Production process control method in lime kiln in upper flow guide cap caking state

Abstract

The invention relates to a production process control method for an upper flow guide cap in a lime kiln in a material caking state. The method comprises the following steps: step 1, carrying out online judgment on material caking abnormity; 2, online treatment is carried out for material caking abnormity; wherein the online judgment of the abnormal material caking is to judge the abnormal material caking grade AggLev according to the variation delta Gas of waste gas in a kiln of the air heat exchanger and the variation delta TTop of the kiln top temperature; according to the online treatment of the abnormal material caking, measures are taken according to the abnormal material caking grade AggLev, and online treatment is carried out. Therefore, the problem of abnormal material caking can be solved, and the production can be influenced by no shutdown of the furnace.

Description

Technical Field

[0001] The invention relates to a control method, in particular to a production process control method in a lime kiln under a material-bonding state of an upper guide cap, and belongs to the technical field of kiln production control. Background Art

[0002] At present, the advanced active lime shaft kilns at home and abroad are mainly sleeve kilns, rotary kilns, Maerz kilns, and Fukas kilns. The sleeve kiln built by Meishan Iron and Steel in the 1990s was the first time that Beckenbach annular sleeve kiln technology was introduced in China. The sleeve shaft kiln has the characteristics of reasonable calcination process, negative pressure operation, high operating rate, wide applicable fuel range, simple kiln equipment, structural design to ensure maximum possible heat recovery, and low heat consumption, and has been widely used. Due to the large amount of dust in the kiln, the exhaust gas entering the upper inner tube under the action of the high-temperature fan enters the heat exchanger through the exhaust gas channel. The space between the top of the lower inner tube and the bottom of the upper inner tube suddenly becomes larger, and the exhaust gas airflow speed decreases rapidly. The dust contained in the airflow produces a large amount of sedimentation due to gravity, and material accumulation occurs on the upper guide cap. When the material accumulation is serious, the amount of exhaust gas entering the inner side of the upper inner tube will be reduced or even completely blocked, causing the amount of exhaust gas passing through the air heat exchanger to decrease, and at the same time, the kiln top temperature will increase, driving the air to decrease in temperature after preheating, thereby increasing the heat consumption of lime kiln calcination, affecting the gas consumption and lime quality. In this case, the kiln will generally be stopped and personnel will be required to manually clean the kiln, which takes about 4-6 days, is time-consuming and labor-intensive, and will affect the supply of active lime in the steel plant. Therefore, it is necessary to automatically detect the severity of the material agglomeration of the upper guide cap of the lime kiln, and develop an online production organization method under the material agglomeration state of the upper guide cap, so as to minimize the impact on the production of the lime kiln. After searching for new technologies, it was found that the prior art similar to the present invention, "A Lime Kiln Slag Cleaning Equipment (Patent No.: CN202221419490.5)", the utility model discloses a lime kiln slag cleaning equipment, including a cleaning assembly at the bottom of the lime kiln cavity, a filter screen plate connected to the inner cavity bolts, a feed pipe connected to the right side, and a storage assembly at the bottom of the feed pipe, which solves the problem that the existing slag cleaning equipment does not have the function of pre-crushing larger slag blocks. Therefore, when larger slag blocks accumulate at the bottom of the kiln, it is very easy to cause the discharge port at the bottom of the kiln to be blocked, and finally the staff needs to loosen it, which greatly increases the labor intensity of the staff, has certain disadvantages, and reduces the practicality of the slag cleaning equipment. The present invention mainly solves the problem of arranging production under the state of material accumulation on the guide cap of the lime kiln. In order to solve this problem, the present invention judges the severity of material accumulation by the exhaust gas in the kiln, the high temperature of the kiln top, the change of the driving air, etc., and then takes measures such as adjusting the gas volume, increasing the frequency of the high-temperature fan, and increasing the material level height in the kiln to solve the material accumulation problem, so as to ensure the normal production without stopping production. The present invention has the beneficial effects of online disposal of material accumulation, not affecting the normal production, increasing output, improving the quality parameters such as the activity of active lime, and reducing the cost of stopping the kiln for maintenance. Summary of the invention

[0003] The present invention aims at the problems existing in the prior art and provides a production process control method under the state of material accumulation in the upper guide cap of a lime kiln. The technical scheme realizes the processing of material accumulation and the stability and quality improvement of lime production.

[0004] In order to achieve the above object, the technical solution of the present invention is as follows: a production process control method in a lime kiln under a material-bound state of an upper guide cap, the method comprising the following steps:

[0005] Step 1: Make online judgment on abnormal material formation;

[0006] Step 2: Take online measures to deal with abnormal material formation;

[0007] The abnormal material formation online judgment is to judge the abnormal material formation level AggLev according to the change of the exhaust gas in the kiln of the air heat exchanger ΔGas and the change of the kiln top temperature ΔTTop;

[0008] The online treatment of abnormal material agglomeration is to take measures and handle it online according to the abnormal material agglomeration level AggLev, so as to solve the problem of abnormal material agglomeration without stopping the furnace and affecting production.

[0009] The online judgment of abnormal material formation includes the following judgment methods:

[0010] 1) When the amount of waste gas in the kiln passing through the air heat exchanger is reduced to (ΔGas1, ΔGas2), and the kiln top temperature is high at (ΔTTop1, ΔTTop2);

[0011] AggLev = 1;

[0012] 2) When the amount of exhaust gas in the kiln passing through the air heat exchanger is reduced to (ΔGas2, ΔGas3), and the kiln top temperature is high at (ΔTTop2, ΔTTop3);

[0013] AggLev = 2;

[0014] 3) When the amount of waste gas in the kiln passing through the air heat exchanger is reduced to (ΔGas3, ΔGas4), and the kiln top temperature is high at (ΔTTop3, ΔTTop4);

[0015] AggLev = 3;

[0016] 4) When the amount of waste gas in the kiln passing through the air heat exchanger is reduced by more than ΔGas4, and the kiln top temperature is higher than ΔTTop4;

[0017] AggLev = 4;

[0018] Among them, ΔGas1, ΔGas2, ΔGas3, ΔGas4, ΔTTop1, ΔTTop2, ΔTTop3, ΔTTop4 are fixed values.

[0019] The value range of ΔGas1 is within (8%, 12%);

[0020] The value range of ΔGas2 is (18%, 22%);

[0021] The value range of ΔGas3 is (28%, 32%);

[0022] The value range of ΔGas4 is (44%, 46%);

[0023] The value range of ΔTTop1 is within (8℃, 12℃);

[0024] The value range of ΔTTop2 is within (18℃, 22℃);

[0025] The value range of ΔTTop3 is within (28℃, 32℃);

[0026] The value range of ΔTTop4 is (44℃, 46℃).

[0027] Among them, the online treatment of abnormal material accumulation includes the following treatment methods:

[0028] For AggLev=1, the treatment method is as follows:

[0029] The following t represents the duration from the start of treatment to the current moment;

[0030] T represents the time required for adjustment when AggLev=1, ranging from (30h, 50h);

[0031] (1) Gas volume regulation, including driving air, combustion air, kiln bottom cooling air, and coal gas volume regulation 1) Increase the driving air volume,

[0032]

[0033] 2) Reduce the supply of combustion air,

[0034]

[0035] 3) Increase the amount of cooling air at the kiln bottom,

[0036]

[0037] 4) Increase gas supply,

[0038] ③ When the calorific value of the gas used is within (800, 1700) Kcal / m3

[0039]

[0040] ④ When the calorific value of the gas used is within (1850, 2450) Kcal / m3

[0041]

[0042] in,

[0043] DriveAir represents the driving air volume at time t;

[0044] DriveAir0 represents the initial amount of driving air before adjustment;

[0045] CombustionAir represents the amount of combustion air at time t;

[0046] CombustionAir0 represents the initial amount of combustion air;

[0047] CoolingAir indicates the amount of cooling air at the kiln bottom;

[0048] CoolingAir0 represents the initial amount of cooling air at the kiln bottom;

[0049] CoalGas represents the amount of gas at time t;

[0050] CoalGas0 represents the initial amount of coal gas;

[0051] α1 constant, the value range is (0.18, 0.25);

[0052] β1 constant, the value range is (0.10, 0.11);

[0053] γ1 constant, the value range is (0.11, 0.13);

[0054] θ 11 ,θ 12 Constant, the value range is (0.07, 0.10), (0.04, 0.06);

[0055] (2) Increase the frequency of high temperature fans:

[0056] HiTemFanS=HigTemFanS0(1*A1);

[0057] in,

[0058] HiTemFanS represents the high temperature fan frequency at time t;

[0059] HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment;

[0060] A1 constant, the value range is (1.037, 1.049);

[0061] (3) Increase the material level in the kiln:

[0062] MaterLevel=MaterLevel+B1;

[0063] in,

[0064] MaterLevel represents the material level height at time t;

[0065] MaterLevel0 represents the initial value of the material level before adjustment;

[0066] B1 constant, the value range is (0.25,0.28).

[0067] Among them, for AggLev=2, the treatment method is as follows:

[0068] The following t represents the duration from the start of treatment to the current moment;

[0069] T represents the time required for adjustment when AggLev=2, ranging from (50h, 60h);

[0070] (1) Gas volume regulation, including driving air, combustion air, kiln bottom cooling air, and coal gas volume regulation 1) Increase the driving air volume,

[0071]

[0072] 2) Reduce the supply of combustion air,

[0073]

[0074] 3) Increase the amount of cooling air at the kiln bottom,

[0075]

[0076] 4) Increase gas supply,

[0077] ③ When the calorific value of the gas used is within (800, 1700) Kcal / m3

[0078]

[0079] ④ When the calorific value of the gas used is within (1850, 2450) Kcal / m3

[0080]

[0081] in,

[0082] DriveAir represents the driving air volume at time t;

[0083] DriveAir0 indicates the initial amount of driving air before adjustment;

[0084] CombustionAir represents the amount of combustion air at time t;

[0085] CombustionAir0 represents the initial amount of combustion air;

[0086] CoolingAir indicates the amount of cooling air at the kiln bottom;

[0087] CoolingAir0 represents the initial amount of cooling air at the kiln bottom;

[0088] CoalGas represents the amount of gas at time t;

[0089] CoalGas0 represents the initial amount of coal gas;

[0090] α2 constant, the value range is (0.26, 0.31);

[0091] β2 constant, the value range is (0.12, 0.13);

[0092] γ2 constant, the value range is (0.14, 0.16);

[0093] θ 21 ,θ 22 Constant, the value range is (0.11, 0.14), (0.07, 0.09);

[0094] (2) Increase the frequency of high temperature fans:

[0095] HiTemFanS=HigTemFanS0(1*A2);

[0096] in,

[0097] HiTemFanS represents the high temperature fan frequency at time t;

[0098] HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment;

[0099] A2 constant, the value range is (1.050,1.058);

[0100] (3) Increase the material level in the kiln:

[0101] MaterLevel=MaterLevel+B2;

[0102] in,

[0103] MaterLevel represents the material level height at time t;

[0104] MaterLevel0 represents the initial value of the material level before adjustment;

[0105] B2 constant, the value range is (0.29,0.31).

[0106] Among them, AggLev = 3, then the treatment method is as follows:

[0107] The following t represents the duration from the start of treatment to the current moment;

[0108] T represents the time required for adjustment when AggLev=3, ranging from (60h, 70h);

[0109] (1) Gas volume regulation, including driving air, combustion air, kiln bottom cooling air, and coal gas volume regulation; 1) Increase driving air volume,

[0110]

[0111] 2) Reduce the supply of combustion air,

[0112]

[0113] 3) Increase the amount of cooling air at the kiln bottom,

[0114]

[0115] 4) Increase gas supply,

[0116] ③ When the calorific value of the gas used is within (800, 1700) Kcal / m3

[0117]

[0118] ④ When the calorific value of the gas used is within (1850, 2450) Kcal / m3

[0119]

[0120] in,

[0121] DriveAir represents the driving air volume at time t;

[0122] DriveAir0 represents the initial amount of driving air before adjustment;

[0123] CombustionAir represents the amount of combustion air at time t;

[0124] CombustionAir0 represents the initial amount of combustion air;

[0125] CoolingAir indicates the amount of cooling air at the kiln bottom;

[0126] CoolingAir0 indicates the initial amount of cooling air at the kiln bottom

[0127] CoalGas represents the amount of gas at time t;

[0128] CoalGas0 represents the initial amount of coal gas;

[0129] α3 constant, the value range is (0.32, 0.35);

[0130] β3 constant, the value range is (0.13, 0.14);

[0131] γ3 constant, the value range is (0.17, 0.18);

[0132] θ 31 ,θ 32 Constant, the value range is (0.15, 0.18), (0.10, 0.13); (2) Increase the frequency of high temperature fan:

[0133] HiTemFanS=HigTemFanS0(1*A3);

[0134] in,

[0135] HiTemFanS represents the high temperature fan frequency at time t;

[0136] HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment;

[0137] A3 constant, the value range is (1.059, 1.067);

[0138] (3) Increase the material level in the kiln:

[0139] MaterLevel=MaterLevel+B3;

[0140] in,

[0141] MaterLevel represents the material level height at time t;

[0142] MaterLevel0 represents the initial value of the material level before adjustment;

[0143] B3 constant, the value range is (0.32,0.39).

[0144] Among them, for AggLev=4, the treatment method is as follows:

[0145] The following t represents the duration from the start of treatment to the current moment;

[0146] T represents the time required for adjustment when AggLev=4, ranging from (70h, 80h);

[0147] (1) Adjustment of gas volume, including adjustment of driving air, combustion air, kiln bottom cooling air, and coal gas volume 1) Increase driving air volume

[0148]

[0149] 2) Reduce the supply of combustion air

[0150]

[0151] 3) Increase the amount of cooling air at the kiln bottom

[0152]

[0153] 4) Increase gas supply

[0154] ③ When the calorific value of the gas used is within (800, 1700) Kcal / m3

[0155]

[0156] ④ When the calorific value of the gas used is within (1850, 2450) Kcal / m3

[0157]

[0158] in,

[0159] DDriveAir represents the driven air volume at time t;

[0160] DriveAir0 represents the initial amount of driving air before adjustment;

[0161] CombustionAir represents the amount of combustion air at time t;

[0162] CombustionAir0 represents the initial amount of combustion air;

[0163] CoolingAir indicates the amount of cooling air at the kiln bottom;

[0164] CoolingAir0 represents the initial amount of cooling air at the kiln bottom;

[0165] CoalGas represents the amount of gas at time t;

[0166] CoalGas0 represents the initial amount of coal gas;

[0167] α4 constant, the value range is (0.36, 0.39);

[0168] β4 constant, the value range is (0.15, 0.16);

[0169] γ4 constant, the value range is (0.19, 0.20);

[0170] Θ 41 ,θ42 Constant, the value range is (0.19, 0.21), (0.14, 0.17);

[0171] (2) Increase the frequency of high temperature fans:

[0172] HiTemFanS=HigTemFanS0(1*A4);

[0173] in,

[0174] HiTemFanS represents the high temperature fan frequency at time t;

[0175] HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment;

[0176] A4 constant, the value range is (1.068, 1.079);

[0177] (3) Increase the material level in the kiln:

[0178] MaterLevel=MaterLevel+B4;

[0179] in,

[0180] MaterLevel represents the material level height at time t;

[0181] MaterLevel0 represents the initial value of the material level before adjustment;

[0182] B4 constant, the value range is (0.41,0.52).

[0183] Compared with the prior art, the present invention has the following advantages: the present invention has a simple structure and is easy to use. Through the method, the processing of aggregates and the stability and quality of lime production are achieved, as follows:

[0184] (1) Online disposal of agglomerates without stopping the machine: With this technology, agglomerates on the upper guide caps can be disposed of online without stopping the machine for disposal, which improves efficiency. Before the implementation of this technology (2020), Meigang Kilns No. 2 and No. 4 had a total of 4 agglomerates on the upper guide caps, and the kiln was stopped for disposal for 198.7 hours (see Table 1). After the implementation of this technology (experimental phase from January to September 2023), Meigang Kilns No. 2 and No. 4 had a total of 4 agglomerates on the upper guide caps, and the kiln was stopped for disposal for 0 hours (see Table 2).

[0185] (2) Increase production: Since the upper guide cap does not need to be shut down for maintenance, it can be automatically cleaned online, thus avoiding the loss of production caused by shutdown for maintenance. According to statistics, the average production of Meishan Iron and Steel's two lime kilns increased by 24,652.3 tons / month - 22,922.1 tons / month = 1,730.2 tons / month;

[0186] (3) Improved the quality parameters of active lime such as activity: the average activity of the two lime kilns of Meishan Iron and Steel Co., Ltd. increased by 352.1 ml / 4NHcl / month - 341.2 ml / 4NHcl / month = 10.9 ml / 4NHcl / month;

[0187] (4) Reduced kiln shutdown and maintenance costs: Reduced the cost of manual kiln cleaning after kiln shutdown. According to statistics, the cost of kiln shutdown and maintenance is reduced by at least RMB 149,000 per year compared with before the implementation of this technology.

[0188] Table 1 Statistics of the upper guide cap of Meishan lime kiln in 2020

[0189]

[0190] Table 2 Statistics of the upper guide cap of Meishan lime kiln in 2023

[0191] DETAILED DESCRIPTION

[0192] In order to deepen the understanding of the present invention, a detailed description is given below in conjunction with embodiments.

[0193] Embodiment 1: A production process control method in a lime kiln under a material-bound state of an upper guide cap, the method comprising the following steps:

[0194] Step 1: Make online judgment on abnormal material formation;

[0195] Step 2: Take online measures to deal with abnormal material formation;

[0196] The abnormal material formation online judgment is to judge the abnormal material formation level AggLev according to the change of the exhaust gas in the kiln of the air heat exchanger ΔGas and the change of the kiln top temperature ΔTTop;

[0197] The online treatment of abnormal material agglomeration is to take measures and handle it online according to the abnormal material agglomeration level AggLev, so as to solve the problem of abnormal material agglomeration without stopping the furnace and affecting production.

[0198] The online judgment of abnormal material formation includes the following judgment methods:

[0199] 1) When the amount of waste gas in the kiln passing through the air heat exchanger is reduced to (ΔGas1, ΔGas2), and the kiln top temperature is high at (ΔTTop1, ΔTTop2);

[0200] AggLev = 1;

[0201] 2) When the amount of exhaust gas in the kiln passing through the air heat exchanger is reduced to (ΔGas2, ΔGas3), and the kiln top temperature is high at (ΔTTop2, ΔTTop3);

[0202] AggLev = 2;

[0203] 3) When the amount of waste gas in the kiln passing through the air heat exchanger is reduced to (ΔGas3, ΔGas4), and the kiln top temperature is high at (ΔTTop3, ΔTTop4);

[0204] AggLev = 3;

[0205] 4) When the amount of waste gas in the kiln passing through the air heat exchanger is reduced by more than ΔGas4, and the kiln top temperature is higher than ΔTTop4;

[0206] AggLev = 4;

[0207] Among them, ΔGas1, ΔGas2, ΔGas3, ΔGas4, ΔTTop1, ΔTTop2, ΔTTop3, ΔTTop4 are fixed values.

[0208] The value range of ΔGas1 is within (8%, 12%);

[0209] The value range of ΔGas2 is (18%, 22%);

[0210] The value range of ΔGas3 is (28%, 32%);

[0211] The value range of ΔGas4 is (44%, 46%);

[0212] The value range of ΔTTop1 is within (8℃, 12℃);

[0213] The value range of ΔTTop2 is within (18℃, 22℃);

[0214] The value range of ΔTTop3 is within (28℃, 32℃);

[0215] The value range of ΔTTop4 is (44℃, 46℃).

[0216] Among them, the online treatment of abnormal material accumulation includes the following treatment methods:

[0217] For AggLev=1, the treatment method is as follows:

[0218] The following t represents the duration from the start of treatment to the current moment;

[0219] T represents the time required for adjustment when AggLev=1, ranging from (30h, 50h);

[0220] (1) Gas volume regulation, including driving air, combustion air, kiln bottom cooling air, and coal gas volume regulation 1) Increase the driving air volume,

[0221]

[0222] 2) Reduce the supply of combustion air,

[0223]

[0224] 3) Increase the amount of cooling air at the kiln bottom,

[0225]

[0226] 4) Increase gas supply,

[0227] ⑤ When the calorific value of the gas used is within (800, 1700) Kcal / m3

[0228]

[0229] ⑥ When the calorific value of the gas used is within (1850, 2450) Kcal / m3

[0230]

[0231] in,

[0232] DriveAir represents the driving air volume at time t;

[0233] DriveAir0 represents the initial amount of driving air before adjustment;

[0234] CombustionAir represents the amount of combustion air at time t;

[0235] CombustionAir0 represents the initial amount of combustion air;

[0236] CoolingAir indicates the amount of cooling air at the kiln bottom;

[0237] CoolingAir0 represents the initial amount of cooling air at the kiln bottom;

[0238] CoalGas represents the amount of gas at time t;

[0239] CoalGas0 represents the initial amount of coal gas;

[0240] α1 constant, the value range is (0.18, 0.25);

[0241] β1 constant, the value range is (0.10, 0.11);

[0242] γ1 constant, the value range is (0.11, 0.13);

[0243] θ 11 ,θ 12 Constant, the value range is (0.07, 0.10), (0.04, 0.06);

[0244] (2) Increase the frequency of high temperature fans:

[0245] HiTemFanS=HigTemFanS0(1*A1);

[0246] in,

[0247] HiTemFanS represents the high temperature fan frequency at time t;

[0248] HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment;

[0249] A1 constant, the value range is (1.037, 1.049);

[0250] (3) Increase the material level in the kiln:

[0251] MaterLevel=MaterLevel+B1;

[0252] in,

[0253] MaterLevel represents the material level height at time t;

[0254] MaterLevel0 represents the initial value of the material level before adjustment;

[0255] B1 constant, the value range is (0.25,0.28).

[0256] Among them, for AggLev=2, the treatment method is as follows:

[0257] The following t represents the duration from the start of treatment to the current moment;

[0258] T represents the time required for adjustment when AggLev=2, ranging from (50h, 60h);

[0259] (1) Gas volume regulation, including driving air, combustion air, kiln bottom cooling air, and coal gas volume regulation 1) Increase the driving air volume,

[0260]

[0261] 2) Reduce the supply of combustion air,

[0262]

[0263] 3) Increase the amount of cooling air at the kiln bottom,

[0264]

[0265] 4) Increase gas supply,

[0266] ⑤ When the calorific value of the gas used is within (800, 1700) Kcal / m3

[0267]

[0268] ⑥ When the calorific value of the gas used is within (1850, 2450) Kcal / m3

[0269]

[0270] in,

[0271] DriveAir represents the driving air volume at time t;

[0272] DriveAir0 indicates the initial amount of driving air before adjustment;

[0273] CombustionAir represents the amount of combustion air at time t;

[0274] CombustionAir0 represents the initial amount of combustion air;

[0275] CoolingAir indicates the amount of cooling air at the kiln bottom;

[0276] CoolingAir0 represents the initial amount of cooling air at the kiln bottom;

[0277] CoalGas represents the amount of gas at time t;

[0278] CoalGas0 represents the initial amount of coal gas;

[0279] α2 constant, the value range is (0.26, 0.31);

[0280] β2 constant, the value range is (0.12, 0.13);

[0281] γ2 constant, the value range is (0.14, 0.16);

[0282] θ 21 ,θ 22 Constant, the value range is (0.11, 0.14), (0.07, 0.09);

[0283] (2) Increase the frequency of high temperature fans:

[0284] HiTemFanS=HigTemFanS0(1*A2);

[0285] in,

[0286] HiTemFanS represents the high temperature fan frequency at time t;

[0287] HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment;

[0288] A2 constant, the value range is (1.050,1.058);

[0289] (3) Increase the material level in the kiln:

[0290] MaterLevel=MaterLevel+B2;

[0291] in,

[0292] MaterLevel represents the material level height at time t;

[0293] MaterLevel0 represents the initial value of the material level before adjustment;

[0294] B2 constant, the value range is (0.29,0.31).

[0295] Among them, AggLev = 3, then the treatment method is as follows:

[0296] The following t represents the duration from the start of treatment to the current moment;

[0297] T represents the time required for adjustment when AggLev=3, ranging from (60h, 70h);

[0298] (1) Gas volume regulation, including driving air, combustion air, kiln bottom cooling air, and coal gas volume regulation; 1) Increase driving air volume,

[0299]

[0300] 2) Reduce the supply of combustion air,

[0301]

[0302] 3) Increase the amount of cooling air at the kiln bottom,

[0303]

[0304] 4) Increase gas supply,

[0305] ⑤ When the calorific value of the gas used is within (800, 1700) Kcal / m3

[0306]

[0307] ⑥ When the calorific value of the gas used is within (1850, 2450) Kcal / m3

[0308]

[0309] in,

[0310] DriveAir represents the driving air volume at time t;

[0311] DriveAir0 indicates the initial amount of driving air before adjustment;

[0312] CombustionAir represents the amount of combustion air at time t;

[0313] CombustionAir0 represents the initial amount of combustion air;

[0314] CoolingAir indicates the amount of cooling air at the kiln bottom;

[0315] CoolingAir0 indicates the initial amount of cooling air at the kiln bottom

[0316] CoalGas represents the amount of gas at time t;

[0317] CoalGas0 represents the initial amount of coal gas;

[0318] α3 constant, the value range is (0.32, 0.35);

[0319] β3 constant, the value range is (0.13, 0.14);

[0320] γ3 constant, the value range is (0.17, 0.18);

[0321] θ 31 ,θ 32 Constant, the value range is (0.15, 0.18), (0.10, 0.13); (2) Increase the frequency of high temperature fan:

[0322] HiTemFanS=HigTemFanS0(1*A3);

[0323] in,

[0324] HiTemFanS represents the high temperature fan frequency at time t;

[0325] HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment;

[0326] A3 constant, the value range is (1.059, 1.067);

[0327] (3) Increase the material level in the kiln:

[0328] MaterLevel=MaterLevel+B3;

[0329] in,

[0330] MaterLevel represents the material level height at time t;

[0331] MaterLevel0 represents the initial value of the material level before adjustment;

[0332] B3 constant, the value range is (0.32,0.39).

[0333] Among them, for AggLev=4, the treatment method is as follows:

[0334] The following t represents the duration from the start of treatment to the current moment;

[0335] T represents the time required for adjustment when AggLev=4, ranging from (70h, 80h);

[0336] (1) Adjustment of gas volume, including adjustment of driving air, combustion air, kiln bottom cooling air, and coal gas volume 1) Increase driving air volume

[0337]

[0338] 2) Reduce the supply of combustion air

[0339]

[0340] 3) Increase the amount of cooling air at the kiln bottom

[0341]

[0342] 4) Increase gas supply

[0343] ⑤ When the calorific value of the gas used is within (800, 1700) Kcal / m3

[0344]

[0345] ⑥ When the calorific value of the gas used is within (1850, 2450) Kcal / m3

[0346]

[0347] in,

[0348] DDriveAir represents the driven air volume at time t;

[0349] DriveAir0 indicates the initial amount of driving air before adjustment;

[0350] CombustionAir represents the amount of combustion air at time t;

[0351] CombustionAir0 represents the initial amount of combustion air;

[0352] CoolingAir indicates the amount of cooling air at the kiln bottom;

[0353] CoolingAir0 represents the initial amount of cooling air at the kiln bottom;

[0354] CoalGas represents the amount of gas at time t;

[0355] CoalGas0 represents the initial amount of coal gas;

[0356] α4 constant, the value range is (0.36, 0.39);

[0357] β4 constant, the value range is (0.15, 0.16);

[0358] γ4 constant, the value range is (0.19, 0.20);

[0359] Θ 41 ,θ 42 Constant, the value range is (0.19, 0.21), (0.14, 0.17);

[0360] (2) Increase the frequency of high temperature fans:

[0361] HiTemFanS=HigTemFanS0(1*A4);

[0362] in,

[0363] HiTemFanS represents the high temperature fan frequency at time t;

[0364] HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment;

[0365] A4 constant, the value range is (1.068, 1.079);

[0366] (3) Increase the material level in the kiln:

[0367] MaterLevel=MaterLevel+B4;

[0368] in,

[0369] MaterLevel represents the material level height at time t;

[0370] MaterLevel0 represents the initial value of the material level before adjustment;

[0371] B4 constant, the value range is (0.41,0.52).

[0372] Embodiment 2: A production process control method in a lime kiln under a material-bound state of an upper guide cap, the method comprising the following steps:

[0373] Taking Meishan Steel's No. 2 Kiln as an example, the technical solution of the present invention is described.

[0374] The online judgment technology of abnormal material formation includes the following judgment methods:

[0375] 1. When the amount of waste gas in the kiln passing through the air heat exchanger is reduced to (ΔGas1, ΔGas2), and the kiln top temperature is high at (ΔTTop1, ΔTTop2);

[0376] Here (ΔGas1, ΔGas2) is a fixed value range, such as (8%, 25%), (ΔTTop1, ΔTTop2) is also a fixed value range, the same as below AggLev = 1;

[0377] 2. When the amount of waste gas in the kiln passing through the air heat exchanger is reduced to (ΔGas2, ΔGas3), and the kiln top temperature is high at (ΔTTop2, ΔTTop3);

[0378] AggLev = 2;

[0379] 3. When the amount of waste gas in the kiln passing through the air heat exchanger is reduced to (ΔGas3, ΔGas4), and the kiln top temperature is high at (ΔTTop3, ΔTTop4);

[0380] AggLev = 3;

[0381] 4. When the amount of waste gas in the kiln passing through the air heat exchanger is reduced by more than ΔGas4, and the kiln top temperature is higher than ΔTTop4;

[0382] AggLev = 4;

[0383] The online treatment technology for abnormal material accumulation includes the following treatment methods:

[0384] 1. If AggLev = 1, the treatment method is as follows:

[0385] In the following, t represents the duration from the start of treatment to the current time; T=44 hours.

[0386] (1) Adjustment of gas volume, including adjustment of driving air, combustion air, kiln bottom cooling air, and coal gas volume 1) Increase driving air volume

[0387]

[0388] 2) Reduce the supply of combustion air

[0389]

[0390] 3) Increase the amount of cooling air at the kiln bottom

[0391]

[0392] 4) Increase gas supply

[0393] ① When the calorific value of the gas used is within (800, 1700) Kcal / m3

[0394]

[0395] ② When the calorific value of the gas used is within (1850, 2450) Kcal / m3

[0396]

[0397] in,

[0398] DriveAir represents the driving air volume at time t;

[0399] DriveAir0 indicates the initial amount of driving air before adjustment;

[0400] CombustionAir represents the amount of combustion air at time t;

[0401] CombustionAir0 represents the initial amount of combustion air;

[0402] CoolingAir indicates the amount of cooling air at the kiln bottom;

[0403] CoolingAir0 represents the initial amount of cooling air at the kiln bottom;

[0404] CoalGas represents the amount of gas at time t;

[0405] CoalGas0 represents the initial amount of coal gas;

[0406] α1 = 0.21;

[0407] β1 = 0.11;

[0408] γ1=0.13;

[0409] θ 11 =0.08;

[0410] θ 12 =0.05;

[0411] (2) Increase the frequency of high temperature fans:

[0412] HiTemFanS=HigTemFanS0(1*A1)

[0413] in,

[0414] HiTemFanS represents the high temperature fan frequency at time t

[0415] HiTemFanS0 indicates the initial value of the high temperature fan frequency before adjustment

[0416] A1=1.046;

[0417] (3) Increase the material level in the kiln:

[0418] MaterLevel=MaterLevel+B1;

[0419] in,

[0420] MaterLevel represents the material level height at time t

[0421] MaterLevel0 indicates the initial value of the material level before adjustment

[0422] B1=0.26;

[0423] 2. If AggLev = 2, the treatment method is as follows:

[0424] The following t represents the duration from the start of treatment to the current time; T = 56 hours;

[0425] (1) Adjustment of gas volume, including adjustment of driving air, combustion air, kiln bottom cooling air, and coal gas volume 1) Increase driving air volume

[0426]

[0427] 2) Reduce the supply of combustion air

[0428]

[0429] 3) Increase the amount of cooling air at the kiln bottom

[0430]

[0431] 4) Increase gas supply

[0432] ① When the calorific value of the gas used is within (800, 1700) Kcal / m3

[0433]

[0434] ② When the calorific value of the gas used is within (1850, 2450) Kcal / m3

[0435]

[0436] in,

[0437] DriveAir represents the driving air volume at time t;

[0438] DriveAir0 represents the initial amount of driving air before adjustment;

[0439] CombustionAir represents the amount of combustion air at time t;

[0440] CombustionAir0 represents the initial amount of combustion air;

[0441] CoolingAir indicates the amount of cooling air at the kiln bottom;

[0442] CoolingAir0 represents the initial amount of cooling air at the kiln bottom;

[0443] CoalGas represents the amount of gas at time t;

[0444] CoalGas0 represents the initial amount of coal gas;

[0445] α2 = 0.27;

[0446] β2 = 0.13;

[0447] γ2=0.14;

[0448] θ 21 =0.12;

[0449] θ 22 =0.08;

[0450] (2) Increase the frequency of high temperature fans:

[0451] HiTemFanS=HigTemFanS0(1*A2);

[0452] in,

[0453] HiTemFanS represents the high temperature fan frequency at time t;

[0454] HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment;

[0455] A2=1.055;

[0456] (3) Increase the material level in the kiln:

[0457] MaterLevel=MaterLevel+B2;

[0458] in,

[0459] MaterLevel represents the material level height at time t;

[0460] MaterLevel0 represents the initial value of the material level before adjustment;

[0461] B2=0.29;

[0462] 3. If AggLev = 3, the treatment method is as follows:

[0463] The following t represents the duration from the start of treatment to the current time; T = 66 hours;

[0464] (1) Adjustment of gas volume, including adjustment of driving air, combustion air, kiln bottom cooling air, and coal gas volume 1) Increase driving air volume

[0465]

[0466] 2) Reduce the supply of combustion air

[0467]

[0468] 3) Increase the amount of cooling air at the kiln bottom

[0469]

[0470] 4) Increase gas supply

[0471] ① When the calorific value of the gas used is within (800, 1700) Kcal / m3

[0472] ② When the calorific value of the gas used is within (1850, 2450) Kcal / m3

[0473] in,

[0474] DriveAir represents the driving air volume at time t;

[0475] DriveAir0 indicates the initial amount of driving air before adjustment;

[0476] CombustionAir represents the amount of combustion air at time t;

[0477] CombustionAir0 represents the initial amount of combustion air;

[0478] CoolingAir indicates the amount of cooling air at the kiln bottom;

[0479] CoolingAir0 represents the initial amount of cooling air at the kiln bottom;

[0480] CoalGas represents the amount of gas at time t;

[0481] CoalGas0 represents the initial amount of coal gas;

[0482] α 3＝ 0.33;

[0483] β3 = 0.14;

[0484] γ3=0.18;

[0485] θ 31 =0.16;

[0486] θ 32 =0.11;

[0487] (2) Increase the frequency of high temperature fans:

[0488] HiTemFanS=HigTemFanS0(1*A3);

[0489] in,

[0490] HiTemFanS represents the high temperature fan frequency at time t;

[0491] HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment;

[0492] A3=1.063

[0493] (3) Increase the material level in the kiln:

[0494] MaterLevel=MaterLevel+B3;

[0495] in,

[0496] MaterLevel represents the material level height at time t;

[0497] MaterLevel0 represents the initial value of the material level before adjustment;

[0498] B3=0.35;

[0499] 4. If AggLev = 4, the treatment method is as follows:

[0500] The following t represents the duration from the start of treatment to the current time; T = 75 hours;

[0501] (1) Adjustment of gas volume, including adjustment of driving air, combustion air, kiln bottom cooling air, and coal gas volume 1) Increase driving air volume

[0502]

[0503] 2) Reduce the supply of combustion air

[0504]

[0505] 3) Increase the amount of cooling air at the kiln bottom

[0506]

[0507] 4) Increase gas supply

[0508] ① When the calorific value of the gas used is within (800, 1700) Kcal / m3

[0509]

[0510] ② When the calorific value of the gas used is within (1850, 2450) Kcal / m3

[0511]

[0512] in,

[0513] DDriveAir represents the driving air volume at time t

[0514] DriveAir0 indicates the initial amount of driving air before adjustment

[0515] CombustionAir represents the amount of combustion air at time t

[0516] CombustionAir0 represents the initial amount of combustion air

[0517] CoolingAir indicates the amount of cooling air at the bottom of the kiln

[0518] CoolingAir0 indicates the initial amount of cooling air at the kiln bottom

[0519] CoalGas represents the amount of gas at time t

[0520] CoalGas0 indicates the initial amount of coal gas

[0521] α4 = 0.37;

[0522] β4 = 0.16;

[0523] γ4=0.19;

[0524] θ 41 =0.20;

[0525] θ 42=0.15;

[0526] (2) Increase the frequency of high temperature fans:

[0527] HiTemFanS=HigTemFanS0(1*A4)

[0528] in,

[0529] HiTemFanS represents the high temperature fan frequency at time t

[0530] HiTemFanS0 indicates the initial value of the high temperature fan frequency before adjustment

[0531] A4=1.075

[0532] (3) Increase the material level in the kiln:

[0533] MaterLevel=MaterLevel+B4;

[0534] in,

[0535] MaterLevel represents the material level height at time t

[0536] MaterLevel0 indicates the initial value of the material level before adjustment

[0537] B4=0.49.

[0538] It should be noted that the above embodiments are not intended to limit the protection scope of the present invention, and equivalent changes or substitutions made on the basis of the above technical solutions all fall within the protection scope of the claims of the present invention.

Claims

1. A production process control method in a lime kiln under a material-bound state of an upper guide cap, characterized in that: The method comprises the following steps: Step 1: Make online judgment on abnormal material formation; Step 2: Take online measures to deal with abnormal material formation; The online judgment of abnormal material formation is to judge the abnormal material formation level AggLev according to the change of the exhaust gas in the kiln of the air heat exchanger ΔGas and the change of the kiln top temperature ΔTTop; The online treatment of abnormal material accumulation is to take measures and handle it online according to the abnormal material accumulation level AggLev.

2. The production process control method in the lime kiln under the material binding state of the upper guide cap according to claim 1 is characterized in that: The online judgment of abnormal material formation includes the following judgment methods: 1) When the amount of waste gas in the kiln passing through the air heat exchanger is reduced to (ΔGas1, ΔGas2), and the kiln top temperature is high at (ΔTTop1, ΔTTop2); AggLev = 1; 2) When the amount of exhaust gas in the kiln passing through the air heat exchanger is reduced to (ΔGas2, ΔGas3), and the kiln top temperature is high at (ΔTTop2, ΔTTop3); AggLev = 2; 3) When the amount of waste gas in the kiln passing through the air heat exchanger is reduced to (ΔGas3, ΔGas4), and the kiln top temperature is high at (ΔTTop3, ΔTTop4); AggLev = 3; 4) When the amount of waste gas in the kiln passing through the air heat exchanger is reduced by more than ΔGas4, and the kiln top temperature is higher than ΔTTop4; AggLev = 4; Among them, ΔGas1, ΔGas2, ΔGas3, ΔGas4, ΔTTop1, ΔTTop2, ΔTTop3, ΔTTop4 are fixed values. The value range of ΔGas1 is within (8%, 12%); The value range of ΔGas2 is (18%, 22%); The value range of ΔGas3 is (28%, 32%); The value range of ΔGas4 is (44%, 46%); The value range of ΔTTop1 is within (8℃, 12℃); The value range of ΔTTop2 is within (18℃, 22℃); The value range of ΔTTop3 is within (28℃, 32℃); The value range of ΔTTop4 is (44℃, 46℃).

3. The production process control method in the lime kiln under the material binding state of the upper guide cap according to claim 2 is characterized in that: The online treatment of abnormal material accumulation includes the following treatment methods: For AggLev=1, the treatment method is as follows: The following t represents the duration from the start of treatment to the current moment; T represents the time required for adjustment when AggLev=1, ranging from (30h, 50h); (1) Adjustment of gas volume, including adjustment of driving air, combustion air, kiln bottom cooling air, and coal gas volume. 1) Increase the driving air volume. 2) Reduce the supply of combustion air, 3) Increase the amount of cooling air at the kiln bottom, 4) Increase gas supply, ① When the calorific value of the gas used is within (800, 1700) Kcal / m3 ② When the calorific value of the gas used is within (1850, 2450) Kcal / m3 in, DriveAir represents the driving air volume at time t; DriveAir0 represents the initial amount of driving air before adjustment; CombustionAir represents the amount of combustion air at time t; CombustionAir0 represents the initial amount of combustion air; CoolingAir indicates the amount of cooling air at the kiln bottom; CoolingAir0 represents the initial amount of cooling air at the kiln bottom; CoalGas represents the amount of gas at time t; CoalGas0 represents the initial amount of coal gas; α1 constant, the value range is (0.18, 0.25); β1 constant, the value range is (0.10, 0.11); γ1 constant, the value range is (0.11, 0.13); θ 11 ,θ 12 Constant, the value range is (0.07, 0.10), (0.04, 0.06); (2) Increase the frequency of high temperature fans: HiTemFanS=HigTemFanS0(1*A1); in, HiTemFanS represents the high temperature fan frequency at time t; HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment; A1 constant, the value range is (1.037, 1.049); (3) Increase the material level in the kiln: MaterLevel=MaterLevel+B1; in, MaterLevel represents the material level height at time t; MaterLevel indicates the initial value of the material level before adjustment; B1 constant, the value range is (0.25,0.28).

4. The production process control method in the lime kiln under the material binding state of the upper guide cap according to claim 2 is characterized in that: For AggLev=2, the treatment method is as follows: The following t represents the duration from the start of treatment to the current moment; T represents the time required for adjustment when AggLev=2, ranging from (50h, 60h); (1) Gas volume regulation, including driving air, combustion air, kiln bottom cooling air, and coal gas volume regulation 1) Increase the driving air volume, 2) Reduce the supply of combustion air, 3) Increase the amount of cooling air at the kiln bottom, 4) Increase gas supply, ① When the calorific value of the gas used is within (800, 1700) Kcal / m3 ② When the calorific value of the gas used is within (1850, 2450) Kcal / m3 in, DriveAir represents the driving air volume at time t; DriveAir0 represents the initial amount of driving air before adjustment; CombustionAir represents the amount of combustion air at time t; CombustionAir0 represents the initial amount of combustion air; CoolingAir indicates the amount of cooling air at the kiln bottom; CoolingAir0 represents the initial amount of cooling air at the kiln bottom; CoalGas represents the amount of gas at time t; CoalGas0 represents the initial amount of coal gas; α2 constant, the value range is (0.26, 0.31); β2 constant, the value range is (0.12, 0.13); γ2 constant, the value range is (0.14, 0.16); θ 21 ,θ 22 Constant, the value range is (0.11, 0.14), (0.07, 0.09); (2) Increase the frequency of high temperature fans: HiTemFanS=HigTemFanS0(1*A2); in, HiTemFanS represents the high temperature fan frequency at time t; HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment; A2 constant, the value range is (1.050,1.058); (3) Increase the material level in the kiln: MaterLevel=MaterLevel+B2; in, MaterLevel represents the material level height at time t; MaterLevel0 represents the initial value of the material level before adjustment; B2 constant, the value range is (0.29,0.31).

5. The production process control method in the lime kiln under the material binding state of the upper guide cap according to claim 2 is characterized in that: For AggLev=3, the treatment method is as follows: The following t represents the duration from the start of treatment to the current moment; T represents the time required for adjustment when AggLev=3, ranging from (60h, 70h); (1) Regulation of gas quantity, including regulation of driving air, combustion-supporting air, kiln bottom cooling air, and coal gas quantity; 1) Increase the driving air volume, 2) Reduce the supply of combustion air, 3) Increase the amount of cooling air at the kiln bottom, 4) Increase gas supply, ① When the calorific value of the gas used is within (800, 1700) Kcal / m3 ② When the calorific value of the gas used is within (1850, 2450) Kcal / m3 in, DriveAir represents the driving air volume at time t; DriveAir0 represents the initial amount of driving air before adjustment; CombustionAir represents the amount of combustion air at time t; CombustionAir0 represents the initial amount of combustion air; CoolingAir indicates the amount of cooling air at the kiln bottom; CoolingAir0 indicates the initial amount of cooling air at the kiln bottom CoalGas represents the amount of gas at time t; CoalGas0 represents the initial amount of coal gas; α3 constant, the value range is (0.32, 0.35); β3 constant, the value range is (0.13, 0.14); γ3 constant, the value range is (0.17, 0.18); θ 31 ,θ 32 Constant, the value range is (0.15, 0.18), (0.10, 0.13); (2) Increase the frequency of high temperature fan: HiTemFanS=HigTemFanS0(1*A3); in, HiTemFanS represents the high temperature fan frequency at time t; HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment; A3 constant, the value range is (1.059, 1.067); (3) Increase the material level in the kiln: MaterLevel=MaterLevel+B3; in, MaterLevel represents the material level height at time t; MaterLevel0 represents the initial value of the material level before adjustment; B3 constant, the value range is (0.32,0.39).

6. The production process control method in the lime kiln under the condition of material accumulation on the upper guide cap according to claim 2, characterized in that: For AggLev=4, the treatment method is as follows: The following t represents the duration from the start of treatment to the current moment; T represents the time required for adjustment when AggLev=4, ranging from (70h, 80h); (1) Gas volume regulation, including driving air, combustion air, kiln bottom cooling air, and coal gas volume regulation 1) Increase the driving air volume, 2) Reduce the supply of combustion air, 3) Increase the amount of cooling air at the kiln bottom, 4) Increase gas supply, ① When the calorific value of the gas used is within (800, 1700) Kcal / m3, ② When the calorific value of the gas used is within (1850, 2450) Kcal / m3, in, DDriveAir represents the driven air volume at time t; DriveAir0 represents the initial amount of driving air before adjustment; CombustionAir represents the amount of combustion air at time t; CombustionAir0 represents the initial amount of combustion air; CoolingAir indicates the amount of cooling air at the kiln bottom; CoolingAir0 represents the initial amount of cooling air at the kiln bottom; CoalGas represents the amount of gas at time t; CoalGas0 represents the initial amount of coal gas; α4 constant, the value range is (0.36, 0.39); β4 constant, the value range is (0.15, 0.16); γ4 constant, the value range is (0.19, 0.20); Θ 41 ,θ 42 Constant, the value range is (0.19, 0.21), (0.14, 0.17); (2) Increase the frequency of high temperature fan: HiTemFanS=HigTemFanS0(1*A4); in, HiTemFanS represents the high temperature fan frequency at time t; HiTemFanS0 represents the initial value of the high temperature fan frequency before adjustment; A4 constant, the value range is (1.068, 1.079); (3) Increase the material level in the kiln: MaterLevel=MaterLevel+B4; in, MaterLevel represents the material level height at time t; MaterLevel0 represents the initial value of the material level before adjustment; B4 constant, the value range is (0.41,0.52).

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