side of the coal distribution pan using shackles. A 3T guide chain is then attached to the lifting lug in the middle of the coal distribution pan. The other ends of the two lifting straps and the guide chain are then attached to a 16T electric hoist and moved to the furnace opening. The 3T guide chain on the winch is attached to the right-end shackle, and another 3T guide chain is attached to the left-end shackle. A 5m long 6T lifting strap is attached to the 5T guide chain at the furnace opening, and the other end of the lifting strap is attached to the left-end shackle of the coal distribution pan. At this time, the 16T electric hoist is lowered, and the winch is raised until the coal distribution pan is in a vertical position. The 3T guide chain on the 16T electric hoist is then removed. Hang the coal distribution plate on the winch hook, adjust the guide chain to lower the coal distribution plate to near the manhole at the furnace opening, hang the guide chain prepared in advance on the left end on the winch hook, gradually level the coal distribution plate, and slowly lower it to near the upper part of the shaft. First, place the 45×160 key on the keyway, and then fix the coal distribution plate to the upper part of the shaft with 6 M45×180 bolts. The method of hoisting the left coal distribution plate is the same as that of the right coal distribution plate. After the left and right coal distribution plates are installed in place, tighten the inner and outer lugs of the left and right coal distribution plates with two M52×500 and two M27×160 bolts. Finally, weld the cooling water pipes on the coal distribution plate.

[0044] Further, in step S416, the base of the tar distributor is moved to the furnace opening using a 16T electric hoist, a 5T winch is installed, and the base is lowered onto the hollow shaft using the winch. The 45×160 key is installed in place, and then the base is fixed to the hollow shaft using two semi-circular positioning rings and four M24×55 bolts. The four cones are hoisted one by one to the vicinity of the base, and the cones are fixed with four M42×120 bolts. After the four cones are fixed to the base, they are secured with sixteen M36×80 bolts.

[0045] Further, in step S417, first install the large gear support. Use four small shackles to hang two slings at both ends of the large gear support. Use a 16T electric hoist to move it to the furnace opening. Hang the 3T guide chain on the winch onto one of the slings. Raise the winch and lower the electric hoist to make the large gear support vertical. Hang another 3T guide chain on the lower sling and lower it to the furnace opening. Gradually level it with the guide chain. After leveling, insert the large gear support into the hollow shaft. After the large gear support is installed in place, lock the positioning ring of the large gear support into the slot of the hollow shaft. Lower the fixing cap of the large gear support. After the fixing cap is in place, rotate it 45° so that the four claws of the fixing cap are locked onto the large gear support. Use four M24×65 bolts to fix the fixing cap onto the large gear support.

[0046] This invention directs the fixed pulley block to the area below the main structural beam of the frame, reducing the amount of space required for the frame structure and minimizing secondary construction. It allows for the simultaneous installation of winches and hoisting of multiple gasifiers, resulting in high machinery utilization, accelerated construction progress, shortened critical path planning time, and reduced project costs. The invention also summarizes the installation process of the BGL gasifier agitator and coal distribution plate, highlighting its important role in ensuring equipment installation quality, shortening installation time, and controlling project costs. Attached Figure Description

[0047] Figure 1 This is a flowchart of the installation and construction method for the BGL gasifier complete set of equipment of the present invention;

[0048] Figure 2 This is a schematic diagram of the main structure of the BGL gasifier complete set of equipment involved in the present invention;

[0049] Figure 3 This is a schematic diagram of the gasifier hoisting process in this invention;

[0050] Figure 4 This is a schematic diagram of the rope threading method in this invention.

[0051] In the diagram, 1-gasifier, 2-coal bunker, 3-coal chute, 4-coal lock, 5-transfer chamber, 6-washer cooler, 7-connecting short section, 8-quench chamber, 9-slag lock, 10-slag-water flash tank, 11-quench water cooler, 12-jacketed water cooler, 13-coal lock gas buffer tank, 14-start-up gas separator, 15-jacketed gas-liquid separator, 16-bag filter, 17-high-pressure cooling water buffer tank, 18-high-pressure cooling water cooler, 19-wire rope, 20-fixed pulley. Detailed Implementation

[0052] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0053] This invention uses a 2 million-ton / year synthetic ammonia / 3.5 million-ton / year urea project as an example to further explain the installation process of the BGL gasifier complete set of equipment proposed in this invention. The project's frame is a hybrid reinforced concrete and steel structure, with a total length of 95 meters (north-south), 34 meters (east-west), and a total height of 62.5 meters, divided into 11 layers. There are 7 gasifiers (each weighing approximately 219.1 tons, 4540×15974 mm), installed on a 19.5-meter steel platform.

[0054] The coal gasification unit of this project is divided into 7 series, with a total of 32 units in each series. The group of units centered around the gasifier (7 units in total) consists of the following components from top to bottom: coal bunker 2, coal chute 3, coal lock 4, transition chamber 5, gasifier 1, washing cooler 6, connecting stub 7, quench chamber 8, and slag lock 9.

[0055] like Figure 1 As shown, the present invention provides an installation process method for a complete set of BGL gasifier equipment, including the following steps:

[0056] Before the construction of S1, after the acceptance of the frame civil construction, the hoisting machine and rigging were arranged, and then the gasifier 1 was hoisted. After the hoisting was completed, the gasifier support beam was welded, the water-cooled wall slag inlet and slag pool were assembled, and the water-cooled wall slag pool piping was pressure tested.

[0057] The gasifier hoisting employed a combination of construction techniques: "double-beam double-lock synchronous sliding method" + "frame column anchor point method" + "suspended lifting point lowering method," as follows: Figure 3 As shown.

[0058] Lifting process calculations and rigging selection:

[0059] (a) Total lifting load

[0060] After the gasifier is pulled out, it is in a completely vertical position. The sling experiences maximum force when the pulley system lifts it vertically. The force analysis and calculation at this location are as follows:

[0061] P = K1 × K2 × (Q + q1 + q2 + q3)

[0062] In the formula, Q represents the net weight of the gasifier, Q = 219.1t; K1 represents the dynamic load coefficient, K1 = 1.2; K2 represents the unbalance coefficient, K2 = 1.1; q1 represents the weight of the four pulley blocks, q1 = 1.552 × 4 = 6.2t; q2 represents the weight of the four 200t shackles, q2 = 0.5t; q3 represents the weight of the wire rope, q3 = 4.5t.

[0063] The total lifting load is calculated to be: P = 1.2 × 1.1 × (219.1 + 6.2 + 0.5 + 4.5) = 304t.

[0064] (ii) Force on each pulley block when the equipment is tilted upwards

[0065] The outer diameter of the equipment body is 4540mm, and the length of the temporary lifting lug (i.e., manhole) is 550mm. Therefore, the spacing between the points where the lifting lug is tied is 4540 + 2 × 300 = 5120mm, making the spacing between the two fixed pulleys under the 35.77m concrete beam 5120mm. Thus, when the equipment reaches the vertical lifting position, the angle α between the axis of the pulley block and the vertical axis of the gasifier is approximately 0°.

[0066] P1=PXc / 2nCosα=304×7.987 / 2×13.674Cos0°=88.78t

[0067] In the formula: Xc represents the distance from the center of gravity of the equipment to its bottom surface; n represents the distance from the lifting point of the equipment to the bottom of the equipment; α represents the angle between the trolley block and the vertical center line when the equipment is in place.

[0068] (III) Calculation of the force on the lifting pulley block

[0069] Since the angle between the pulley block axis and the equipment axis is 0° during the vertical lifting process, P2=Q / 2Cosα =304 / 2 Cos0°=152t. It is calculated that the maximum force P2=152t is subjected to by a single lifting pulley block. Therefore, this hoisting scheme selects two 200-ton pulley blocks, model H200×10D.

[0070] (iv) Selection of rigging for the main crane

[0071] 1) Selection of the main hoisting winch

[0072] The hoisting pulley block uses an H200×10D pulley system, with 10 fixed pulleys in the upper section and 10 movable pulleys in the lower section, forming a 10×9 pulley block. The wire rope is threaded using a double-ended, forward-threading method, as detailed below. Figure 4 As shown, its effective number of ropes is 18;

[0073] The force on the running rope is:

[0074]

[0075] In the formula, S1 represents the force on the running rope; n represents the number of working ropes; C represents the friction coefficient of the movable pulley. The bearing of the movable pulley block in this hoisting is a bronze bushing bearing, and the friction coefficient is set to 1.04.

[0076] Based on the site conditions, the running rope needs to pass through three guide pulleys after being pulled out of the pulley block before reaching the winch. Therefore, the tension S exerted on the winch by the running rope is:

[0077] S = S1 × Cn =12.01 × 1.043 = 13.51t<20t, therefore a 20t winch is selected. Each set of pulley blocks has double exits, requiring two 20t winches. Two sets of pulley blocks with double exits require four 20t winches.

[0078] 2) Selection of main hoisting wire rope

[0079] The running rope is made of φ36-6×37+1-187 steel wire rope with a breaking strength of 71.4t.

[0080] The safety factor is: K = 71.4 / 13.51 = 5.28 > 5 (safe);

[0081] According to HG20201-2000, the running rope is fixed with φ36 rope clips, with a spacing of 200mm, model Y11-40, and the clip rod diameter is M24.

[0082] 3) Selection of the fixing wire rope for the 200t fixed pulley block

[0083] Based on stress analysis, when the equipment is lifted to the designated height, the force on each pulley block is 152 tons. Referring to the table, φ66-6×37+1-187 steel wire rope is selected, with a breaking strength of 259t. Two steel wire ropes are used at each lifting point, forming a single rope with one bend and two strands, or two ropes with two bends and four strands. The calculated length of a single rope is 26.06m. The steel structure box girder above the 45.5m concrete beam is looped vertically downwards, avoiding the two east-west oriented concrete beams at 39.97m and 35.77m along axis D. Two strands of steel wire rope are used on each of the east and west sides of the two concrete beams. Under the 35.77m concrete beam, the steel wire rope is connected to a 200t fixed pulley block using a 200t shackle. The safety factor for rope exiting on both sides is:

[0084] (Safety).

[0085] The main hoisting wire rope suspension adopts the "suspension-type lifting point lowering method", which adds two Φ66—6×37+1--187 wire ropes to lead the tethering pulley point from the steel structure box-type hoisting beam to below the 35.77m beam. Two sets of H200×10D pulley blocks are hung at the ropes below the 35.77m concrete beam, and four 20t winches are matched.

[0086] like Figure 3As shown, considering that the concrete beam is a north-south oriented transverse beam, no hoisting method can achieve the desired setup and lifting process (positioning, traction, detachment, and lifting). Furthermore, since the lifting lugs are installed on both the north and south sides, the only solution is to modify the load-bearing steel box girder above. Therefore, two box girder beams are installed above the concrete beam as load-bearing beams, and the fixed pulley is lowered from 45 meters to 28.5 meters via the lower edge of the wire rope. This reduces uneven stress on the wire rope and its swing amplitude during traction and lifting.

[0087] 4) Selection of the fixing wire rope for the 200t moving pulley block

[0088] The main hoist pulley block and the temporary lifting lugs of the equipment (i.e., manholes M1 and M2, with an outer diameter of 770mm) are tied together with φ66-6×37+1-187 steel wire rope with a breaking strength of 240t using three-bend, six-strand ropes, and then connected to the 200t pulley block with a 200t shackle.

[0089] The safety factor is calculated as follows:

[0090] (Safety).

[0091] 5) Calculation of the center distance X between the pulleys of the two trolleys in the pulley block when the equipment is hoisted to the installation elevation:

[0092]

[0093] X = 3.43m ≥ 5D = 5 × 0.54 = 2.7m;

[0094] In the formula, L represents the distance from the bottom of the 35.77m concrete beam to the top of the lifting lug (i.e., manholes M1 and M2) when the equipment is hoisted to the installation elevation, which is 8.35m; C represents the distance from the center of the 200t pulley to the end of the pulley ring, which is 1.16m; n represents the height of the 200t shackle, which is 0.5m; L' represents the required allowance of 0.6m for the steel wire rope at the bottom of the 35.77m concrete beam; and L」 represents the required allowance of 1.0m for the top of the lifting lug.

[0095] (V) Calculation of stress on the traction steel trolley and selection of rigging:

[0096] 1) Process Description

[0097] After the gasifier 1 arrives on site, its unloading position is some distance from the installation position. On-site, the head of gasifier 1 needs to be placed on a steel trailer on the west side, and the tail on a trailer on the south side. Wooden planks are placed on the steel trailers, and gasifier 1 is placed on top of these planks. The two steel trailers are connected and securely locked together with wire ropes and shackles to form a single unit. Gasifier 1 is then tied to the steel trailers with wire ropes. The trailer with the head of gasifier 1 is pulled by a winch, and gasifier 1 and its tail trailer are moved to the installation position.

[0098] 2) Calculation of traction force of steel trailer during equipment transportation

[0099] During equipment transportation, based on the force analysis of the gasifier 1 during transportation, the traction force P of the winch is equal to the sliding friction force between the tow bar and the roller. The sliding friction force Q can be approximately calculated using the following formula:

[0100] P=Q=(G+g)×η

[0101] In the formula, G represents the calculated weight of 219.1t, g represents the total weight of the trailer, timber and other accessories of 11.4t, and η represents the coefficient of kinetic friction, which is 0.1.

[0102] Calculations show that the winch traction force P=Q=23.05t. For safety, based on the available equipment, this hoisting plan selects a 50-ton pulley block, model H50-6D.

[0103] 3) Selection of traction machine locks

[0104] Selection of traction winch:

[0105] The traction pulley block uses an H50-6D pulley, with a single-end threading method for the wire rope, and an effective number of 12 ropes. Therefore, the running rope tension is:

[0106] Therefore, a 5t winch was selected.

[0107] Selection of traction wire rope:

[0108] The running rope is made of φ20-6×37+1-187 steel wire rope with a breaking strength of 22t and a safety factor of 22 / 2.46=8.94>5 (safe).

[0109] According to "HG20201-2000", the running rope is fixed with a φ20 rope clip, the rope clip spacing is 120mm, the model is Y6-20, and the clip rod diameter is M16.

[0110] (vi) Instantaneous stress analysis of the tailing steel trolley and selection of rigging:

[0111] 1) Calculation of relevant data at the moment of tail-drift and exhaust separation

[0112] The equipment tilt angle is selected as θ=75° (selected);

[0113] The distance from the bottom centerline of the equipment to the installation axis is 3.53m;

[0114] The distance from the center of the bottom of the equipment to the bottom support is 1.135m;

[0115] The distance from the lifting point to the bottom of the equipment is 15.974 - 2.3 = 13.674 m;

[0116] The top elevation of the trailer timber is +1.0m;

[0117] The distance between the rear rope anchor point and the center line of the bottom suspension point is 9.97 meters, and the suspension elevation of the rear rope anchor point is +0.00m.

[0118] The distance from the suspension point of the 200-ton pulley block to the top of the log is approximately 34.27m;

[0119] Therefore, the distance from the bottom center of the equipment to the log is L1 = 1.135 × cosθ, and substituting the data, we get L1 = 0.29m.

[0120] The distance from the equipment hoisting point to the top of the trailer is H = 13.674 × sinθ + L1; after substituting the data, we get H = 13.50m;

[0121] The distance from the center of the equipment bottom to the axis where the lifting point is located is L2 = 13.5 / tanθ; after substituting the data, we get L2 = 3.62m;

[0122] Therefore, the distance from the lifting point to the equipment installation axis is B = 3.62 - 3.53 = 0.1m;

[0123] The hoisting angle α = arctan0.1 / (34.27 - 13.5), and after substituting the data, we get α = 0.3°;

[0124] The angle of the backward sliding rope β = arctan[(1.135 × sinθ + 1m) / 9.97] = 11.87°

[0125] instantaneous force calculation during degassing

[0126] Based on the force analysis, the mechanical equilibrium equation is established as follows:

[0127] P1×cosα=G / 2+S×sinβ

[0128] P1×sinα= S×cosβ

[0129] In the formula, G represents the calculated weight of 304t; P1 represents the tension of the main sling at the moment of release; S represents the tension of the rear guide rope; α = 0.3°; β = 11.87°

[0130] Substituting the data, we get: P1 = 152.32t; S = 1.52t;

[0131] Calculations show that, based on the existing equipment, a 32-ton pulley block, model H32-4D, is selected for this hoisting process.

[0132] Rigging selection for tail slide

[0133] Selection of tail winch:

[0134] The tail pulley block uses the H32-4D pulley, the wire rope is threaded in a single-head manner, and there are 8 working ropes.

[0135] Then the running rope tension

[0136] Therefore, a 5t winch was selected for the tail section.

[0137] Selection of tail wire rope

[0138] The tailing wire rope is made of φ20-6×37+1-187 steel wire rope with a breaking strength of 22t.

[0139] The safety factor is 22 / 0.3 = 6 > 5 (safe).

[0140] 3) According to HG20201-2000, the running rope is fixed with φ20 rope clips, the rope clip spacing is 120mm, the model is Y6-20, and the clip rod diameter is M16.

[0141] (vii) Anchor point selection

[0142] The anchor points of the winch and guide pulley adopt "frame column anchor points" based on the calculated running rope tension and design verification.

[0143] After the gasifier 1 is in place, S2 installs the remaining steel structure and the connecting section 7, and then installs the proprietary internal water-cooled wall of the gasifier 1.

[0144] The water-cooled wall of the BGL gasifier internals, i.e. the slag pool, as referred to in this invention, includes the following components: slag inlet, annular burner, lower slag pool (2 sections), and upper slag pool (4 pieces). The component descriptions are shown in the table below:

[0145] Table 1. Description of Water-Cooled Wall Components in the BGL Gasifier Internals

[0146] Serial Number name Function Introduction 1 Slag discharge port The copper casting is integrally cast and installed at the bottom of the slag pool. It has water-cooled pipelines inside. When the gasifier is running, liquid slag can be intermittently discharged into the quench chamber through this slag discharge port. 2 Slag Tank Protector The copper casting is the upper part of the gasifier slag pool. Each set consists of four arc-shaped plates and has internal water-cooling pipelines. The slag pool can provide intermittent storage of liquid slag when the gasifier is running. 3 Upper Components of Slag Discharge Tank The copper casting is integrally cast, and the upper part of the lower half of the gasifier slag pool is integrally cast. It has water-cooling pipelines inside, and the slag pool can provide intermittent storage of liquid slag when the gasifier is running. 4 Lower Components of Slag Tank The copper casting is integrally cast, and the lower part of the gasifier slag pool is integrally cast. It has water-cooling pipelines inside, and the slag pool can provide intermittent storage of liquid slag when the gasifier is running. 5 Ring burner Methane gas is used as fuel gas and installed below the slag discharge port for start-up ignition of the BGL gasifier, insulation of the slag discharge port, and control of the slag pool level.

[0147] The specific process for installing the proprietary water-cooled wall internal components of the gasifier is as follows:

[0148] S21: Recheck the dimensions of the upper and lower slag tanks and pre-assembly.

[0149] Before unpacking, check whether the proprietary components are damaged or deformed during transportation. Check whether the upper opening size of the slag pool (section 2) has an installation margin with the lower flange size of gasifier 1 to avoid the inability to install the connecting short section (with slag pool) into the lower furnace chamber of gasifier 1 due to size errors after installation. Before pre-assembling the upper slag pool, check its ellipticity, because the installation gap between the upper slag pool and the lower furnace chamber of gasifier 1 is relatively small, and this component is composed of 4 90° arc halves, which need to be entered into the confined space inside gasifier 1 for operation. All of the above work must be carefully checked before construction begins.

[0150] S22: Remove internal components of the connecting short section, install the slag outlet quench water pipe, the annular burner gas source pipe, slag outlet installation, and annular burner installation.

[0151] a. Flip the connecting section 7 so that its lower flange faces upward, and remove the internal parts of the connecting section 7;

[0152] b. Since the gap between the slag outlet and the bottom of the support plate on the connecting short section 7 is small after the slag outlet is installed, it is impossible to weld the cooling water pipe connected to it. Therefore, before installing the slag outlet, the cooling water pipe and the slag outlet should be welded in advance, and a fixing port should be reserved for the pipe connected to the internal parts of the connecting short section 7. The fixing port should be welded after the slag outlet is installed.

[0153] c. Then install the slag outlet at the center of the upper support plate of the connecting short section 7, put the special slag discharge port 'O' ring on the neck of the slag discharge port, and then slowly push the slag discharge port into the installation position; install 16 M20 hex bolts, manually tighten the bolts in sequence, and measure the flange clearance every 90° to ensure that the flange is flattened.

[0154] After manually tightening, use a 17mm hex wrench to tighten the bolts in the same order as follows, and tighten the final torque to 150Nm: Round 1: Tighten to 20% of the final torque, Round 2: Tighten to 40% of the final torque, Round 3: Tighten to 80% of the final torque, Round 4: Tighten to 100% of the final torque.

[0155] d. After the slag outlet is installed, locate the 0° mark on the annular burner and align it with the zero point on the slag outlet. Install four M12 fixing bolts and manually tighten them to ensure the annular burner is level. Measure the gap between the annular burner and the fixing plate every 90° to ensure the burner is installed horizontally. After manual tightening, use a hexagonal torque wrench to tighten the four M20 bolts to a final torque of 35 Nm. Tighten two opposing bolts first, then tighten the other pair before installing the annular burner gas supply pipe.

[0156] One point to note is:

[0157] For the internal components of connecting section 7, the equipment supplier can be required to pack and deliver the internal piping and flue hood in a box. After the slag outlet, annular burner and piping are installed, the internal components of connecting section 7 can be installed on site, which can save the removal and installation of the internal components of connecting section 7.

[0158] Position the slag discharge port to the center under the support plate, then install the O-ring for the slag discharge port and push it onto the upper surface of the fixed flange. Do not use any oil or grease to lubricate the O-ring during this operation; use clean water if necessary.

[0159] After the slag discharge port, annular burner and their respective piping are installed, the remaining piping and flue hood inside the connecting section 7 cannot be restored.

[0160] S23: Flip the connecting section 7 again so that its upper flange faces upward, install the slag pool (2 sections), and pressure test the slag port and slag pool piping.

[0161] Flip the connecting section 7 again so that its upper flange faces upward. Before moving the lower section of the slag bin to the upper part of the section, ensure that the upper surface of the mounting plate is clean and free of debris, and that the lower flange of the slag bin is also clean. Install the locating pins in the holes provided on the mounting plate, and then install the eight M20×100 stud bolts, ensuring that these locating pins are fully tightened to the mounting plate. Locate the 0° mark on the upper flange of the slag bin and align it with the zero point on the support plate. Install the three eye bolts on the M24 threaded holes of the upper flange of the slag bin, and use these eye bolts to lift the slag bin to the appropriate position. Slowly lower the slag bin and carefully and flexibly move it to the appropriate position, taking care not to tilt or clog the stud bolts.

[0162] Before tightening the flange to its final position, measure the flange clearance every 90° to ensure the flange is installed level. Install the M20 gaskets and nuts, then manually tighten the nuts in sequence to ensure the flange is installed level. Again, check that the flange clearance is consistent throughout the entire flange every 90° to ensure the flange is installed level.

[0163] After manually tightening, tighten the nuts sequentially using a torque wrench with a maximum torque of 20 Nm. Do not use a torque exceeding 30 Nm in this operation.

[0164] Remove the lifting eye bolts from the upper flange of the lower section of the slag sink and install them onto the upper flange of the upper section of the slag sink, using the same method and requirements as for installing the lower section.

[0165] After the upper and lower sections of the slag discharge tank are installed, the cooling water pipes for the slag discharge tank will be installed.

[0166] It should be noted that since the slag discharge port is connected to the cooling water pipe of the slag sink, a water pressure test must be carried out as required after all the piping in the slag sink is completed, and a water pressure test record must be filled out and accepted.

[0167] S24: Install the connecting short section 7 into the lower opening of the gasifier.

[0168] After the slag inlet and slag sink are installed and the cooling water pipeline passes the pressure test, move connecting section 7 into the frame and use the "double-lock synchronous sliding method" to hoist connecting section 7 into the lower furnace. Special attention must be paid to the synchronization of the winch during this step to avoid damage to the slag sink during hoisting. After installation, the internal parts of connecting section 7 and the flue hood that have been removed must be restored.

[0169] S25: Construction of ramming mix (refractory material) for water-cooled walls of slag discharge pit.

[0170] Because the space inside the gasifier is limited after the slag tank is installed, it is impossible to pour the ramming material between the slag tank and the inner wall of the furnace. Therefore, this step must be completed before the slag tank is installed.

[0171] S26: Four slag collection tanks inside the gasifier.

[0172] After the rammed earth (refractory material) of the slag lowering pool water-cooled wall is poured, the upper slag lowering pool, composed of four 90° arc halves, is sequentially hoisted into the gasifier from port S1 at the top for assembly. M24 lifting eye bolts are installed onto all four upper slag lowering pool components, and the first part is lowered into the gasifier. Based on the upper flange of the slag lowering pool, the first component is arranged and positioned along the inner end of the upper slag lowering pool, thus occupying the 0° to 90° quadrant of the gasifier, with the inlet adjacent to port S32.3 and the outlet adjacent to S32.4. Then, the next component is placed in, and the operation is repeated, aligning the component so that the inlet is adjacent to S32.5 and the outlet to S32.6.

[0173] Connect the two components together using a flange and six 100mm long M20 bolts. Repeat the above steps until all four components are in place. Check that the alignment lines of the cooling water connectors connected to the gasifier inlets S32.1~8 are correct, and check that the gaps between the components (if any) are minimal. If the gap between one pair of components is larger than any other pair, it must be adjusted until all gaps (if any) are equal and of similar size, and all eye bolts are removed.

[0174] S27: Welding of slag pool support components, piping, and water pressure test.

[0175] a. The upper slag tank support components include an open ring and 12 bends. Place the locking ring under the upper flange of the upper slag tank, install two pairs of fixing bolts, and then tighten them. Install 24 M12 capped bolts and then manually tighten them to ensure the open ring is exactly at the standard. Check the gap between the upper flange and the lower part of the open ring assembly to ensure the open ring meets the standard and uniform requirements. After manual tightening, use a 10mm hex wrench to tighten the M12 capped bolts in a specific sequence to a final torque of 35Nm. Tighten all 6 capped bolts on each assembly, and then do the same for the next assembly. Ensure all assemblies are evenly distributed, of the same height, and that no part is lifted from the lower end of the lower slag tank. Then, cut the 12 bends, each 12mm thick and approximately 634mm long, to the correct size, weld them to the open ring, and finally weld them into the interior of the gasifier shell.

[0176] b. After the above procedures are completed, weld the cooling water pipes of the four slag tanks to the four inlet and four outlet cooling water pipes reserved in the gasifier body.

[0177] c. After welding is completed, a water pressure test must be carried out as required and the test must be passed.

[0178] S28: Construction of ramming mix (refractory material) for water-cooled walls of slag discharge pit.

[0179] This step is carried out after the piping of the slag collection tank is completed and the water pressure test is passed.

[0180] Because the gasifier in this process contains water-cooled walls (slag pool), a large agitator, and a coal distribution plate, the installation of equipment above and below the furnace body involves close connections and mutual influences between various processes. To shorten the construction period and ensure that the construction of each process does not interfere with each other, the project team summarized its experience in practice and determined the following installation sequence for the complete set of equipment in the BGL gasifier construction:

[0181] Gasifier hoisting; water-cooled wall (slag inlet, slag sink) installation; connecting section 7 installation; water-cooled wall (slag sink) ramming material construction; quench chamber 8 installation; slag lock 9 installation; water-cooled wall (upper slag sink) ramming material construction; washing cooler 6 installation; furnace construction and drying; agitator and coal distribution plate installation; transition chamber 5 installation; coal lock 4 installation; coal chute installation;

[0182] Since the gasification frame of this project is a mixed steel and concrete frame structure, the installation of the upper and lower equipment of the gasifier is mainly carried out using the "double-lock synchronous sliding method".

[0183] After the S3 gasifier's proprietary internal water-cooled wall is installed, the furnace is constructed and then baked.

[0184] S4 is equipped with an agitator and coal distribution plate inside the gasifier, and is put into trial operation.

[0185] After the gasifier is baked out, the installation of the agitator and coal distribution plate begins. The specific installation steps for the agitator and coal distribution plate in the BGL gasifier include:

[0186] S411. Installation of mixing tank.

[0187] 1) Lifting of the lower cone of the mixing tank.

[0188] First, use a 16T electric hoist to lift the lower stirring cone to the furnace opening (pass a steel wire rope through the two water outlet holes of the lower stirring cone). Then, use two 3T slings to pass through the water outlet holes of the lower stirring cone and hang them on the guide chain of the winch. Raise the winch and lower the 16T electric hoist until the hook on the 16T electric hoist is removed. Slowly send the lower stirring cone to the bottom of the furnace and adjust it to place it into the tooling.

[0189] 2) Hoisting of the mixing arms (small mixing arm, large mixing arm I, large mixing arm II).

[0190] Before hoisting, the PTFE ring must be installed into the cooling water pipe groove of the small agitator arm. First, use a 6m long, 5T sling, wrapping one end around one blade of the small agitator arm and connecting the other end with a shackle. Then, use two 3m long, 3T slings to hold the blades of the two agitator arms. Use a 16T electric hoist to lift the two 3T slings and slowly move them to the furnace opening. Use a 3T chain hoist on the winch to suspend one end of the 5T sling. The winch rises while the electric hoist descends until the two 3T slings can be removed, making the agitator arm vertical. Slowly lower the agitator arm to the vicinity of the lower agitator cone. Hang another 3T chain hoist on the wire rope, suspending the 3T sling on the other blade. Adjust the two chains to make the agitator arm horizontal, allowing the cooling water pipe of the small agitator arm to pass through the cooling water pipe of the lower agitator cone. Loosen the slings and spot weld them in place. The hoisting method for the other two agitator arms is the same as that for the small agitator arm. The large stirring arm I and the gasifier wall must be supported with wooden beams to prevent the stirring tank from tilting and damaging the furnace wall during the hoisting of the coal distribution plate. A PTFE ring seal is used at the cooling water interfaces between the various components of the stirring tank.

[0191] S412. Upper part of the shaft is hoisted.

[0192] Use a 16T electric hoist to move the upper part of the shaft to the gasifier inlet (one 3T sling is tied to the coal distributor mounting plate on the upper part of the shaft, and another 3T sling is tied to the hollow shaft). Use a 3T winch to hook the 3T sling on the hollow shaft, and use the 16T electric hoist on the south side to erect the upper part of the shaft. After erection, remove the 16T hook and slowly lower the upper part of the shaft using the winch. After the hollow shaft is hoisted, its verticality needs to be checked (the method is to hang a plumb line on the hollow shaft to measure the verticality of the upper part of the shaft, and use a spirit level on the coal distributor mounting plate to measure the horizontality).

[0193] S413. Lifting of the coal distribution tray.

[0194] First, use shackles to attach two 3T, 3m lifting straps to the left and right lifting lugs of the right side of the coal distribution pan. Then, use a 3T chain guide to hang the lifting lug in the middle of the coal distribution pan. Finally, hang the other end of the two lifting straps and the chain guide on a 16T electric hoist and move it to the furnace opening. Hang the 3T guide chain from the winch on the right-hand shackle, and another 3T guide chain on the left-hand shackle. Hang a 5m long 6T sling on the 5T guide chain from the furnace opening, with the other end of the sling attached to the shackle on the left side of the coal distribution tray. At this point, lower the 16T electric hoist and raise the winch until the coal distribution tray is vertical. Remove the 3T guide chain from the 16T electric hoist and hang it on the winch hook. Adjust the guide chain to lower the coal distribution tray near the furnace opening manhole. Hang the previously prepared guide chain on the left side on the winch hook, gradually leveling the coal distribution tray and slowly lowering it to near the upper part of the shaft. Note that you should first place the 45×160 key on the keyway, and then use the six M45×180 bolts to secure the coal distribution tray to the upper part of the shaft. The method for hoisting the left coal distribution tray is the same as for the right tray. After both the left and right plates are installed in place, tighten the inner and outer lugs of the left and right plates with two M52×500 bolts and two M27×160 bolts. Finally, weld the cooling water pipes on the coal distribution plate.

[0195] S414. Installation of coal retaining cover, radial bearing and protective cover.

[0196] The coal retaining hood, radial bearing, and protective cover are much smaller than the furnace opening diameter, making them easier to hoist. They are moved to the gasifier opening using two 1T 3M steel wire ropes and a 16T electric hoist, and then lifted into the furnace using a 5T winch.

[0197] The coal retaining cover is installed above the cooling water pipe of the coal distribution plate, and there are two lifting lugs on the coal retaining cover.

[0198] Before installing the radial bearing, apply a layer of iron oxide red to the installation location on the hollow shaft. The radial bearing has four M24x60 studs on its upper part for securing the pressure cap above it. During hoisting, use discarded M24 studs to prefabricate the hoisting points.

[0199] The radial bearing cover is fixed to the hollow shaft with four M36x55 screws.

[0200] S415. Welding of the circumferential weld of the mixing tank.

[0201] At this point, the coal distribution tray is fixed in place and can then serve as a protective device. The welding of the four circumferential welds at the bottom of the coal distribution tray and the hoisting of the upper components of the coal distribution tray can be carried out simultaneously.

[0202] 1) Process requirements for four circumferential welds:

[0203] a. The base material of the mixing tank is 15CrMo, with a base plate thickness of 15~20mm. R307 welding material is required.

[0204] b. The weld gap should be 3~4mm and the misalignment of the weld joint should be ≤5mm.

[0205] c. Before welding, the weld seam must be polished to a metallic luster;

[0206] d. Before welding, the base material must be symmetrically preheated. The preheating temperature must be ≥150℃ and the maximum interpass temperature must be 230℃.

[0207] f. Welding materials must be baked at 350℃ and kept at that temperature for 1 hour before welding.

[0208] g. After welding, heating and heat preservation should be carried out with a temperature rise of ≥200℃ and heat preservation for 2 hours to eliminate welding stress.

[0209] h. After the root pass welding is completed, the base layer high temperature resistant material INCONEL 625 should be welded, requiring a full weld of 2+0.5mm, and the welding requirements are the same as above;

[0210] i. After INCONEL 625 is welded, a wear-resistant coating material E CoCr-A is welded, requiring spot welding of 2+1mm;

[0211] 2) Post-welding inspection:

[0212] a. After the R307 root pass is completed, the weld should be subjected to ultrasonic testing to detect any leaks or defects. The testing method is random sampling, and the testing length should be no less than 20% of the circumference of each weld joint and no less than 250 mm.

[0213] b. After ultrasonic testing is passed, magnetic particle testing shall be performed before INCONEL 625 overlay welding to determine whether the base layer can be overlaid. Level I qualification is required.

[0214] c. After the INCONEL 625 weld overlay is completed, the weld surface is subjected to penetrant testing to confirm whether there are cracks in the weld overlay. Level I qualification is required.

[0215] S416. Installation of tar distributor.

[0216] Use a 16T electric hoist to move the tar distributor base to the furnace opening. Then, switch to a 5T winch and use the winch to lower the base onto the hollow shaft, ensuring the 45×160 key is properly installed. Next, use two semi-circular positioning rings and four M24×55 bolts to secure the base to the hollow shaft. Hoist the four cone segments one by one to the vicinity of the base and secure them with four M42×120 bolts. After securing the four cone segments to the base, use sixteen M36×80 bolts to firmly hold them in place. Pay attention to the installation sequence of the cone segments. Finally, install the two protective covers of the tar distributor into place.

[0217] S417. Installation of large gear support plate, positioning ring, and support cap.

[0218] First, install the large gear support. Use four small shackles to hang two slings at both ends of the gear support. Use a 16T electric hoist to move it to the furnace opening. Attach a 3T chain guide from the winch to one of the slings. Raise the winch and lower the electric hoist to make the support vertical. Attach another 3T chain guide to the lower sling and lower it to the furnace opening, gradually leveling it with the chain guide. After leveling, insert the gear support into the hollow shaft, ensuring the 45×450 key on the hollow shaft enters the keyway of the gear support. After the large gear support is in place, engage the positioning ring of the large gear support in the slot of the hollow shaft. Lower the fixing cap of the large gear support. Once the fixing cap is in place, rotate it 45° so that the four claws of the fixing cap engage with the large gear support. Secure the fixing cap to the large gear support with four M24×65 bolts.

[0219] S418. Large gear hoisting.

[0220] Using two steel wire ropes, shackles, and a 16T electric hoist, hoist the half-gear to the furnace opening. Attach the 3T guide chain from the winch to the shackle at one end of the gear. Raise the winch and lower the electric hoist. Remove the hook at the other end, attach the 3T guide chain, and lower it to the furnace opening. Use the guide chain to level the half-gear. After leveling, connect its six M48×140 bolts, but do not tighten them. After securing, fix the other half-gear, ensuring the 56×32×200 key is inserted into the keyway of the gear. Next, use two M45×3×300 double-ended studs to secure both half-gears. Finally, tighten all 12 bolts.

[0221] S419. Thrust bearing, upper radial bearing installation of agitator.

[0222] Apply Iron Baron to the hollow shaft of the radial bearing in the mounting section. Lubrication for the thrust bearing is provided by the lubrication station.

[0223] S420. Guide sleeve installation.

[0224] The agitator guide sleeve is secured to the agitator support claws with six M33x250 bolts. The agitator cooling water inlet elbow is fixed to the top cover inside the guide sleeve. The distributor has three PTFE sealing rings at the hollow shaft connection and one PTFE sealing ring at the cooling water inlet pipe connection. The entire distributor is secured to the guide sleeve with eight evenly distributed M16 bolts.

[0225] a. First, use 3T3M slings to tie the two cylinders of the guide sleeve and hang them on the 5T winch.

[0226] b. A 3T chain hoist is attached to the winch, and the chain hoist hook is tied to the cylinder opposite the guide sleeve.

[0227] c. Slowly start the winch, lift the guide sleeve to directly above the furnace opening, and pull the chain hoist to level the guide sleeve.

[0228] d. Start the winch and lower the guide sleeve onto the agitator support claw, insert the bolts, and tighten them.

[0229] S421. The entire agitator is hoisted.

[0230] First, use two 16T electric hoists to move the 32T carrying pole directly above the gasifier. Hook the carrying pole onto the hooks of the two 16T electric hoists. Attach 10T 8-meter steel wire ropes to both ends of the carrying pole, and then tie them to the north and south tie rods of the gear support plate. Next, hang four 10-ton steel wire ropes as lifting points on the crossbeam between the two coal locks. Attach a 10T chain hoist to each wire rope, and another 10T steel wire rope below the chain hoist, respectively, and tie them to the north-south gear lifting lugs and the east-west tie rods of the gear support plate. After all the steel wire ropes are secured, simultaneously start the 16T electric hoists to lift the agitator. As the electric hoists rise, pull the four chain hoists to keep them constantly applying force to the agitator. Due to the limited lifting distance of the electric hoists, the steel wire ropes on the carrying pole need to be switched three times to lift the agitator to the appropriate position.

[0231] Precautions for overall hoisting:

[0232] Each time the steel wire rope is moved, it is necessary to ensure that all four 10T chain hoists exert force on the agitator, and that the force is evenly distributed.

[0233] Ensure the coal distribution tray is level (this can be observed using a spirit level). This prevents the coal distribution tray from tilting and one side from being too high and touching the refractory bricks of the furnace body. When approaching the water ring, ensure there is a gap between the tray and the water ring to prevent contact.

[0234] When the gear ring passes the water ring, ensure that the agitator is in the center of the furnace, does not collide with the water ring, and is not stuck by the water ring.

[0235] S422. Installation of mixer scraper, scraper blade, and support plate.

[0236] S423. Filler filling.

[0237] S424 transmission system (motor, reducer, eccentric sleeve).

[0238] 1) Eccentric sleeve installation.

[0239] The eccentric sleeve of the agitator is the agitator drive device, used to transfer the kinetic energy transmitted from the reducer to the large gear, thereby driving the agitator to rotate.

[0240] The eccentric sleeve shaft and sleeve are not concentric; the upper part is filled with packing. The eccentric sleeve has three holes on its side: two on the right for lubricating oil inlets and one on the left for an oil drain. There are three holes on the upper part; the two on the right are process holes, which need to be plugged before on-site installation (after inserting pins and welding). The leftmost hole connects to the drain outlet. The eccentric sleeve shaft has two process machining holes, which also need to be plugged during installation.

[0241] When hoisting the eccentric sleeve, hook a 1T wire rope onto the two bolts on both sides of the eccentric sleeve, then hook the wire rope onto the 16T electric hoist on the north side, and slowly lift it above the S8 opening. Then, hook one end of the wire rope onto the 16T electric hoist on the south side, and hook the other end of the wire rope onto one of the bolts on the eccentric sleeve. Simultaneously lift both 16T electric hoists to ensure that the eccentric sleeve is directly above the S8 opening. Slowly lower the north electric hoist to lower the eccentric sleeve. If the eccentric sleeve is tilted, it can be adjusted by raising or lowering the south electric hoist to place the eccentric sleeve vertically inside the S8 opening.

[0242] When the eccentric sleeve is lowered to near the gear position, one person can enter the furnace to observe and direct the personnel above to rotate the eccentric sleeve to ensure that the gear does not jam and that the eccentric sleeve and the large gear mesh smoothly.

[0243] Eccentricity adjustment of eccentric sleeve:

[0244] The degree of meshing between the eccentric sleeve gear and the large gear can be adjusted by adjusting the eccentricity.

[0245] Eccentricity adjustment method:

[0246] a. Determine the zero point

[0247] The zero position of the eccentric sleeve is located at the level of the upper and lower flanges of the eccentric sleeve flange. The zero position of the S8 port is located between the two lugs.

[0248] b. Adjustment method

[0249] When the zero position of the eccentric sleeve coincides with the zero position of port S8, the two gears are in the middle meshing position. Rotating the eccentric sleeve clockwise increases the meshing degree of the two gears. Conversely, rotating the eccentric sleeve counterclockwise decreases the meshing degree of the two gears.

[0250] 2) Installation of speed reducer and motor.

[0251] The agitator uses a five-stage gear reducer, filled with 220# medium-load industrial gear oil. The input speed is 905 r / min, and the transmission ratio is 596.18.

[0252] The mixer motor is a three-phase asynchronous motor. The speed is adjusted by changing the power supply frequency through a frequency converter in the control cabinet. A force-limiting coupling is used between the motor and the reducer.

[0253] S425. Agitator trial run

[0254] The following checks must be performed before the agitator is tested:

[0255] Oil System: The lubrication station must meet the conditions for operation. First, the lubrication pipeline must be properly purged, and the oil tank of the lubrication station must be thoroughly cleaned (using dough to clean it). The three lubrication pipes (thrust bearing, eccentric sleeve bearing, and eccentric sleeve packing) must be properly installed. Start adding 64# cylinder oil to the tank; this time, add 170kg, approximately 3 / 4 of the tank capacity.

[0256] After the water and oil systems are in place and have passed inspection, trial operation can begin. First, reduce the water pressure to 0.05 MPa and start the trial run. The pressure should not drop after 4 hours of continuous operation. The agitator speed should be at full load, i.e., 12 rpm.

[0257] During the trial run, observe the agitator's rotation speed. This can be done by focusing on a single blade, timing the rotation for one revolution. Also, measure the agitator motor's current and check if the three current phases are balanced. Visually inspect the meshing of the large and small gears during operation.

[0258] The BGL gasifier frame of this invention is a hybrid frame of reinforced concrete and steel structure. The steel box girder used for hoisting intersects the main structural beams of the frame below the hoisting load-bearing beam in a spatial "cross" shape. To protect the main frame structure, a "suspension-type lifting point relocation" method is adopted, directing the fixed pulley block of the 200t main hoist pulley block to below the main structural beams of the frame. This reduces the amount of allowance for the frame structure and minimizes secondary construction of the frame structure. The coal bunker support beam at frame elevation △45.5m serves as the load-bearing beam, upon which two steel box girder beams are placed to bear the hoisting load. Since the gasifier is installed at the center of axis D, and there are two concrete beams at 35.77m and 40.05m along axis D, the steel box girder used for hoisting intersects the two main structural beams of the frame below the hoisting load-bearing beam in a spatial "cross" shape. To protect the main frame structure, a "suspension-type lifting point relocation" method is adopted, adding two Φ66—6×37+1--18 A 7mm steel wire rope is used to guide the tethering pulley point from the steel structure box-type hoisting beam to below the 35.77m beam. Two sets of H200×10D pulley blocks, equipped with four 20t winches, are hung at the rope point below the 35.77m concrete beam. The winches and guide point anchor points are fixed in one go using the "frame column anchor point method" to vertically lift the gasifier body. The gasifier support beam box-shaped beam is placed near the installation position in advance. When the gasifier is lifted to the hoisting elevation, the support beam is assembled and welded, and the gasifier is then placed in position. This one-time deployment of winches allows for the hoisting of multiple gasifiers, resulting in high machinery utilization, reduced costs, and faster construction progress.

[0259] This invention relates to the installation of the water-cooled wall and upper and lower equipment inside the BGL gasifier. It demonstrates advanced construction methods for the installation of BGL pulverized coal and slag gasifiers, fills the gap in the installation of proprietary foreign equipment components for BGL gasifiers, and masters the installation sequence and method of the upper and lower equipment of the gasifier in this process. This shortens the planned construction period of the critical path and reduces project costs.

[0260] This invention relates to an in-furnace agitator and coal distribution plate installed within the BGL gasifier body. These components break up the adhesion of raw coal and ensure uniform coal distribution. The agitator is associated with a complex lubrication system, transmission system, and control system. Furthermore, the entire agitator body is a jacketed device, making installation difficult and requiring limited working space. It is closely linked to the gasifier's construction, drying, and installation of upper equipment. The summary of the installation process for the BGL gasifier agitator and coal distribution plate highlights its crucial role in ensuring installation quality, shortening the installation period, and controlling project costs.

[0261] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should be able to analyze that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the essence and scope of the technical solutions of the present invention.

Claims

1. A method for installing a BGL gasifier plant, characterized in that, The method comprises the following steps: S1, after the frame civil construction is accepted, the hoisting machine rigging is arranged, and then the gasification furnace is hoisted; after the gasification furnace is hoisted, the gasification furnace support beam is assembled and welded, the slag port and the lower slag pool of the inner water cooling wall are assembled, and the lower slag pool pipe of the inner water cooling wall is pressure tested; The hoisting of the gasification furnace adopts the "double-beam double-lock synchronous sliding method", the "frame column anchor point method" and the "suspension type lifting point downward movement method"; During the hoisting of the gasification furnace, the suspension type lifting point downward movement method is adopted, that is, a steel wire rope is introduced from the steel structure box type hoisting beam to the concrete beam below the hanging trolley point, a rope is hung on the pulley set below the concrete beam, and a winch is matched to complete the hoisting of the gasification furnace; S2, after the gasification furnace is positioned, the remaining steel structure is installed, the connecting short section is installed, and then the inner water cooling wall in the gasification furnace is installed; S3, after the inner water cooling wall in the gasification furnace is installed, the furnace is built and baked; S4, the agitator and the coal distribution plate in the gasification furnace are installed, and the linkage test run is performed; The installation of the agitator and the coal distribution plate in the gasification furnace comprises the following steps: S411, the agitator is installed, including hoisting of the agitator lower cone and hoisting of the stirring arm; S412, the upper shaft is hoisted; S413, the coal distribution plate is hoisted; S414, the coal blocking cover, the radial bearing and the cover are installed; S415, the welding of the agitator ring weld is performed; S416, the installation of the tar distributor is performed; S417, the installation of the large gear support plate, the positioning ring and the support cap is performed; S418, the large gear is hoisted; S419, the installation of the thrust bearing and the upper radial bearing of the agitator is performed; S420, the installation of the guide sleeve is performed; S421, the whole agitator is hoisted; S422, the installation of the agitator scraper, the scraper plate and the support plate is performed; S423, the filling material is filled; S424, the installation of the transmission system is performed.

2. The BGL gasifier plant installation construction method according to claim 1, characterized by, In step S2, the installation steps of the inner water cooling wall in the gasification furnace comprise: S21, the size and pre-assembly of the upper slag pool and the lower slag pool are reviewed; S22, the connecting short section inner part is disassembled, the slag port cooling water pipe and the annular burner gas source pipe are installed, the slag port is installed, and the annular burner is installed; S23, the connecting short section is turned again, the upper flange opening is upward, the two sections of the lower slag pool, the slag port and the lower slag pool pipe are pressure tested; S24, the connecting short section is installed into the lower bore of the gasification furnace, and the slag port and the lower slag pool are attached; S25, the water cooling wall of the lower slag pool is tamped; S26, the upper slag pool in the gasification furnace is assembled; S27, the upper slag pool support, the pipe and the water pressure test are welded; S28, the water cooling wall of the lower slag pool is tamped.

3. The BGL gasifier plant installation construction method according to claim 2, characterized by: In step S3, after the furnace is built, the quenching chamber is installed, the slag lock is installed, the pump is installed and the baking equipment is installed, then the jacket water and the high-pressure cooling water pipe are piped, and after the baking water system pump is tested, the furnace is baked.

4. The BGL gasifier plant installation construction method according to claim 3, characterized by: In step S411, The steps of hoisting the agitator lower cone are as follows: Firstly, the agitator lower cone is hoisted to the furnace opening by using a 16T electric hoist, two 3T hoisting belts are passed through the water hole of the agitator lower cone outlet, the two hoisting belts are hung on the guide chain of the winch, the winch is raised, the 16T electric hoist is lowered, until the hook on the 16T electric hoist is taken off, the agitator lower cone is slowly sent to the furnace bottom, and the agitator lower cone is adjusted and placed in the tooling. The steps of hoisting the stirring arm are: The stirring arm comprises a small stirring arm, a large stirring arm I, and a large stirring arm II; before hoisting, a tetrafluoro ring is installed into the cooling water pipe groove of the small stirring arm; first, a 6m-long 5T hoisting belt is used, one end of which is wound around a paddle of the small stirring arm, and the other end is connected by a clasp ring; then, two 3m-long 3T hoisting belts are used to hold the paddles of the two stirring arms; a 16T electric hoist is used to hoist the two 3T hoisting belts and move them to the furnace mouth; a 3T guide chain on the winch is used to hoist one end of the 5T hoisting belt; the winch is raised, and the electric hoist is lowered until the two 3T hoisting belts can be removed, so that the small stirring arm is vertical; the small stirring arm is slowly lowered to the vicinity of the lower cone of the stirring tank; a 3T guide chain is hung on the steel wire rope to hoist the 3T hoisting belt on the other paddle; the two guide chains are adjusted to make the small stirring arm horizontal and to make the cooling water pipe of the small stirring arm pass through the cooling water pipe of the lower stirring cone; the hoisting belts are loosened and are spot-welded to be fixed; the hoisting methods of the large stirring arm I and the large stirring arm II are the same as those of the small stirring arm.

5. The BGL gasifier plant installation construction method according to claim 4, characterized by: In step S412, the upper part of the shaft is moved to the gasification furnace mouth by using a 16T electric hoist; a 3T hoisting belt is bound to the fixed disc behind the coal distributor of the upper part of the shaft, and another 3T hoisting belt is bound to the hollow shaft; a 3T winch is used to hook the 3T hoisting belt on the hollow shaft; the upper part of the shaft is raised by using the 16T electric hoist; after the upper part of the shaft is raised, the 16T hook is removed, and the upper part of the shaft is slowly lowered by using the winch.

6. The BGL gasifier plant installation construction method according to claim 5, characterized by: In step S413, first, the left and right lifting lugs of the right disc of the coal distribution disc are bound by two 3T, 3m hoisting belts by using a clasp ring; a 3T guide chain is hung on the lifting lug in the middle of the coal distribution disc; the other ends of the two hoisting belts and the guide chain are hung on a 16T electric hoist; the coal distribution disc is moved to the furnace mouth; a 3T guide chain on the winch is hung on the right clasp ring; another 3T guide chain is hung on the left clasp ring; a 5T guide chain on the furnace mouth is hung on a 6T hoisting belt which is 5m long; the other end of the hoisting belt is hung on the clasp ring on the left end of the coal distribution disc; at this time, the 16T electric hoist is lowered, and the winch is raised until the coal distribution disc is vertical; the 3T guide chain on the 16T electric hoist is removed and is hung on the hook of the winch; the guide chain is adjusted to make the coal distribution disc fall to the vicinity of the manhole of the furnace mouth; the guide chain prepared in advance on the left end is hung on the hook of the winch; the coal distribution disc is gradually leveled and is slowly lowered to the vicinity of the upper part of the shaft; a 45×160 key is placed in the key groove, and six M45×180 bolts are used to fix the coal distribution disc on the upper part of the shaft; the hoisting method of the left disc of the coal distribution disc is the same as that of the right disc; after the left disc and the right disc of the coal distribution disc are installed in place, the inner and outer lugs of the left disc and the right disc are fastened by using two M52×500 bolts and two M27×160 bolts; finally, the cooling water pipes on the coal distribution disc are welded.

7. The BGL gasifier plant installation construction method according to claim 6, characterized by: In step S416, the base of the tar distributor is moved to the furnace mouth by using a 16T electric hoist; a 5T winch is used to lower the base to the hollow shaft; a 45×160 key is installed in place; then, the base is fixed on the hollow shaft by using two semicircular positioning rings and four M24×55 bolts; the four conical petals are hoisted one by one to the vicinity of the base; the conical petals are fixed by using four M42×120 bolts; after the four conical petals are fixed on the base, the four conical petals are fixed by using sixteen M36×80 bolts.

8. The BGL gasifier plant installation construction method according to claim 7, characterized by, In step S417, first install the gear support, with four small clamps to hang two belts on both ends of the gear support, with 16T electric hoist to move to the furnace mouth, the 3T guide chain on the winch is hung on one of the belts, the winch is lifted, the electric hoist is lowered, and the gear support becomes vertical. The lower belt is also hung with a 3T guide chain, which is lowered to the furnace mouth and gradually leveled with the guide chain. After leveling, the gear support is inserted into the hollow shaft. After the gear support is installed in place, the positioning ring of the gear support is clamped in the clamping groove of the hollow shaft, the fixing cap of the gear support is lowered, and the fixing cap is rotated 45° after being in place, so that the four clamping claws of the fixing cap are clamped on the gear support. Four M24x65 bolts are used to fix the fixing cap on the gear support.

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