Clinker Burning System

HOFUF CEMENT PLANT 5th & 6th EXTENSION PROJECT Burning System
烧成系统
Burning System
1. 概述 General
烧成系统包括生料均化库的生料出库系统和生料入窑（337/338 子项）、烧成窑尾（417/418 子
项）、烧成窑中（437/438 子项）、烧成窑头（447/448 子项）、熟料库及熟料输送的进库系统（457/458
子项）、旁路放风及回灰输送（427/428）共 6 个子项。
本系统的核心部分：烧成窑尾、烧成窑中、烧成窑头的主机分别由 SINOMA 提供了在线旋喷

式分解炉和双系列六级预热器组合成的窑外分解系统；SINOMA 提供了 Φ6.2×92m 回转窑；IKN 提
供了中部带辊式破碎机的推动篦式冷却机；PILLARD 提供了窑和分解炉燃烧器系统等，另外配置有
旁路放风系统。
本操作规程是根据本系统特点和要求，为保证系统正常运行和生产而提出的主要操作事项。操
作人员须在全面掌握规程中各项操作要领的同时，还必须通晓系统中每台设备的性能和操作维护等
方法与要求，以便在实际生产操作中能及时解决随时可能出现的各种问题，并可根据实际情况灵活
调整，系统中每台设备性能和操作维护的详细方法与要求，请参阅各相应设备供货厂商另行提供的
单机使用说明书。当其内容与本操作手册有矛盾时，以设备供货厂商提供的单机使用说明书为准。
本操作手册仅限于 HOFUF CEMENT PLANT 5TH/6TH EXTENSION PROJECT 2×10000t/d

熟料水泥生产线的烧成系统生产操作使用。
The burning system includes the raw meal delivery system of a raw meal homogenizing storage
and a total of six subitems, such as raw meal into kiln (Subitem 337/338), calcinating kiln inlet
(Subitem 417/418), calcinating kiln middle (Subitem 437/438), calcinating kiln outlet (Subitem
447/448), clinker storage and storage entry system for clinker conveyance (Subitem 457/458), and
bypass and returned ash conveyance (Subitem 427/428).
For the core part of this system, the main machines for the calcinating kiln inlet, calcinating kiln
middle and calcinating kiln outlet, SINOMA has provided the on-line rotary spray precalciner and
the outside-the-kiln decomposition system combined by Two-string six-stage preheaters ,
SINOMA has provided the Φ 6.2 × 92 m rotary kiln, IKN has provided the pendulum grate cooler
for the middle roll crusher, and PILLARD has provided the kilns the precalciner burner system, etc.
Besides, a bypass system has been arranged.
This operating procedure has some main items put forward according to this system’s
characteristics and requirements, and for ensuring its normal running and production. An operator
shall thoroughly understand the performance, operation, maintenance and so on of each piece of
equipment in the system at the time of grasping various operating essentials in the procedure so
as to in time solve various problems that may appear at any time in actual production and
operation, and according to an actual circumstance, shall make flexible adjustment. For the
detailed methods and requirements for the performance, operation and maintenance of each
piece of equipment in the system, please refer to a single machine instruction book provided by a
corresponding equipment supplier. If the contents of the book with those of the single machine
instruction book provided by equipment supplier conflict, those of the single machine instruction
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book provided by equipment supplier will be finalized.
This operating manual is used only for the production and operation of the burning system of the
clinker cement production line in the Hofuf Cement Plant 5th/6th Extension Project 2 ×10,000 t/d.
2．生产工艺流程简述 Brief Description of Production Process Flow
烧成系统的范围从生料由均化库充气卸料开始，经预分解系统预热、预分解后入回转窑煅烧成
水泥熟料，经过推动篦式冷却机的冷却和破碎后，由链斗输送机送至熟料库顶为止。
本系统可分为生料入窑、生料预热与分解（烧成窑尾）、窑头热风引至分解炉（三次风管）与
熟料煅烧（烧成窑中）、熟料冷却与废气处理和窑头燃烧系统（烧成窑头）、熟料输送、旁路放风及
回灰输送六大部分。
烧成系统的范围从生料由均化库充气卸料开始，经预分解系统预热、预分解后入回转窑煅烧成
水泥熟料，经过推动篦式冷却机的冷却和破碎后，由链斗输送机送至熟料库顶为止。
本系统可分为生料入窑、生料预热与分解（烧成窑尾）、窑头热风引至分解炉（三次风管）与
熟料煅烧（烧成窑中）、熟料冷却与废气处理和窑头燃烧系统（烧成窑头）、熟料输送、旁路放风及
回灰输送六大部分。
The range of the burning system starts from raw meal gas filling and unloading in the
homogenizing storage, preheating in the predecomposition system, the calcination into cement
clinker in the rotary kiln after precalcining system, the cooling and crushing of the pendulum grate
cooler, and ends at the sending to the top of the clinker storage by the chain bucket conveyor.
This system may be divided into the six parts, including raw meal into kiln, raw meal preheating
and precalcining (calcinating kiln inlet), kiln outlet hot wind introduction into the precalciner (tertiary
air duct) and clinker calcination (calcinating kiln middle), clinker cooling, waste gas treatment and
kiln outlet combustion system (calcinating kiln outlet), clinker conveyance, bypass, and returned
ash conveyance.
The range of the burning system starts from raw meal gas filling and unloading in the
homogenizing storage, preheating，precalcining in the system, the calcination into cement clinker
in the rotary kiln system, the cooling and crushing of the pendulum grate cooler, and ends at the
sending to the top of the clinker storage by the chain bucket conveyor.
This system may be divided into the six parts of raw meal kiln entry, raw meal preheating and
precalcining (calcinating kiln inlet), the hot air out of kiln outlet introduced into the precalciner
(tertiary air duct) and clinker calcination (calcinating kiln middle), clinker cooling, waste gas
treatment and kiln outlet combustion system (calcinating kiln outlet), clinker conveyance, bypass,
and returned ash conveyance.
2.1 生料入窑 Feeding Raw Meals into the Kiln
生料均化设置了一座Φ28m、储量为 40000t的连续式生料均化库（337SB1/338SB1），生料经
过库底外环区轮流分区充气均化，进入中心混合仓，在混合仓被充气搅拌均匀后，由流量控制阀
（337DV1,DV2/338DV1,DV2）卸出，DV1 与DV2 互为备用，卸料能力：1000t/h，卸出的料经空气
输送斜槽（ 337AS2/338AS2 ）和胶带斗式提升机（ 337BE4/338BE4 ）再经空气输送斜槽
（337AS3/338AS3）入生料计量仓（337BI1/338BI1），生料计量仓的容量：250m3。通过计量仓的
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称重传感器（337LI1/338LI1）控制库底流量阀（337DV1，DV2，/338DV1，DV2）开度，保证计
量仓内有相对的固定料位。计量仓内的生料经过仓底流量控制阀（337DV3，DV4，DV5/338DV3，
DV4，DV5）、固体流量计（337FM1，FM2，FM3/338FM1，FM2，FM3）后，再由空气输送斜槽
（337AY1，AY2，AS4，AS5，AS6/338AY1，AY2，AS4，AS5，AS6）、胶带斗式提升机（337BE5，
BE6，BE7/338BE5，BE6，BE7）、预热器顶部斜槽（337AS7，AS8/338AS7，AS8）输送，经回
转锁风阀（337RF7，RF8/338RF7，RF8）、气动闸板阀（337SGL，SGM/337SGL，SGM）分别
喂入窑尾双系列预热器（417PH1/418PH1）。计量仓底流量控制阀至喂料提升机为两用一备。其中
仓底流量控制阀（ 337DV3/338DV3 ）、固体流量计（ 337FM1/338FM1 ）、空气输送斜槽
（337AS4/338AS4）、喂料提升机（337BE6/338BE6）为备用系统。另外提升机出口设有多个电动
开关阀，用于控制生料是入窑还是返回均化库。
固体流量计的流量信号控制仓底流量控制阀的开度，以保证生料以设定的流量稳定地喂入窑尾
系统。计量仓底设置备用出口的目的是当主出口有故障时，生料经由备用出口喂入。
A Φ28m continuous raw meal homogenizing storage (337 SB1/338 SB1) with a storage capacity
of 40,000t has been built. An raw meal passes the storage bottom outer ring area for alternation
zoning gas filling and equalization, enters the central blending bin, and after the gas filling and
uniform agitation in the bin, is unloaded from the flow control valves(337 DV1, DV2/338 DV1, DV2).
DV1 and DV2 is on stand by for each other. The unloading capacity is 1,000t/h. The unloaded
material enters the raw meal measuring bin (337 BI1/338 BI1) through the air slide (337 AS2/338
AS2) and the belt bucket elevators (337 BE4/338 BE4) and through the the air slide (337
AS3/338 AS3). The capacity of the measuring bin is 250m3 .The weighing sensors(337 LI1/338
LI1) in the measuring bin control the spans of the storage bottom flow valves(337 DV1, DV2, /338
DV1, DV2) to ensure that the measuring bin has a relatively fixed material level. An raw meal in
the measuring bin passes the bottom flow control valves(337 DV3, DV4, DV5/338 DV3, DV4,
DV5),the solid flow rate gages(337 FM1, FM2, FM3/338 FM1, FM2, FM3), then is transported
through the the air slide (337 AY1, AY2, AS4, AS5, AS6/338 AY1, AY2, AS4, AS5, AS6),belt
bucket elevators (337BE5，BE6，BE7/338BE5，BE6，BE7) and the preheater top chute(337 AS7,
AS8/338 AS7, AS8), and finally is fed into the kiln inlet double series preheaters(417 PH1s/418
PH1s) through the rotary air-lock valve (337RF7，RF8/338RF7，RF8) and the pneumatic paddle
valves (337 SGL, SGM/337 SGL, SGM) respectively. For the flow control valve of on the
measuring bin bottom and the feeding elevators, two of them are in use and one is on stand by.
Among them, the flow control valves on the measuring bin bottom (337 DV3/338 DV3), solid flow
rate gages (337 FM1/338 FM1), the air slide (337 AS4/338 AS4) and the feeding elevator s(337
BE6/338 BE6) are standby systems. In addition, an elevator outlet is equipped with many
dynamoelectric switch valves, used for determining whether a raw meal is to go into a kiln or return
to the homogenizing storage.
A flow signal of a solid flow gage controls the span of a storage bottom flow control valve to ensure
that an raw meal is stably fed into the kiln inlet system at a preset flow rate. The aim of a standby
outlet built on the measuring bin bottom is that when the main outlet has a fault, an raw meal will
be fed in via a standby outlet.
2.2 生料预热与分解（烧成窑尾）Preheating and precalcining of Raw Meals (Calcinating Kiln

Inlet)
窑尾系统采用双系列六级预热器，由旋风筒及连接管道、料管以及在线旋喷式分解炉等构成。
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顶部旋风筒为一级即C1，底部旋风筒为六级即C6，旋风筒的规格：4-C1：Φ6200mm，2-C2，C3：
Φ8400mm，2-C4：Φ8800mm，2-C5，C6：Φ9000mm。生料粉经计量由提升机等输送设备送入
C2旋风筒气体出口管道内，在气流作用下立即分散、悬浮在气流中，并随气流进入C1旋风筒。气料
分离后，料粉通过重锤翻板阀进入C3旋风筒气体出口管道，并随气流进入C2旋风筒。这样经过五级
热交换后，生料粉得到了充分预热，经C5旋风筒气料分离后通过重锤翻板阀喂入分解炉，物料在分
解炉内吸热分解后，随气流进入C6旋风筒，分离后喂入窑内，此时物料的分解率可达到95%左右。
而废气沿着逐级旋风筒及气体出口管道上升，最后由一级旋风筒出风管排出，经高温风机337IF1，
IF2/338IF1，IF2）送往原料粉磨和窑尾废气处理系统。
为防止气流沿下料管返窜而影响分离效率，在各级旋风筒下料管上均设有带重锤平衡的翻板阀。
正常生产中应检查各翻板阀动作是否灵活，必要时应调整重锤位置，控制翻板动作幅度小而频繁，
以保证物料流动顺畅、料流连续均匀，避免大幅度地脉冲下料。为了防止旋风筒锥部和下料管结皮、
堵塞，在C6~C3旋风筒的锥部和C6~C4旋风筒下料管的拐点处设有空气炮（417BQ1~K/418BQ1~K）
清堵系统。
The kiln inlet system uses double-serial six- stage preheaters and consists of cyclones,
connecting pipes, feeding pipes, an on-line rotary spray precalciner, etc. A top cyclone is Class 1,
namely C1, and a bottom cyclone is Class 6, namely C6. The specifications of a: 4-C1: Φ 6200
mm, 2-C2, C3: Φ 8400 mm, 2-C4: Φ 8800 mm, 2-C5, C6:Φ 9000 mm. After measurement, raw
meal powder is sent into a C2 cyclone gas outlet pipe from such conveyance equipment as an
elevator, etc. is immediately dispersed and suspended in an air flow by the agency of the air flow,
and with the air flow, enters a C1 cyclone. The material powder passes a heavy bob flap valve to
enter a C3 cyclone gas outlet pipe after the separation material out off gas, and with an air flow,
enters a C2 cyclone. Thus after five-level heat exchange, raw meal powder receives full
preheating, and after the separation of a C5 cyclone gasified material and through a heavy bob
flap valve, is fed into the precalciner. After a material absorbs heat and is decomposed in the
precalciner, it will enter a C6 cyclone, and after separation, it will be fed into a kiln. At this time, the
decomposition rate of the material can attain to 95% or so. And the waste gas will rise along
various cyclones and gas outlet pipes, and finally is discharged by one air duct and sent by high
temperature induce draft fan (337 IF1s, IF2/338 IF1s, IF2) to a raw material powder mill and a kiln
inlet waste gas treating system.
In order to prevent an air flow from returning along a discharging pipe so as to influence the
separation efficiency, a discharging pipe in each cyclone is equipped with a flap valve with heavy
bob balance. In normal production, check whether the movement of each flap valve motion is vivid
or not. When it's necessary, adjust the position of a heavy bob and make sure that the movement
range of a flap valve is small and frequent so as to ensure a material flow is smooth, continuous
and even and to avoid significant pulse discharge. In order to prevent the conic section of a
cyclone and a discharging pipe from surface crusting and blockage, the inflection points at the
conic sections of the C6~ C3 cyclones and C6~ C4 cyclone discharging pipes are equipped with
air cannon(417 BQ1~ K/418 BQ1~K) blockage-clearing system.
分解炉（Φ8.8×37m）采用了在线旋喷形式。分解炉燃烧所需的三次风分别从锥部两侧割向对
旋进入，形成旋转上升气流，窑尾烟室的烟气从分解炉底部进入，被包裹在中间，使氧浓度形成了
外圈高，中心低的分布。分解炉柱体下部设有4个燃烧器（417BU1~4/418BU1~4）间隔互为90°，4
个燃烧器的喷出气流又构成了旋转流场，环形的富氧浓度区为4个燃烧器形成的环形火焰区提供了良
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好的燃烧条件。物料在分解炉柱体下部由两侧喂入，由于喂料落差造成的下降惯性，物料在入炉的
瞬间打击在撒料板上被分散，炉底部的旋转上升气流强化了分散效果，并携料在上升气流中快速分
解。
The precalciner(Φ 8.8×37 m) uses the on-line rotary spray form. The tertiary air needed by the
combustion in the precalciner enters the two sides of the conic section in a disrotatory way,
forming a spiraling-up air current. The fumes from the kiln inlet smoke chamber go in from the bed
of the precalciner and are wrapped up in the middle, making the oxygen concentration form a
distribution of being high on the outer ring and low at the center. The lower part of a precalciner
column is equipped with 4 burners (417 BU 1~4/418 BU 1~4) at intervals of 90 °with each other.
The ejected air current from the 4 burners forms a rotary flow field. The annular rich oxygen
concentration zone provides a good combustion condition for the annular flame zone that the 4
burners form. A material is fed in from the two sides of the lower part of the precalciner columns.
Because of the descending inertia resulted in by a feeding falling head, the moment the material
goes into the furnace, it is struck onto the distribution board and dispersed. The spiraling-up air
current from the furnace bottom enhances the dispersion effects, and together with a rising air flow,
is quickly decomposed in an ascending air current.
为分解炉配置的4个燃烧器由Pillard供货，可燃烧原油和天然气。燃烧器的总能力：260GJ/h，
每个燃烧器的燃油量（5200kg/h，normal；5900kg/h，max）或燃气量（6900Nm3/h，normal；
7900Nm3/h，max）。4个燃烧器燃油或燃气时，分别由4个燃油（417VT2~5/418VT2~5）或燃气
（ 417VT7~a/418VT7~a ）的小阀组控制，而 4 个燃油或燃气的小阀组又分属于燃油
（417VT1/418VT1）或燃气（417VT6/418VT6）的大阀组控制。原油由专供分解炉的双联高压泵
（L37FP1/ L38FP1）送至燃油的大阀组。一般情况下，燃料量的调节是在中控室通过调节大阀组上
的流量阀实现，小阀组上的阀需要现场调节，通常调试好后基本保持不变，通过阀组的显示仪表判
断各燃烧器的工作状态。燃烧器的燃烧空气的4~6%由燃烧器风机（417FN1/418FN1）提供，风机
的性能参数为：风量：473.3m3/min，风压：12000Pa，功率：160kW。该风机除提供燃烧器的燃
烧空气外，在系统正常或故障停机时，用于燃烧器的冷却。
The 4 burners arranged for the precalciner was supplied by Pillard, and they can burn crude oil
and natural gas. The total capacity of the burners: 260 GJ/h, the burnt oil capacity of each
burner(5200 kg/h, normal;5900 kg/h, max)or the burnt gas capacity (6900 Nm3/h, normal;7900
Nm3/h, max). While the 4 burners are burning oil or gas, they are respectively controlled by 4
small valve train for burning oil( 417 VT 2~5/418 VT 2~5) or 4 for burning
gas(（417VT7~a/418VT7~a）.The 4 small valve train for burning oil or gas are controlled by the big
valve train for burning oil(417 VT1/418 VT1) or for burning gas(417 VT6/418 VT6). The crude oil is
sent by the duplex high pressure pumps （L37FP1/ L38FP1）special for the precalciner to the big
valve train used for burning oil. Under a general circumstance, the adjustment of a fuel quantity is
carried out by adjusting a flow rate valve of a big valve train in the central control room, while a
valve of a small valve train needs to be adjusted on the spot. Usually, the debugging is kept
fundamentally constant. From an indicating instrument of a valve train, you can judge the
operating state of each burner. 4~6% of the burnable air of the burners is provided by the burner
fan (417 FN1/418 FN1). The performance parameters of the fan are: air volume: 473.3 m3/min, air
pressure:12,000 Pa, power:160 kW. In addition to providing burnable air for the burners, the fan is
used for the cooling of a burner after the system’s normal or disorderly closedown.
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预分解系统中的每级旋风筒的出口风管上均设有温度、压力测点，旋风筒锥部设有压力测点，
料管设有温度测点。分解炉中部和出口设有温度、压力测点。窑尾烟室、分解炉出口、C1 出口风管
均设有在线气体分析仪，C6 下料管上设有在线热料取样和送样系统，可随时可监视系统的预热、煅
烧、分解和运行状况。
正常情况下，系统的总阻力损失为 5800~6500Pa，出一级筒飞灰量约 70g/Nm3，废气温度为

280～310℃。炉出口温度可控制在 860～880℃之间，入窑物料表观分解率可达 90%以上。
由于该项目的原料中，氯含量超标，在窑尾上升烟道上设有旁路放风的抽风口，该部分见后面的专
题介绍。
The outlet air duct of each cyclone in the precalcining system is furnished with temperature and
pressure measuring points, the conic section of a cyclone has pressure measuring points and a
discharging pipe has temperature measuring points. A kiln inlet smoke chamber, a precalciner
outlet or a C1 outlet air duct is equipped with an on-line gas analysis instrument, and a C6
discharging pipe is furnished with an on-line hot material sample-taking and sample-sending
systems, which can at any time monitor the preheating, calcination, decomposition and operation
in a system.
Under a normal circumstance, the total resistance loss of the system is 5800~6500Pa, the outlet
air duct of C1 dust content is about 70 g/ Nm3, and the exhaust temperature is 280-310 ℃.The furnace
outlet temperature can be controlled at 860-880 ℃, and the apparent decomposition rate for a kiln-entering
material can reach 90% or above.
As in the raw material for this project, the chlorine content has exceeded the standard, bypass air
vents have been built on a kiln inlet ascending smoke flue. For the contents of this part, see the
special-subject introduction at the back.
尽管该项目设有旁路放风系统，本系统在生产过程中仍必须充分重视可能发生的结皮堵塞现
象，并在生产操作中严加防范。一般在系统易结皮或堵塞的部位均设有清灰孔或捅料孔，可根据实
际生产具体情况定期清理结皮或处理积料；经长期生产经验证实某些不必要的孔洞也可封死，以减
少系统漏风。另外，在系统中还预留了一些空气炮的安装孔，可根据实际生产中结皮、堵塞的具体
情况，调整空气炮的安装位置。
Though the project is equipped with a bypass system, it is necessary to fully value the surface
crusting and blockage phenomena that may occur in the procedure in production and sternly
guard against them in production and operation. Generally, a part of the system with easy surface
crusting or blockage has ash-clearing holes or material-poking holes, which, according to a
concrete production circumstance, can periodically help clear off the surface crusting or treat
accumulated materials. It is verified from long-time production experience that some otiose holes
may also be sealed dead to reduce air leaks in the system. Besides, the system has also reserved
some installation holes for air cannons. You can adjust the installation position of an air cannon
according to a concrete circumstance of surface crusting or blockage in actual production.
2.3 窑头热风引至分解炉与熟料煅烧（烧成窑中） Leading hot air at the kiln outlet into the
Precalciner and clinker calcinating (Middle of the Calcinating Kiln)
两根外径为 Φ3000mm 的三次风管（437TD1，TD2/438TD1，TD2），一端与篦冷机的前端两侧

取风口连接，另一端与分解炉连接。其作用是把篦冷机回收的高温气体引入分解炉。三次风管上设
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有电动闸板阀（437TV1，TV2/438TV1，TV2），通过调节窑尾的 ID 风机的转速和电动闸板阀的开
度来控制三次风的用量。
For one of the two tertiary air ducts (437 TD1, TD2/438 TD1, TD2)with an outside diameter of Φ
3000 mm, one end is connected with the tuyeres of the front-end two sides of a grate cooler, and
the other end, with the precalciner. Its function is to guide the high temperature gas recovered by
the cooler lead into the precalciner. A tertiary air duct has electric dampers (437 TV1, TV2/438
TV1, TV2), which control the amount of tertiary air by adjusting the revolving speed of kiln inlet ID
wind machine and the span of an electric dampers.
三次风管的电动闸板阀上还配有冷却风机（437FNM，FNN/438FNM，FNN），用于冷却闸板，
以延长闸板的使用寿命。
A tertiary air duct’s electric dampers are also equipped with cooling fan (437 FNM, FNN/438 FNM,
FNN), used for cooling the paddle to lengthen its useful life.
经C6旋风筒分离出的分解后的热料粉顺着下料斜坡喂入回转窑（437KL1/438KL1）的进料端，
并借助回转窑的旋转慢慢地向窑头运动。在运动过程中，继续与窑内的热烟气换热，实现窑内的系
列化学反应，最终在烧成带用窑头燃烧器提供的燃烧热将其烧结成水泥熟料。
The decomposed hot material powder separated from a C6 cyclone follows a discharging slope to
be fed into the rotary kilns(437 KL1/438 KL1), and relying on the rotation of a rotary kiln, slowly
move toward the kiln outlet. During the period of the movement, the powder is going on with
exchanging heat with the hot fumes inside the kiln, realizing the serial chemical reactions in the
kiln, and finally, at a burning zone, the combustion heat provided by the kiln outlet burners makes
the powder sintered into cement clinker.
Φ6.2×92m 的回转窑，斜度为 4%，三档支撑，窑尾配有汽缸压紧式密封装置，并配有两台空压

机（437CP1，CP2/438CP1，CP2），一用一备；还配有多点式干油泵（437LQ1/438LQ1），用于
密封装置的润滑。窑头配有钢片式密封装置，并配有冷却风机（437FN1/438FN1）。该窑配置有双
传动，主电机（437MM1，MM2/438MM1，MM2）功率 1050kW，变频调速，调速范围：0.4~3.98~5r/min。
除主电机外，还设有辅助传动电机（437AM1，AM2/438AM1，AM2）和柴油发电机（437DE1，
DE2/438DE1，DE2），供特殊情况下使用。该窑还配置有双液压挡轮系统，分别设在窑的第三档和
第二档。液压挡轮共用一套挡轮油泵站（ 437HD1/438HD1 ）。正常情况下使用窑尾挡
（437KT1/438KT1），该档故障时可用窑中挡（437KT2/438KT2）替代。液压挡轮系统用于限制调
节筒体上、下窜动。各托轮、轴瓦为油润滑和水冷却，并设有温度监测。小齿轮设有喷雾润滑系统
（437LQ4/438LQ4）以满足窑的传动齿面的润滑。窑的筒体配置有筒体扫描温度监测系统，可随时
监测烧成过程中烧成带及前后的筒体表面的温度变化情况。在烧成带及后部设有 16 台筒体冷却风机
（437FN6~L/438FN6~L），以用于筒体表面的冷却，该系列风机设有轨道可根据需要调整其位置。
一、二号轮带两侧设有 4 台冷却风（437FN2~5/437FN2~5）机用于冷却轮带的垫板和间隙。
For the Φ6.2×92m rotary kiln, the gradient is 4%, with three supports, the kiln inlet has a cylinder
compression type sealing apparatus and two air compressors(437 CP1, CP2/438 CP1, CP2), one
in use and one on standby, multipoint grease pumps (437 LQ1/438 LQ1) are also provided, used
for the lubrication of a sealing apparatus. The kiln outlet has steel sheets sealing apparatuses and
cooling fans (437 FN1/438 FN1).The kiln is equipped with twin drive. For the main motors (437
MM1, MM2/438 MM1, MM2), power: 1050 kW, with frequency control. Speed adjustable range:
0.4~3.98~5 r/min. In addition to the main motors, there are also auxiliary motors (437 AM1,
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AM2/438 AM1, AM2) and diesel generators (437 DE1, DE2/438 DE1, DE2), to be used under a
special circumstance. The kiln is also equipped with double hydraulic thrust roller systems,
respectively established in the third and second supports of the kiln. The hydraulic thrust rollers
share a set of thrust roller oil pump stations (437 HD1/438 HD1). Under a normal circumstance,
the kiln inlet shelves (437 KT1/438 KT1) are used. If the shelves malfunction, the kiln middle
shelves (437 KT2/438 KT2) may be used instead. The hydraulic thrust roller system is used for
restricting and adjusting the upward or downward movement of the kiln. Each supporting roller or
axle bush is lubricated by oil and cooled by water, with temperature monitoring. A pinion has fog
lubrication systems(437 LQ4/438 LQ4) to satisfy the lubrication of a drive flank. The body of a kiln
is equipped with a kiln body surface scanning temperature monitoring system, which can at any
time monitor the temperature change of the firing zone and its front and rear cylinder surfaces in
the process of calcination. The burning zone and its back have 16 cylinder body cooling axial fan
(437 FN 6~ L/438FN 6~ L), used for cooling a cylinder body surface. The serial axial fan have
tracks, whose positions can be adjusted according to demands. The two sides of No. 1 or No.2
tyre have 4 cooling fans ( 437 FN 2~5/437 FN 2~5), used for cooling the liner plate and clearance
of a tyre.
2.4 熟料冷却与废气处理和窑头燃烧系统（烧成窑头）Clinker cooling, exhaust treatment and

kiln outlet calcining system(Calcinating kiln outlet)
窑内煅烧所需的燃料主要是原油和天然气。原油由专供窑头的双联高压泵（L37FP2/ L38FP2）
送至窑头原油控制阀组（447VT1/448VT1），通过调节阀组上的流量阀来调节燃烧器的喷油量，再
结合对燃烧器一次风的调节，使窑内火焰满足窑内熟料的烧成要求。燃气时由天燃气阀组
（447VT2/448VT2）控制。窑头燃烧器（447BU1/448BU1）与分解炉燃烧器一样为Pillard提供。窑
头燃烧器为多通道燃油、燃气燃烧装置，含有三个空气通道分别为轴向风（外圈）、旋流风（次外圈）、
中心风（第4圈），一个燃气通道（第3圈）），一个燃油通道（内圈油枪），一个点火通道（内圈）。燃
烧器喷出的燃料与一次风机（447FNG/448FNG）的冷风和来自冷却机的二次风一起进入窑内充分
混合燃烧，为熟料的烧成提供所需的热量。与一次风机并联的还有一台备用风机（447FNH/448FNH）
和事故风机（447FNI/448FNI）。事故风机用于在一次风机、备用风机停车时，及时吹风冷却，保护
燃烧器而不被损坏。燃烧器悬挂在电动移动小车支架上，移动小车由悬吊的轨道梁支撑，燃烧器可
在一定范围内上下、左右调节、前后移动以满足煅烧要求。
The main fuels that calcination needs inside a kiln are crude oil and natural gas. Crude oil is sent
from the duplex high-pressure pumps ( L37 FP2/L38 FP2) provided particularly for the kiln outlet to
the kiln outlet crude oil control valve train (447 VT1/448 VT1). Adjusting the flow rate valve of the
valve train to control the amount of oil injection of a burner plus the accommodation of primary air
to the burner can make the flame inside a kiln satisfy the requirements for clinker calcination.
Burning gas is controlled by the natural gas valve train (447 VT2/448 VT2). The kiln outlet burners
(447 BU1/448 BU1) as well as precalciner burners were provided by Pillard. The kiln outlet burner
is a multichannel oil-burning and gas-burning combustion train, containing three air channels for
axial wind(outer ring), spiral-flow wind (second outer ring) and center wind(fourth ring)respectively,
one gas-burning channel(third ring), one oil-burning channel(inner ring oil gun) and one ignition
channel(inner ring).The fuel a burner ejects, the cold air from the primary air fans and the
secondary air from the coolers enter the kiln together for sufficient mixture and calcination,
providing heat needed for the calcination of clinker. Together with a primary fan are a standby
fan(447 FNH/448 FNH) and an emergency fan(447 FNI/448 FNI).The emergency fan is used for
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timely blowing and cooling when the primary fan and standby fan stop so that the burner is
protected from damage. The burner is suspended on the support of an electric moving cart. The
cart is shored by a suspended track beam. In a certain range, the burner can be adjusted up and
down, left and right, and move to and fro to satisfy the calcination requirements.
烧结后的高温熟料出窑落入推动篦式冷却机的篦床上。篦冷机（447GQ1/448GQ1）由IKN公
司供货，能力：11000t/d，篦床有效面积：250m2。冷却机分为前后两段冷却，两段篦床均分为固
定篦床和活动篦床两区域。固定篦床区域均采用梁供风形式，活动篦床区域采用室供风形式。前后
两段活动篦床均采用液压传动，分属液压油泵站（ 447HD1/448HD1 ）的两个传动装置
（447MD1,MD2/448MD1,MD2），篦床速度可根据篦下压力调节以保持一定的熟料层厚度，篦下风
室，各配有单独的风机，各室间隔密封，风量、风压均可单独调节，从而确保冷风能克服相应区段
的篦板及料层阻力，均匀穿透物料层，使篦床上熟料得到有效的冷却。冷却机分为前后两段，两段
之间设有辊式破碎机（447CR1/448CR1），出窑熟料温度为 1400℃,经前段的冷却，然后经过辊式
破碎机的破碎，95%以上的熟料粒度小于 25mm。破碎机的型号：6×4.8m，辊直径Φ490mm，辊长
度：4800mm，装机：6×18kW，辊速：3~5 r / min，辊的工作温度约 150~200℃。破碎后的熟料在
经后段篦床的冷却，出冷却机熟料温度可降至环境温度+65℃以下，经冷却机末端的卸料口卸到熟
料链斗输送机（457DP1/458DP1）上，由链斗输送机送入熟料库。前端固定床的端部,设有 9 台空
气炮（447BQ1~9/448BQ1~9），通过循环工作，帮助推动此处的熟料运动。熟料在通过篦板的往复
推动中，偶尔通过篦孔落入风室的小颗粒收集在灰斗中，前段篦床灰斗中的细熟料颗粒由灰斗的气
力输送系统(简称PHD系统)（447PC1/448PC1）送入熟料的链斗输送机上，后段篦床灰斗中的细熟
料颗粒由灰斗的气动锁风阀（447FV1~FV6/448FV1~FV6）在料位和时间控制器的控制下,直接送到
熟料链斗输送机上。前段篦床固定床和活动床前部通过物料层换热后的气体可分别作为二次风直接
入窑和作为三次风抽往窑尾分解炉锥部入炉。后部多余的废气（约 250～300℃）将通过窑头电收尘
器（447EP1/448EP1）净化后，由窑头排风机（447FNF/448FNF）导入烟囱（447SK1/448SK1）
排入大气。电收尘器的气体处理量：1100,000m3/h，收尘面积：361m2，净化后的气体含尘浓度：
≤20mg/Nm3，高压硅整流器的电压：66kV，额定功率：66kW。熟料电收尘器捕集的粉尘由分别由
4 台熟料拉链机（447CV1~4/448CV1~4）和叶轮喂料机（447RF1~4/448RF1~4）送到汇总的熟料
拉链机（447CV5/448CV5）中，再送至熟料链斗输送机。窑头排风机的风量：1150,000m3/h，风
压：2000Pa，装机功率：1050kW，可变频调速调节风量。
After leaving the kiln, the sintered high-temperature clinker falls onto the grate bed of a pendulum
grate cooler. The grate cooler (447 GQ1/448 GQ1) is provided by the IKN company, with a
capacity: 11000 t/d, grate bed effective area: 250m2. The cooler is divided into two sections, front
and rear, for cooling. Each of the two grate bed sections is divided into two areas of a fixed grate
bed and a movable grate bed. The fixed grate bed area uses the beam-providing-wind form, while
the movable grate bed area involves the chamber-providing-wind form. The two front and rear
movable grate bed sections use hydraulic drive, belonging to the two drive units(447 MD1,
MD2/448 MD1s, MD2) of the hydraulic oil pump station(447 HD1/448 HD1).The speed of a grate
bed can be adjusted according to the pressure under the grate so as to retain a certain clinker
layer thickness. Each under-grate wind chamber is equipped with a single fan. Each chamber is
airtight, with its air volume and air pressure adjustable alone, thus ensuring that cold air can
overcome a corresponding section’s grate plate and material layer resistance and evenly
penetrate a material layer, making the clinker on the grate bed receive effective cooling. A cooler
is divided into two sections, front and rear, and between them, there is a roll crusher (447 CR1/448
CR1).The temperature of the kiln-leaving clinker is 1,400 ℃. The clinker is cooled by the front
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section and crushed by a roll crusher so that the fineness of more than 95% of the clinker is less
than 25 mm. The type of the crusher:6 × 4.8 m, roller diameter Φ 490 mm, roller length:4800 mm,
loader:6 × 18 kW, roller speed:3~5 r/ min, working temperature of the roller: about 150~ 200 ℃.
After the crushed clinker is cooled by the rear grate bed, the temperature for the clinker to leave
the cooler can decline to an ambient temperature below +65 ℃. Through the unloading mouth at
the end of the cooler, the clinker is unloaded to the clinker chain bucket conveyor (457 DP1/458
DP1), which sends the clinker to a clinker storage. The end of the front fixed bed is equipped with
9 air cannons (447 BQ 1~9/448 BQ 1~9), whose duty-cycle operation helps push the movement of
clinker here. While clinker is passing a grate plate in reciprocating push, the small particles
occasionally passing grate holes and falling into a wind chamber are collected in an ash bucket.
The fine clinker particles in the front grate bed ash bucket are sent to a clinker chain bucket by
pendulum (briefly called PHD system) (447 PC1s/448 PC1s). The fine clinker particles in the
rear-section grate bed ash bucket are sent directly to the chain conveyors by ash bucket air-lock
valves (447FV1~FV6/448FV1~FV6) under the control of material level and time controllers. The
gas after the heat exchange of the material layers at the front grate fixed bed and in front of the
movable bed may directly enter a kiln as secondary air and may be discharged to the conic section
of the kiln inlet precalciner to enter the furnace. The rear exhaust (about 250-300 ℃) is purified by
the kiln outlet electrostatic precipitator (EP) (447 EP1/448 EP1) (447 FNF/448 FNF) and guided to
the chimney(447 SK1/448 SK1) and into the atmosphere by the kiln outlet fan (447FNF/448FNF).
Air flow of an EP: 1,100,000 m 3/h, Cross area: 361 m2, dust concentration after gas purification:
≤ 20 mg/Nm3, voltage of high-voltage silicon rectifier: 66 kV, rated power: 66 kW. The dust caught
by the clinker EP is sent to the general clinker chain conveyor (447CV5/448CV5) by 4 clinker
chain conveyor (447CV1~4/448CV1~4) and rotary valve feeders (447RF1~4/448RF1~4)
respectively and then sent to the clinker chain bucket conveyor. The air flow of the kiln outlet vent
air fan: 1,150,000 m3/h, air pressure: 2,000 Pa, installed power: 1050 kW, with adjustable
frequency control air volume.
2.5 熟料输送
2.5 Clinker Conveyance
熟料经链斗输送机（457DP1/458DP1）经分料溜子分别由开关阀（457SG1/458SG1）经熟料
链斗输送机（457DP2/458DP2）进熟料散装库，开关阀（457SG2/458SG2）控制进熟料储存库。
在熟料储存库内还建有中心库专门存放次熟料，可通过选择电动开关阀（457SG4/458SG4）进中心
次熟料库区和选择电动开关阀（457SG3/458SG3）进熟料储存库的合格熟料区。
After being conveyed by bucket conveyer (457DP1/458DP1) and divided by the diversion
chute, the clinker will go into the clinker bulk silo after being controlled by the switch valve
(457SG1/458SG1) and conveyed by the clinker bucket conveyer (457DP2/458DP2), and the
clinker storage silo after being controlled by the switch valve (457SG2/458SG2) respectively. A
central silo has been set up in the clinker storage silo for storage of unqualified clinker. People
could send the clinker to the central unqualified clinker silo by selecting the electric switch valve
(457SG4/ 458SG4) or the qualified clinker silo by selecting the electric switch valve
(457SG3/458SG).
2.6 旁路放风及回灰输送
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2.6 Bypass and Returned Ash Conveyance
由于该厂原料中氯含量超标，会给预分解系统造成结皮堵塞，因此在窑尾上升烟道上设有旁路
放风口，可实施旁路放风，减少有害气体的循环富集。
Due to over-standard chlorine content of the raw material used by this plant, the precalcining
system will be crusted and blocked. Therefore, the bypass air outlet is set up on the uptake at the
kiln inlet in order to carry out the bypass and decrease the circulation and concentration of harmful
gases.
当需要开启旁路放风系统时，窑尾高温废气由旁路放风口抽出经旁路放风装置时与一次冷却风
机（417FN2/418FN2）掺入的冷风混合，再与二次冷却风机（417FN3/418FN3）掺入的冷风混合
成 200℃左右的废气，经系统袋收尘器（427BF1/428BF1）净化后由旁路放风系统的排风机
（427FN1/428FN1）经烟囱（427SK1/428SK1）排入大气。旁路系统的放风量通过调节排风机的
转速和调节阀（417DA3/418DA3）的开度实现。旁路放风量小，可开启冷风阀（417DA6/418DA6）
来替代二次冷却风机。系统故障时，也是优先开启冷风阀作为短暂保护。一次冷却风机的风量：
300,000m3/h，风压：2100Pa，功率：280kW；二次冷却风机的风量：300,000m3/h，风压：1800Pa，
功率：250kW，变频调速。一次冷却风机不可调，正常情况下一次冷却风机全负荷操作, 二次冷却
风机可根据袋收尘器进口的温度调节供风量。袋收尘器的处理风量: 900000m3/h，出口含尘浓
度:≤20mg/Nm3，气体温度: 正常 180℃~220℃，袋收尘器的阻力: ≤ 1700 Pa。系统的排风机的风
量: 920000 m3/h，风压: 3800Pa，功率: 1450kW，可变频调速。
When the bypass system is started, the hot gas of the kiln inlet will be drawn out through the
bypass air outlet, and then become the waste gas of about 200 ℃ after being mixed with the cool
air from the primary cooling fan (417FN2/418FN2) and the cool air for the secondary cooling fan
(417FN3/418FN3); and then, the waste gas will be purified by the system bag filter
(427BF1/428BF1) and exhausted to atmosphere by the exhaust fan (427FN1/428FN1) of the
bypass system through the chimney (427SK1/ 428SK1).Regulation of the air volume of the bypass
system could be realized through adjustment of the rotation speed of the exhaust fan and opening
degree of the adjusting valve (417DA3/418DA3). When the air volume of the bypass system is
small, the cold-air valve (417DA 6/418DA6) could be opened to work instead of the secondary
cooling fan. When the system failure occurs, the cold-air valve will also be opened first as
temporary protection. The air volume of the primary cooling fan:300,000m3/h, wind pressure:
2100Pa, power efficiency:280 kW; the air volume of the secondary cooling fan: 300,000m3/h, wind
pressure: 1800 Pa, power efficiency: 250 kW, frequency control. The primary cooling fan is not
adjustable. Under normal circumstances, the primary cooling fan will be operated with full load,
and the air supply volume of the secondary cooling fan could be adjusted according to the inlet
temperature of the bag filter. Air volume the bag filter: 900000m3 /h, outlet dust concentration:≤20
mg /Nm3, gas temperature:180℃～ 220℃normally, resistance of the bag filter:≤1700Pa.Air flow
of the exhaust fan of the system: 920000 m3 / h, wind pressure: 3800 Pa, power efficiency: 1450
kW, frequency control.
由袋收尘收集的粉尘，经过拉链机（427CV1，CV2/428CV1，CV2）、叶轮给料机（427RF1，
RF2/428RF1，RF2）、转运拉链机（427CV3，CV4/428CV3，CV4）、提升机（427BE1/428BE1）
被送入散装仓（427BI1/428BI1）。因富含氯、碱等有害成分不能返回烧成系统，故需经过仓底的螺
旋闸门（427SG1/428SG1）、叶轮给料机（427RF4/428RF4）、散装头（427BS1/428BS1）卸入散
装罐车外运。
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After being conveyed by the drag chain conveyor (427CV1,CV2/428CV1,CV2), revolving plow
rotary feeder (427RF1,RF2/428RF1, RF2), transfer drag chain conveyor
(427CV3,CV4/428CV3,CV4) and the elevator (427BE 1/428BE1), the dust collected by the bag
filer will be fed into the bulk bin (427BI1/428BI1).The dust could not be returned to the burning
system due to rich contents of noxious constituents such as chlorine and alkaline, so it will be
discharged to the bulk tanker for transportation to other places through the bulk loading machine
(427 BS1/428BS1) after being controlled by the screw gate valve (427SG1/428SG1) under the bin
and conveyed by the rotary feeder (427RF4/428RF4).
3．烧成系统主要设备单元的操作规程
3. Operation Instructions of Major Equipment Units of the Burning system
3.1 概述
3.1 General Description
本节只对烧成系统主要设备单元的操作、维护作一介绍，更为详尽的设备性能、配置情况以及
操作要求，请参见工艺设备表和设备说明书，如与供货厂商提供的说明书不一致，则以供货厂商的
说明书为准。
This section only introduces the operation and maintenance of major equipment units of the
burning system. For detailed equipment performance, configuration situation and operation
requirements please refer to the process equipments table and equipment instruction manuals. If
unconformity between the manuals provided by us and those provided by the manufacturers
occurs, the manufacturers' manual should be taken as final.
3.2 范围
3.2 Scope
本规程适应于烧成系统主要设备单元的操作、维护，即从生料充气卸料到熟料入库之间的设备。
This regulation is applicable to the operation and maintenance of major equipment units of the
burning system , that is, the equipments used from raw meal aeration and discharging to clinker
warehousing.
3.3 目的
3.3 Objective
本规程旨在规范操作巡检制度，提升工作质量，对主要设备单元的操作、维护需要注意的方面
提供正确的信息，以帮助操作人员准确判断设备故障及采取正确、有效的处理方法，树立安全生产、
质量第一的观念，保证设备长期、安全、高效的运行。
Objective of this regulation is to standardize the operation and patrol system, improve working
quality and provide accurate information on operation and maintenance matters of major
equipment units that require attention, in order to help operating personnel determine equipment
failures correctly and take correct and effective treatment measures, establish the concept of "
safe production and quality first” and guarantee the long-term, safe and efficient operation of
equipments.
3.4 操作摸式
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3.4 Operation Mode
各设备控制均有“集中程控”、“机旁控制”两种状态，现场有“开”、“停”、“闭锁”开关，正常生产时
各设备都处于 “集中控制” 状态；现场进行单机试机时，设备处于“机旁控制”状态，开单机时设备不
参与联锁控制，但停单机时，设备受联锁控制，主要是考虑设备的安全操作、防止设备内积料过多
而导致故障等方面因素，从而达到安全、可靠生产的目的。
All of the equipments have two control modes, namely, the "centralized program control" and "local
control". There are "Start", "Stop" and "Lock" switches at the field. During regular production, all of
the equipments are in the mode of "centralized control"; during single unit test run at the field, the
equipment is in the mode of "local control". When a single unit is started, the equipments will not
participate in the interconnected control; when a single unit is stopped, the equipments will be
controlled by the interconnected control in order to guarantee the safe operation of equipments
and prevent equipment failures due to material deposits in the equipments, thus realizing the
objective of safe and reliable production.
3.5 主要设备单元的操作规程 Operating Instructions of Main Equipment Units
3.5.1 回转窑 Rotary kiln
3.5.1.1设备概述 Equipment Summary
回转窑是烧成系统的主要热工设备之一，主要由窑筒体、传动装置、支承装置、挡轮装置、窑
头密封装置、窑尾密封装置、窑头罩等部分组成。The rotary kiln is one piece of the main thermal
technical equipment of a burning system , consisting mainly of a kiln cylinder, drive unit, supporting
apparatus, thrust roller device, kiln outlet sealing apparatus, kiln inlet sealing apparatus, kiln hood,
etc.
3.5.1.2主要技术性能 Main Technical Performances

规格 Specification（m）: Φ6.2×92m
有效内径 Effective inside Φ5.7
diameter（m）:
斜度 Gradient（%）: 4（正弦）(sine)
支座数（档）Number of 3
support abutments:
产量 Output（t/d）: 10000
窑转速 Kiln revolving speed 用主传动时调速范围 Speed adjustable range at main
（r/min）: drive:0.4~3.98~5
用辅助传动时 At auxiliary drive:0.105
传动型式 Drive type: 双传动 Twin drive
挡轮型式 Thrust roller type: 双液压挡轮 Double hydraulic thrust roller
窑头密封形式 Kiln outlet 钢片密封 Sealed by sheet steel
sealing form:
窑头冷却方式 Kiln outlet 风冷 Air cooling
cooling mode:
窑尾密封形式 Kiln inlet 汽缸压紧端面密封 Sealed by pneumatic cylinder
sealing form: pressing end surface
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3.5.1.3 主要结构和控制元器件概述 Summary of Main Structures and Control Components
1）窑筒体Kiln shell
窑筒体是回转窑的躯干，窑筒体倾斜地安装在三对托轮上，在窑筒体低端装有耐高温耐磨损的
窑口护板并组成套筒空间，设有专用风机对窑口部分进行冷却。沿窑筒体长度方向上套有三个轮带，
轮带下采用浮动垫板，可根据运转后的间隙进行调整或更换，以获得最佳间隙，垫板起到增加窑筒
体刚度、避免由于轮带与窑筒体有圆周方向的相对滑动而使窑筒体遭受磨损和降低轮带内外表面温
差的作用。
The kiln shell is the trunk of the rotary kiln and has been slantwise installed on three pairs of
supporting rollers. The lower end of the cylinder is equipped with thermostable and abrasion-proof
kiln outlet guard boards, constituting a casing space, and with exclusive-use fans to cool the kiln
outlet. Along the length of the kiln cylinder, there are three tyres, under which there are floating
liner plates. They may be adjusted or replaced according to the clearance after operation to
acquire the best clearance. The liner plates have the functions to increase kiln cylinder rigidity,
prevent the kiln cylinder from abrasion because of the relative slip of the tyres and the kiln cylinder
in the circumferential direction and lower the surface temperature range inside and outside a tyre.
窑筒体内设有3道挡砖圈，并在长度方向按温度、作用不同砌有性能不同的耐火砖保护筒体。为
了帮助筒体表面冷却，在烧成带及后部设有14台冷却风机，风机的位置可以根据需要适当调整。为
了监测筒体表面温度，设置了在线筒体温度扫描仪，可时时监测筒体的温度变化，并在中控室显示
曲线和图像。
The kiln cylinder inside has 3 brick-blocking circles, and along the length direction and according
to different temperatures and functions, there are firebricks with different performances to protect
the shell. For the sake of helping the cylinder surface cool, the burning zone and its rear are
equipped with 14 cooling fans, whose positions may be properly adjusted as required. For the
sake of monitoring the cylinder surface temperature, an on-line shell temperature scanner has
been set. It can always monitor the temperature change of the cylinder and display curves and
pictures in the central control room.
2）传动装置 Drive unit
传动系统采用双传动，每边各有一台主传动电动机驱动一台主减速器和一个小齿轮,共同通过一个大
齿轮带动窑筒体转动。每台主减速器配有一套主减速器稀油站。为保证主电源中断时仍能盘窑操作，
防止窑筒体弯曲，便利检修，设有辅助传动装置。
The drive system uses twin drive. Each side has a main drive motor to drive a main reducer and a
pinion, arousing the rotation of the kiln cylinder by jointly using a gearwheel. Each main reducer
has one main reducer thin oil station. For the purpose of ensuring that the main power supply can
still control the working of the kiln at power failure, preventing the kiln cylinder from being bent and
facilitating an overhaul, an ancillary drive unit has been installed.
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传动电动机Driving motor：
主传动 Main drive 辅助传动 Auxiliary drive
额定
额定调速额定额定
型号转速型号
功率范围功率转速
Model Rated Model
Rated Speed Rated Rated rotary
rotary
power adjustable range power speed
speed
(kW) (r/min) (kW) (r/min)
(r/min)
1PQ4560-6CM90-Z 1050 1197 120~1197~1504 1LG4223-4AA 54 1770
减速器Reducer：
主传动 Main drive 辅助传动 Auxiliary drive
型号总中心距公称速比型号总中心距公称速比
Model Total center Nominal Model Total center Nominal
distance speed ratio distance speed ratio
H3SH24-31.5 1570 31.5 H3SH9-56 580 56
主传动电动机与辅助传动电动机的电源设有连锁装置，当辅助传动电动机电源接通时，主传动
电动机的电源会自动切断；当主传动电动机电源接通时，辅助传动电动机的电源会自动切断，并窑
中传动与中控室设置有联络讯号。
The power supply for the main drive motor and auxiliary drive motor is equipped with an
interlocking device. When the power supply for the auxiliary drive motor is switched on, the
power supply for the main drive motor will be automatically switched off and vice versa. The local
drive in the kiln and the central control room are furnished with communication signals.
为安全可靠的实现主传动电动机与辅助传动电动机的转换，系统设置有电磁式制动器。电磁式
制动器的电源随辅助电动机同时开或关,即辅助电动机接通电源的同时,制动器也接通电源使之松开,
辅助电动机断开电源的同时,制动器也断开电源,使之即刻制动。
For the safe and reliable implementation of the switchover of a main drive motor and auxiliary drive
motor, the system is equipped with an electromagnetic brake. The power supply of the
electromagnetic brake is switched on or off simultaneously with the auxiliary motor, that is, the
moment the auxiliary motor is powered on, the brake will be powered on and unclenched, while
the moment the auxiliary motor is powered off, the brake is powered off, arresting motion instantly.
为安全可靠地实现主、辅减速器的转换，辅助减速器带超越离合器,其作用；在使用辅助传动时,
离合器啮合，辅助传动的动力通过辅助减速器传到主减速器上,再进一步带动窑旋转。当使用主传动
时，离合器处于脱开状态，主传动的动力不能传到辅助减速器上。
For the safe and reliable implementation of the switchover of a main reducer and an auxiliary
reducer, the latter is equipped with an overrunning clutch. Its action lies in that while using auxiliary
drive, the clutch is engaged. The dynamic force that auxiliary drive passes an auxiliary reducer
and spreads to a main reducer, further arousing the rotation of a kiln. While using main drive, the
clutch is disengaged and the dynamic force of the main drive can not spread to an auxiliary
reducer.
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主减速器高速轴端带有3个Pt100轴承测温传感器和1个Pt100测油温传感器,此外还带2个测振传
感器。温度、振动超限会发出报警。主减速器稀油站配有水冷却系统。
The high-speed shaft end of a main reducer has 3 Pt100 bearing temperature measuring sensors
and one Pt100 oil temperature measuring sensor as well as 2 vibration measuring sensors.
Temperature or vibration exceeding a limit will send out an alarm. A main reducer’s thin oil station
has a water cooling system.
由于采用了双传动，因此还需考虑同步性要求，传动系统控制中设有自动跟踪控制。
关于传动齿轮的润滑方面，在小齿轮的齿面配有喷雾润滑系统。间歇供油，间隙时间的设定可根据
实际使用情况调整。喷头发生堵塞时，油路分配器上的传感器会发出报警信号并报警。中控室会显
示报警信号。
As twin drive is adopted, it is also necessary to consider the synchronization requirements. There
is automatic tracking in the drive system’s control.
Concerning the lubrication of the drive gears, a fog lubrication system has been provided on the
tooth face of a pinion. Oil is provided intermittently and the setting of the interval time may be
adjusted pursuant to an actual employment circumstance. When a spray nozzle is jammed, a
sensor on the oil route distributor will send out an alarm signal. The central control room will
display an alarm signal.
3）支承装置 Supporting Unit
支承装置承受着窑筒体的全部重量，并对窑筒体起定位作用，使其能安全平稳地进行运转。支
承装置为调心式滑动轴承结构，轴承的瓦、油配置有测温报警装置。每个轴承配有齿轮泵，窑启动
初期提供润滑。还为托轮的轴承配有水冷却系统。
The supporting unit bears the complete weight of the kiln cylinder, and have the positioning action
to the kiln cylinder, making it operate safely and steadfastly. The supporting unit is of
core-adjusting sliding bearing structure. The bearing bush and oil are equipped with a temperature
measuring alarm. Each bearing has a gear pump, providing lubrication at the early stage of kiln
starting. The bearings of a supporting roller have a water cooling system.
4）液压挡轮装置 Hydraulic thrust roller unit
液压挡轮设置在回转窑中部支承装置及窑尾部支承装置轮带的下侧。通过液压挡轮迫使轮带和
窑筒体一起按一定的速度和行程沿窑中心线方向在托轮上往复移动，使轮带和托轮在全宽上能均匀
磨损，以延长使用寿命。正常情况下使用窑尾的主控挡，该挡故障时可把窑中备用挡设为主控挡。
Hydraulic thrust rollers are installed at the downside of tyres of bearing sets at the middle part and
charging side of the rotary kiln. The hydraulic thrust roller forces the tyre and the kiln shell to
reciprocate on the supporting roller in the direction of kiln center line at the certain speed and
distance together, in order to make the tyre and the supporting roller worn evenly at the full width,
so as to increase their service lives. Under normal circumstances, the main control thrust roller at
the charging side of the kiln will be used. When the failure of this thrust roller occurs, the standby
thrust roller at the middle of the kiln could be set as the main control thrust roller.
双挡轮共用一套挡轮油泵站。每个液压挡轮配置有油温报警装置。每个液压挡轮配置 5 只行程
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开关，双挡轮共配置 10 只。窑运转时只能是一档上的行程开关起作用，即正常生产时窑尾档是主控
挡轮，此时它上面的 5 个行程开关接通，控制挡轮油泵站的动作，而窑中档的行程开关全部断开；
异常情况当将窑中档液压挡轮作主控挡轮时，则其上的行程开关接通而窑尾档的行程开关全部断开。
This pair of thrust rollers shares a set of oil pump station of thrust roller. Each of the hydraulic
thrust rollers is equipped with the oil temperature alarm unit. Each hydraulic thrust roller is
equipped with 5 travel switches, so, this pair of thrust rollers are equipped with 10 travel switches.
During running of the kiln, only one set of the travel switches could work, that is, during regular
production, the thrust roller at the charging side of the kiln is used as the main control thrust roller,
and the 5 travel switches on which are switched in to control actions of oil pump station of the
thrust roller, while all of travel switches at the middle of the kiln are switched off; Under abnormal
situations, when the hydraulic thrust roller at the middle of the kiln is used as the main control
thrust roller, then the travel switches on it will be switched in while all of the travel switches at the
charging end of the kiln will be switched off.
5 个行程开关的的动作分别代表窑的 5 个位置，由 5 个行程开关的信号分别控制挡轮油泵站的

油泵和电磁换向阀的动作，从而调整窑体上行或下行，如此循环。若窑偏离正常情况向上窜或向下
窜，行程开关的信号会指挥发出报警信号，若窑继续偏离正常情况向上窜，行程开关的信号会跳停
主电机。
Actions of the 5 travel switches stand for 5 parts of the kiln respectively. Signals of the 5 travel
switches control actions of oil pump and electromagnetic directional valve of the oil pump station
of the thrust roller respectively, in order to adjust the kiln body to go up or down, and then circulate
in this way. If the kiln and goes up or down deviating from normal condition, the signal of the travel
switch will direct to issue alarm signals, and if the kiln continues to goes up deviating from the
normal condition, the signal of the travel switch will lead to trip of the primary motor.
挡轮油泵站还配有磁感式电接点压力表用于监控液压系统的压力，当系统压力超过其上限设定
值和下限设定值（此压力值现场调定）时，分别发出报警信号。通知巡检工查明原因，排除故障，
使系统恢复到正常工作。
The oil pump station of thrust roller is also equipped with magnetic-induction type electro
connecting pressure gauge for monitoring of the pressure of the hydraulic system. When the
system pressure exceeds the setting value (the value of the pressure could be set up at the field)
of its upper limit or lower limit, the alarm signals will be issued respectively to notify the patrol
personnel to find out the reason, clear the fault and restore the system to normal operations.
挡轮油泵站在油箱中装有热电阻，用于测定油液温度并在中控室监控,当油温高于 55℃时,发出
报警信号,通知工人打开油冷却器冷却水球阀. 当油温低于 35℃时发出报警信号,通知工人关闭油冷
却器冷却水球阀。
The resistance temperature sensor is installed in the oil tank of oil pump station of the thrust roller,
in order to measure the temperature of the liquid oil and monitor it in the central control room.
When the oil temperature is over 55℃, the alarm signal will be issued to notify the worker to open
the cooling water ball valve of the oil cooler. When the oil temperature is lower than 35 ℃, the
alarm signal will be issued to notify the work to close the cooling water ball valve of the oil cooler.
挡轮油泵站内设有过滤器，当系统发生堵塞，其压差发讯器会发出报警信号，应通知工人清洗
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或更换滤芯。
The filter is equipped in the oil pump station of thrust roller. When blocking occurs in this system,
the pressure difference signal sender will issue alarm signals. The worker should be notified to
wash and replace the filter element.
5）窑头密封装置
5) Sealing Device of the Kiln Outlet
窑头密封装置采用GP型(钢片式)径向接触式的密封形式，能自动补偿窑筒体运转时的偏摆和
运转中沿轴向的往复窜动，有良好的密封性能。与窑头罩的结合部位有风冷套，并配有冷却风机。
为防止罩壳内积存熟料细颗粒，下部设有灰斗，灰斗经导料溜子直接与篦冷机连接，将熟料细颗
粒直接送入篦冷机的篦床上部，并配有两个空气炮帮助送料。
The sealing device of the kiln outlet adopts the GP (sheet steel) radial contact sealing method,
which could automatically compensate the deflection and axial reciprocating motion of the kiln
shell during running, and has favorable sealing property. The wind cooling cover is used at the
combining part of the kiln outlet and the kiln hood, and the cooling fan is installed there. In order to
prevent accumulation of fine particles of clinkers in the hood casing, the ash hopper is installed at
the bottom. The ash hopper is directly connected with the grate cooler through the
material-guiding chute. The fine particles of clinker will be sent onto the grate bed of the grate
cooler directly. Two air cannons have been equipped to help transport the materials.
6）窑尾密封装置
6) Sealing Device of the Kiln inlet
窑尾密封装置采用QD型气缸压紧端面接触式，整个密封圈受力均匀，能消除由于安装和窑筒体
挠度产生的不良影响。为窑尾密封配置了两台空压机，一用一备，为汽缸提供动力。此外还配置有
一台电动多点干油脂泵，可将润滑脂注入摩擦圈接触面进行润滑，以减小摩擦阻力，减少磨损。干
油泵设定为定时间歇供油，间歇时间可调。
The sealing device of the kiln inlet adopts QD type of air cylinder pressing end-surface
contact type. The entire sealing ring is under even stress, and it could eliminate the adverse
effect generated by installation and deflection of the kiln shell. Two air compressors have been
equipped for sealing of the kiln inlet, one for use and one standby, to provide power for the cylinder.
Moreover, an electric multipoint consistent grease pump has been equipped. It could feed the
lubricating grease into the contact surface of the friction ring for lubrication in order to reduce the
frictional resistance and decrease abrasion. The grease pump is set as interrupted oil supply at
fixed time, and the pause time is adjustable.
7）窑头罩
7）Kiln hood
窑头罩是将窑和冷却机密封连接的罩形装置，两侧的支腿座落在窑头操作平台上。窑头罩内砌
筑耐火砖或浇灌耐热浇注料，窑头罩的外端面设有二扇悬挂移动式窑门，以便进入窑内检修及窑衬
砌筑等工作。窑门上设有观察孔和电视探头，可现场借助工具和远程观察窑内的烧成情况；窑门上
还设有温度探头，可监测烧成带温度。窑头罩侧面设有温度、压力测点，可监测窑头气体的温度、
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压力。另外窑门上还开有窑燃烧器的进出孔。
The kiln hood is hood-shape equipment connecting the kiln and the cooling machine tightly. The
legs on the two sides of the kiln hood are located on the operating platform of the kiln outlet. The
firebricks or castables are laid or poured in the kiln hood. A pair hanging and movable kiln Door is
installed at the outer end surface of the kiln hood, so that workers could enter into the kiln to do
works such as overhaul and laying of the kiln lining and so on. The sight window and TV probe
have been set on the kiln door. People could observe the calcinating situation in the kiln by using
the tools at the field or remotely; the temperature probe is also installed on the kiln door for
monitoring of the temperature of the calcinating zone. Measuring points of temperature and
pressure are set on the side of the kiln hood, in order to monitor the temperature and pressure of
the gas at the kiln outlet. In addition, the entry & exit hole of kiln burner is opened on the kiln door.
3.5.1.4 开机前的准备 Preparations before Startup
1）窑体 Kiln body
a、确认窑出入口处密封护板及窑口护铁的安装螺栓是否松动;
a, Confirm whether an erection bolt of a kiln access sealing guard board or a kiln outlet cover
iron is loose or not;
b、确认轮带与垫板间是否加足石墨锂基脂。
b, Confirm whether sufficient graphite lithium based grease has been added to the space
between a tyre and a liner plate.
c、确认轮带与托轮接触面之间有无异物。
C, Confirm whether there is foreign matter on the interface between a tyre and a supporting
roller.
d、确认轮带与托轮在旋转时是否碰到其它物体。
d, Confirm whether a tyre and supporting roller run into other bodies while revolving.
e、确认窑内耐火砖完好，耐火砖厚度可满足开机要求。
e, Make sure that the firebricks inside the kiln are intact and their thickness can satisfy the
startup requirements.
2）托轮 Supporting roller
a、确认各部位螺栓有无松动。
a, Confirm whether each part’s bolts are loose or not.
b、托轮轴温检测装置是否完好。
b, Confirm whether a shaft temperature detection apparatus is intact or not.
c、确认润滑油位，冷却水阀是否打开。
c, Confirm whether a lub oil level valve or a cooling water valve is unbolted or not.
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3）传动装置 Drive unit
a、检查大齿轮与小齿轮的啮合、磨损与润滑情况。
a, Check the engagement, abrasion and lubrication circumstances of a gearwheel or a pinion.
b、小齿轮轴承润滑油路是否畅通，齿面喷油装置是否正常。
b. Check whether the lub oil route of the pinion bearings is unimpeded or not and the tooth
face oil injection apparatus is normal or not.
c、检查油箱油量；
c, Check the oil amount of an oil tank;
d、确认各部位螺栓有无松动。
d, Confirm whether each part’s bolts are loose or not.
e、稀油站冷却水是否畅通。
e. Check whether the thin oil station’s cooling water is unimpeded or not.
f、各测量元件是否完好，报警系统是否正常。
f Check whether each measuring element is intact and each alarm system is normal.
g、检查主、辅离合器是否能正常离合，是否在正确的位置，限位开关是否能动作准确。
g. Check whether a main or auxiliary clutch can work normally and is in an exact position, and
whether a limit switch can act accurately.
h、检查各阀门、管道是否正常，有无渗、漏油。
h Check whether each valve or pipeline is normal and leaks oil.
4）液压挡轮 Hydraulic thrust roller
a、检查液压挡轮轴承和油箱油质，油量是否满足要求；
a, Check a hydraulic thrust roller bearing, oil tank and oil quantity and whether the oil quantity
can satisfy the requirements;
b、泵吸入侧阀是否全部打开，送油管路内气体是否全部排出；
b Check whether all the pump suction side valves are unbolted and whether the gas inside
the oil delivery pipe route is all discharged;
c、确认各过滤器的指标是否处于正常位置；
c, Confirm whether the indexes of each filter are placed in normal positions or not;
d、检查泵安全阀设定压力是否在规定值；
d, Check whether the set pressure of a pump safety valve is a rated value;
e、检查各手动阀门是否动作灵活，是否有泄漏或损坏现象，如有应立即更换。
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e, Check whether the motion of each hand operated valve is flexible and whether there is a
leakage or damage phenomenon. If there is, replace the valve immediately.
f、检查液压挡轮的石墨润滑情况，保持石墨块与挡轮接触面接触良好。
f, Check the black lead lubrication circumstance of a hydraulic thrust roller, and maintain the
good interface of a black lead cake and a thrust roller.
g、检查电接点压力表有无损坏及异常现象，指针是否放在设定的控制点上。
g, Check whether a pressure gauge with electric contact has a damage and abnormal
phenomena and whether a needle pointer is put on the stated control point.
h、检查各测量元件是否完好，报警系统是否正常。
h, Check whether each measuring element is intact and an alarm system is normal.
5）窑头罩 Kiln hood
a、确认耐火材料是否符合砌筑要求，燃烧器入窑孔周围密封是否添加。
a, Confirm whether a refractory material meets laying requirements and the sealing of a burner
going into the kiln is affixed.
b、窑头罩是否与旋转部件摩擦。
b Check whether the kiln hood rubs with a revolving part.
3.5.1.5开停机顺序及注意事项 Startup and Shutdown Sequence and Matters Need Attention
1）开停机顺序遵循的原则 Principles to be followed for startup and closedown sequences
开机时遵循的原则是：a）开保护系统的设备，如冷却水、润滑系统等；b）启动尾部设备；c）
启动主体传动设备；d）筒体冷却设备。而关机时遵循的原则是：a）停主体传动设备；b）停尾部设
备；c）停润滑设备；d）停筒体冷却设备；e）停保护系统的设备如冷却水系统。1) Principles to be
followed for startup and closedown sequences
Principles to be followed for startup are: a) turning on the equipment of a protecting system,
such as cooling water, lubricating system, etc.; b)starting tail equipment; c) starting master drive
equipment; d)cylinder cooling equipment Principles to be followed for closedown are: a)stopping
the master drive equipment; b)stopping tail equipment; c)stopping the lubrication equipment;
d)stopping the cylinder cooling equipment; e)stopping the equipment of a protecting system, such
as a cooling water system.
2）开停机顺序 Sequences for Startup and Closedown
开停机顺序在集中控制系统中已有设置，并有启动的顺序的时间控制和联锁关系。此处的简单介
绍是为了更充分地了解其中的关系。
The sequences for startup and closedown have already been set up in the centralized control
system, and there are startup sequence control and interlocking relations. The simple introduction
here is for understanding their relations more adequately.
A）开机顺序 Sequence for startup
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托轮的水冷却系统→减速机稀油站水冷却系统→启动多点式干油泵（437LQ1/438LQ1）→启动
窑尾空压机（437CP1/438CP1）→启动支撑装置的轴瓦供油的齿轮泵（12 台）（437LQ5/438LQ5），
启用支撑装置的温度监测系统→打开窑尾档的 5 个行程开关（窑中档的 5 个行程开关必须是关闭状
态）→启动小齿轮喷雾润滑系统（437LQ4/438LQ4）→启动减速机稀油站（437LQ2，LQ3/438LQ2，
LQ3），消除窑力矩→启用减速机的温度、压力、振动监测系统→确认主辅传动的超越离合器脱开→
启动窑主电机（437MM1，MM2/438MM1，MM2）的同时启动挡轮油泵站（437HD1/438HD1）→
启用双传动同步监测系统 → 窑头冷却风机（ 437FN1/438FN1 ） → 轮带冷却风机
（437FN2~5/438FN2~5）→筒体冷却风机（437FN6~L/438FN6~L）
Water cooling system of a supporting roller → retardance machine thin oil station water cooling
system → starting multipoint grease pump(437 LQ1/438 LQ1) →starting kiln inlet air
compressor(437 CP1/438 CP1) →starting 12 gear pumps(437 LQ5/438 LQ5)whose oil is provided
by shoring apparatus axle bush and starting shoring apparatus temperature monitoring system
→unbolting 5 travel switches(5 travel switches of the kiln middle must be in closed status) at the
kiln inlet →starting the pinion fog lubrication system(437 LQ4/438 LQ4) →starting retardance
machine thin oil station(437 LQ2, LQ3/438 LQ2, LQ3), removing the kiln moment of force
→starting retardance machine temperature, pressure and vibration monitoring system
→confirming the disengagement of main and auxiliary drive overrunning clutches →at the time of
starting kiln main motors(437 MM1, MM2/438 MM1, MM2), starting thrust roller oil pump
station(437 HD1/438 HD1) →initiating twin drive synchronic monitoring system →kiln outlet
cooling fan(437 FN1/438 FN1) →tyre cooling fans(437 FN 2~5/438 FN 2~5) →cylinder cooling
fans(437 FN 6~ L/438 FN 6~ L)
B）停机顺序 Sequence for Closedown
停窑主电机（437MM1，MM2/438MM1，MM2）的同时停挡轮油泵站（437HD1/438HD1）→
主辅传动的超越离合器啮合→启动辅助电机→进入慢转控制程序→停减速机稀油站→根据温度要求
停冷却风机→停窑尾空压机→窑慢转结束，设备的轴承、轴瓦温度满足要求，停水冷却系统。
At the time of stopping kiln main motors(437 MM1, MM2/438 MM1, MM2), stopping thrust roller
oil pump station(437 HD1/438 HD1) →main and auxiliary drive overrunning clutch engagement →
starting auxiliary motor →entering slow running control procedure →stopping thin oil station of
retardance machine →stopping cooling fan according to temperature requirements →stopping kiln
inlet air compressor →kiln slow running ending, the temperature of bearings and axle bushes of
the equipment satisfying requirements, stopping water cooling system.
3）注意事项 Points for attention
a、禁止窑主电机启动时，窑力矩未消，损伤动力机构；
a, Prohibit the kiln moment of force not being eliminated to avoid damaging the actuating unit
when the main kiln motor starts;
b、窑主电机启动时，窑速应设在最低值；
b, When the main kiln motor starts, the kiln speed shall be set at the lowest value;
c、停窑检修时应尽量送空窑内的物料。
c, If the kiln is stopped for an overhaul, empty the kiln of materials as far as possible.
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d、不要在无油状态下启动油泵和传动装置。
d. Do not start an oil pump and drive unit without oil.
e、确认好离合器的位置。
e, Confirm the position of a clutch.
f、窑停机时不能开液压挡轮油泵；
f, Do not turn on a hydraulic thrust roller oil pump when the kiln is shut down;
g、托轮的油温、瓦温超过 70℃时，应检查原因并采取降温措施。
g, When the oil and bush temperatures of a supporting roller are more than 70 ℃, find out the
cause and take measures for temperature reduction.
3.5.1.6 运转过程中的检查 Inspection During Operation
1）传动装置的检查 Drive unit inspection
A.电动机： Motor:
a、电动机的运行情况，电流是否在规定值内，如突然增大应查明原因，及时处理；
a, Check the running circumstance of an motor and whether the current is a rated value.
If it is enlarged suddenly, find out the cause and handle it in time;
b、检查有无异常振动、不正常响声及异常气味；
b, Check whether there are abnormal vibration, noise and odor;
c、检查地脚螺栓有否松动现象。
c, Check whether the foundation bolts are loose.
B.减速器 Reducer
a、检查运转是否平稳，齿轮啮合声音是否正常；
a, Check whether the operation is steady and the gears engagement sound is normal;
b、检查有无异常振动及漏油现象；
b, Check whether there are abnormal vibration and oil leakage;
c、检查稀油站冷却效果是否良好；
c, Check whether the thin oil station cooling effect is good or not;
d、停窑时，根据需要可以打开齿轮罩上观察门盖，检查轮齿有无点蚀、磨粒磨损等不良
现象。
d, While the kiln is not in use, as required, it is allowable to unbolt the observation door
cover of a gear hood to check whether a gear tooth has such bad phenomena as
pitting corrosion, abrasive particle abrasion, etc.
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e、检查减速器油泵站工作参数是否正常，检查冷却水流量是否正常。
e, Check whether the working parameters of a reducer oil pump station are normal and
the flow rate of cooling water is normal.
C.联轴器 Coupling
a、检查联接螺栓有无松动，组合联轴器的夹层板是否有不允许的变形；
a, Check whether the adjoining bolts are loose and the sandwich panel of a combination
coupling has unallowable deformation;
b、检查有无摆动现象。
b, Check whether there is a swinging phenomenon.
D.传动大、小齿轮及轴承 Driving Gearwheel, Pinion and Bearing
a、检查齿轮传动装置运转是否平稳，有无敲击声；
a, Check whether the operation of a gear drive apparatus is steady and has knock
sound;
b、检查大、小齿轮齿面接触斑点，沿齿高不少于40%，沿齿长不少于50% ；
b, Check the contact patterns on a gearwheel or pinion tooth surface and make sure that
they shall not be less than 40% in tooth depth and not less than 50% in tooth length;
c、大齿轮的径向、轴向摆动情况；
c, Check the radial and axial swing circumstances of a gearwheel;
d、检查喷雾润滑效果是否良好，齿面油量是否充足，油的粘度是否合适，有无不正常冒
烟现象；
d, Check whether the effect of fog lubrication is good or not, a tooth face oil quantity is
ample or not, the oil viscosity is appropriate and there is an abnormal phenomenon
of smoke emission;
e、检查传动轴承温升是否正常，密封装置是否有效，有否漏油和不正常现象；
e, Check whether the drive bearing temperature rise is normal and the sealing
apparatus is effective, and whether there are oil leakage and other abnormal
phenomena;
f、传动装置地脚螺栓及其它联接螺栓有无松动，是否产生振动或摆动。
f, Check whether the drive unit foundation bolts and other adjoining bolts are loose
and whether there is vibration or swing.
2）轮带及支承装置的检查 Inspection of tyre and supporting apparatus
a、检查轮带与垫板之间的间隙是否正常，有无异常响声，挡块、挡环是否有效；
a, Check whether the clearance between a tyre and a liner plate is normal, whether there
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is abnormal noise, and whether a baffle block or baffle ring is available;
b、检查轮带与托轮的接触情况及其表面的磨损情况；
b, Check the contact circumstance and surface abrasion circumstance of a tyre and
supporting roller;
c、检查窑筒体窜动情况，并及时调整托轮和控制窑筒体的上、下窜动。各对托轮推力方向应
一致。一般判别推力方向的方法是观察止推圈与衬瓦端面是接触还是有缝隙。当推力向上
时，缝隙应保持在托轮轴的下端（热端），上端应接触无缝隙。若托轮止推圈是在托轮轴
的内侧缝隙应保持在上端（冷端），下端应接触无缝隙。当推力向下时，缝隙保持的方位
则与上述情况相反。判断托轮推力大小可以根据止推圈与衬瓦接触处所形成的油膜的厚
度。油膜少而薄说明推力大，反之则小。
各托轮承受正压力大小应均匀，其识别的方法一般是通过轮带与托轮的接触面光泽程度。
接触面发亮则受力大，发暗则受力小。也可以通过观察托轮轴颈上油膜厚薄加以识别。油
膜薄的受力大，反之则小；
c, Check the axial slinging of the kiln cylinder, and in time adjust the supporting rollers and
control the upward and downward axial slinging of the kiln cylinder. The thrust direction
of each pair of supporting rollers shall consistent. The general method for judging a
thrust direction is to observe whether a thrust washer and a lining tile end contact or
have a gap at joint. When the thrust is heading up, the gap at joint shall be kept at the
lower end (the hot end) of a supporting roller spindle, and the upper end shall contact no
gap. If the thrust washer of a supporting roller is inside the spindle, the gap shall be kept
at the upper end (the cold end), and the lower end shall contact no gap. When the thrust
is getting down, the orientation that the gap retains is contrary to the above-mentioned
circumstance. Judging the value of a thrust may be based on the thickness of an oil film
formed at the contact place between a thrust washer and a lining tile. The less and
thinner an oil film is, the bigger the thrust is, and if conversely, the thrust is smaller.
The positive pressure borne by various supporting rollers shall be even. Generally, its
identification method is based on the degree of luster of the interface between a tyre
and a supporting roller. If the surface of contact becomes bright, the bearing force will
be big, while if the surface of contact becomes dark, the bearing force will be small.
Identification may also be based on observing the thickness of an oil film on the axle
neck of a supporting roller. If the oil film is thin, the bearing force will be big, while if
conversely, the bearing force will be small;
d、检查球面瓦内冷却水是否畅通，管路有无漏水现象；
d, Check whether the cooling water inside the spherical tiles is unimpeded or not and
whether the pipeline has water leakage;
e、检查托轮轴的表面油膜是否均匀和清洁，有无出现拉丝和沟槽。观察托轮轴承组油标的油
位是否符合要求，有无漏油现象；
e, Check whether the surface oil film on the axle of a supporting roller is even and clean
and whether there is wire drawing and grooves. Observe whether the level of a
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supporting roller bearing pack meets a requirement and whether there is oil leakage;
f、检查托轮轴承温升是否正常；
f, Check whether the supporting roller bearing temperature rise is normal;
g、检查挡轮转动是否灵活，有无因受力过大而引起挡轮表面发亮、起毛及轴承发热、响声等
不正常现象；
g Check whether the rotation of a thrust roller is flexible and whether there are such
abnormal phenomena as surface brightening and fuzzing caused by oversize force, and
a bearing emitting heat, noise, etc;
h、检查支承装置地脚螺栓有无松动或断裂现象；
h, Check whether the supporting apparatus foundation bolts are loose or ruptured;
i、检查基础有无震动和局部沉陷。
i, Check whether the foundation has dither and local settlement.
3）液压挡轮及挡轮油泵站Hydraulic thrust roller and thrust roller oil pump station
a、泵的油量是否稳定，油压波动范围是否正常；
a, Check whether the oil quantity of a pump is stable and whether the oil pressure
fluctuation range is normal;
b、检查轮带与挡轮间的接触和磨损是否均匀，有无受力过大和出现表面损伤等情况；
b, Check whether the contact and abrasion between a tyre and thrust roller are even and
whether there are oversize force, surface damage, etc;
c、工作泵噪音及各部异音是否过大，气缸活塞行程是否达到规定值；
c, Check whether the noise of a working pump and each part is oversize and whether
the cylinder piston stroke attains to a rated value or not;
d、检查各点油温是否正常；
d, Check whether the oil temperatures at all points are normal;
e. 检查油箱油位，使之经常保持在规定的油量内，注意工作油的透明度，以及油的起泡
情况；
e, Check the level of an oil tank, make it often kept at a specified oil quantity and note the
transparency and effervescence circumstance of power oil;
f. 各限位开关的动作是否准确、灵敏；
f, Check whether the motion of each limit switch is accurate and sensitive;
g. 检查各部位是否有渗、漏油现象；
g, Check whether each part has oil leakage;
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h. 使用水冷却时，检查冷却水流量是否正常
h, Check whether a cooling water flow rate is normal while using water for cooling.
4）窑筒体的检查 Inspection of kiln Shell
a、检查窑筒体表面温度变化情况，以防掉砖红窑事故及提供在何处何时更换耐火砖的
依据。特别提醒注意的是：窑筒体表面最高温度不允许超过400℃，否则将会由于窑
筒体钢板强度和刚度的显著降低，引起产生裂纹的危险；
a, Check the kiln shell surface temperature change in order to prevent an accident of
bricks dropping into the kiln and to provide references for where and when to
replace firebricks. What is specially reminded is that the kiln shell surface’s
maximum temperature is not allowed to be more than 400 ℃ otherwise the
remarkable reduction in the strength and rigidity of the kiln shell steel plates will
result in a hazard of generating cracks;
b、检查窑筒体对接焊缝有无裂缝；
b, Check whether the kiln shell butt joint soldering seams have cracks;
c、检查窑筒体有无严重摆动现象，窑筒体窜动是否稳定；
c, Check whether the kiln cylinder has a severe swing phenomenon and whether the
axial slinging of the kiln cylinder is stable;
5）密封装置的检查 Inspection of sealing apparatus
a、检查密封装置的零部件，有无严重磨损或损坏，润滑部位是否完整有效，联接螺栓有
无松动和脱落；
a lubricated part is integral and available and whether the adjoining bolts are loose
and have come off;
b、密封元件是否完整有效，密封摩擦部位是否接触良好，是否有严重漏风现象。
b, Check whether the sealing components are integral and available, whether the
contact of a sealed friction part is good and whether there is severe air leakage.
3．5．1．7 日常运转中的维护及注意事项Maintenance in Routine Running and Matters Need

Attention
a、传动系统、支承装置、挡轮系统必须经常（每小时）检查，发现有噪音、振动和发热
等不正常情况时应及时处理；
a, A drive system, supporting unit or thrust roller system shall often(per hour) be
inspected and such abnormal circumstances as noise, vibration, heat generation,
etc shall be handled in time;
b、所有的润滑点的润滑是否正常，应严格遵照润滑制度，经常检查油量是否充足；
b, Check whether the lubrication of all lubrication points is normal, strictly observe the
lubrication system and often check whether the amount of oil is ample or not;
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c、托轮衬瓦每小时要检查一次轴承温度及其润滑情况；
c, For a supporting roller lining tile, check the bearing temperature and its lubrication
circumstance per hour;
d、根据轮带与其垫板之间在一转中的相对位移，来判明间隙及磨损情况；
d, According to the relative displacement of a tyre and its liner plate in one revolution,
judge the clearance and abrasion circumstance;
e、注意窑筒体有规律的上下窜动情况（每班上下窜动一次）；
e, Note the regular axial slinging of the kiln cylinder(one upward and downward axial
slinging per shift);
f. 注意各冷却水出口是否水流畅通，以及托轮下部水槽水面的高度，高度不适宜应利用水
位调节器进行调整；
f, Note whether the flow of each cooling water outlet is unimpeded and note the level
of the water trough under a supporting roller. It is not suitable to make use of a water
level regulator for adjustment;
g. 经常注意窑筒体温度。窑筒体温度可通过红外线扫描装置的自动记录仪上来判明。窑
筒体表面温度最高不得超过400℃ ；
h, Often note that the kiln cylinder temperature. The kiln cylinder temperature may be
judged from an automatic recording instrument of an infrared scanning device. The
maximum kiln cylinder surface temperature shall not be more than 400 ℃;
h. 对检查中发现的问题，应根据问题性质适时地进行处理和记录；
i, For an issue discovered in inspection, carry out treatment and recording in good
time according to its nature;
i. 维护工作应与窑的操作工紧密配合，加强联系。检查及处理中务必注意安全，有些项
目的检查处理应在停窑后进行。
j, The maintenance work shall closely fit the operation work for the kiln, and
coordination shall be intensified. Pay attention to safety in the inspection and
treating. The some inspection and treating of some items shall be conducted after
stopping the kiln.
3.5.1.8 基础不均匀沉降的检查 Inspection of Unequal Foundation Settlement
回转窑是大而重的设备。窑筒体支撑在多个独立的窑墩基础上，基础的沉降是不可避免的。但
如果沉降量过大或各窑墩出现不均匀的下沉，将直接影响窑的直线性，使窑产生不正常弯曲变形，
给窑的安全运转带来危害。同时回转窑的窑头与窑头罩相连，窑尾又与窑尾设备相接，窑墩与这些
设备基础的不均匀下沉，将对衔接部件带来损伤，并直接影响窑头、窑尾的密封效果。因此对这些
设备基础沉降量的检查是非常必要的。
The rotary kiln is a piece of big and heavy equipment. The kiln cylinder is shored on many
separate isolated foundations, so the foundation settlement is ineluctable. But if the settling
28 / 120
volume is oversize or each kiln foundation shows unequal settlement, it will directly influence the
linearity of the kiln, making the kiln generate abnormal bend and deformation and endangering the
safe operation of the kiln. At the same time, the kiln outlet and the kiln outlet hood and are
connected with each other, and the kiln inlet is connected with the kiln inlet equipment, so the
unequal settlement of the kiln and these pieces of equipment damages the connecting parts and
directly influence the sealing effects of the kiln outlet and the kiln inlet. Therefore it is very
necessary to inspect the settling volumes of the equipment foundations.
1）窑墩基础沉降的检查 Inspection of kiln pier foundation settlement
在每个窑墩的侧面已安装了标高测点，并在设备安装时已对这些点的标高进行了测量和记录，它
是窑墩沉降测量的基准。从回转窑的安装开始，分阶段的对这些点的标高变化进行观察和测量：
True height survey points have already been installed on each side of a kiln pier and at the time of
equipment installation, and the true heights of these points were measured and recorded. These
are the reference for measuring kiln pier settlement. From the beginning of the installation of the
rotary kiln on, the changes of the true heights of these points shall be observed and measured:
a. 从设备安装到试运转的这段时间内，窑墩基础可能有最大15mm的垂直沉降，所以试运转前需
对基础下沉量进行测量，并根据测量结果对支承装置托轮的位置进行调整，以使窑筒体中心
线恢复到设计位置；
a, During the period from equipment installation to test running, a kiln pier foundation may have
the perpendicular settlement of maximum 15 mm, so it is necessary to measure a foundation
settling volume before test running and adjust the position of the supporting apparatus of a
supporting roller according to the measurement results to make the kiln cylinder’s center line
restored to the designed position;
b. 在回转窑运转初期的6 个月内，窑墩基础还可能有最大5mm的沉降，所以在这期间应经常对
窑墩基础沉降进行测量；
b, Within the early 6 months of the operation of the rotary kiln, a kiln pier foundation may have
the settlement of another maximum 5 mm, so in this period, it is necessary to often
measure the kiln pier foundation settlement;
c. 在回转窑运转6个月以后，窑墩基础还可能有每年1mm的沉降，所以必要时亦对基础沉降进行
测量。
c. After 6 months of the operation of the rotary kiln, the kiln pier foundation may have the
settlement of another 1 mm each year, so when it's necessary, the foundation settlement
shall also be measured.
2）基础沉降的分析与处理 Analysis and treatment of foundation settlement
对回转窑各窑墩的相对垂直沉降是允许的，但该设备不允许基础出现倾斜沉降因为设备本身对倾
斜沉降很难进行处理：
The relative perpendicular settlement of each pier of the rotary kiln is allowable, but the slant
settlement of the equipment foundation is not because slant settlement is very difficult to treat:
a、当各窑墩的垂直沉降差超过3mm时，就应对相关支承装置的托轮位置进行调整，调整时应
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注意两托轮中心与轮带中心夹角应满足60°±2°的要求；
a, When the perpendicular settlement difference of each kiln pier exceeds 3 mm, the
supporting roller positions of the related supporting devices shall be adjusted. , During
adjustment, note that the included angle between the center of two supporting rollers and
the center of a tyre should satisfy the requirement of 60°± 2;
b、窑头档窑墩及窑尾档窑墩与其相应的冷却机（或窑头罩）、窑尾设备基础的沉降差超过 25mm
是不允许的。如果已超过或已经对密封产生影响，则必须对有关部件进行处理，以达到满意
为止。
b, The settlement difference exceeding 25mm for a kiln outlet pier and a kiln inlet pier, and a
cooler or kiln outlet hood, and a kiln inlet equipment foundation corresponding with them
is disallowed. If the difference has been exceeded or has already generated impacts on
sealing, it is necessary to treat relevant parts until attaining satisfaction.
3.5.1.9 停机后的维护保养和主要零件的磨损与更换 Maintenance and Upkeep after Closedown

and Abrasion and Replacement of Main Parts
a、确认轮带的内径与轮带下垫板外径之间的间隙达 20mm 时，应做相应的处理。
a. When the clearance between the bore of a tyre and the outside diameter of a liner plate
under the tyre reaches 20 mm, corresponding treatment shall be given.
b、轮带发现断面磨损了 10% （这时应对其应力及刚度核算），或表面磨成锥形、多边形，以及

局部出现穿通裂纹时需进行更换；
b. If the cross section of a tyre is found to be abraded by 10%(its stress and rigidity shall be
examined and calculated at this time), or the surface has been ground into a taper or
polygon and a local part has shown continuous cracks, replacement shall be needed;
c、当托轮厚度磨损了 10% ，挡轮的轮缘厚度磨去 20% ，或托轮表面磨成锥形、多边形或其

他异形，或托轮与挡轮的轮缘有穿通裂纹时，必须更换或修理。更换托轮时，如轴也要换，
其相应的衬瓦必须重新配研；
c. When the thickness of a supporting roller has been abraded by 10%, the rim thickness of a
thrust roller has been ground by 20%, or the surface of a supporting roller has been
ground into a taper, polygon or other abnormal shape, or the rim of a supporting roller or
thrust roller has continuous cracks, replacement or repair shall be needed. When a
supporting roller is replaced, the shaft shall also be replaced and its corresponding lining
tile shall be re-faced up;
d、传动齿轮的齿厚磨损了 30%或 0.5 模数时；或轮缘具有不可恢复的损伤时需更换；
d. When the tooth thickness of a driving gear has been abraded by 30% or the modulus of
0.5 or a rim has non-recoverable damage, replacement shall be needed;
e、窑筒体段节有裂纹或局部变形时，要进行修理或更换；
e. If a kiln shell segment has cracks or local deformation, repair or replace it;
f、确认托轮润滑石墨块的消耗情况，必要时更换。
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f. Determine the dissipation circumstance of a supporting roller lubrication black lead cake,
and replace it when it's necessary.
g、确认冷却水是否正常，润滑油是否更换和补充。
g. Determine the flow cooling water,lubrication is good and enough, and replace it when it's
necessary.
h、确认窑头、窑尾密封装置的磨损情况，必要时更换。窑尾密封装置的固定摩擦环和活动摩擦
环的厚度磨损了 2/3 时必须进行更换。
h. Confirm the abrasion circumstance of a kiln outlet or kiln inlet sealing device, and replace
it when it's necessary. If the thickness of a fixed friction ring or movable friction ring of a
kiln inlet sealing apparatus has been abraded by 2/3, replacement shall be done.
i、检查窑口护铁及窑衬厚度，必要时更换。
i. Check the thickness of the kiln cover iron and the kiln lining, replacement shall be done
when it's necessary.
j、检查窑、窑头罩等处的耐火材料，掉砖必须补，蚀薄大于 1/3 必须更换。
j. Check the refractory material of the kiln, the kiln outlet hood, etc. A dropped brick shall be
supplemented. If the corrosion thickness is greater than 1/3, replacement shall be done.
3.5.1.10 常见故障分析及处理 Common Fault Analysis and Treatment
当生产过程中出现故障时，需根据不同的情况区别对待，重大的问题必须经过使用单位，
制造单位和设计单位共同调查、分析原因，商讨处理办法。下面对常见故障产生原因及处理方
法作一简叙：
If a fault appears in a procedure in production, it shall be differentiated according to a different

circumstance. For an important question, a user, manufacturer and designer shall investigate
and analyze the cause, and discuss a treating way together. The causes and treatment
processes of some common faults and their causes are briefly described as follows:
常见故障产生原因处理方法
Common fault Cause Treatment process
窑衬及其镶砌质量不良或腐蚀后过簿选用质量高的耐火砖，停窑补换新
没有按期更换、导致掉砖红窑。砖，提高镶砌质量，严禁压补。
The quality of the kiln lining and its laying Select high-quality firebricks, replace
are poor or the lining is ultra-thin after with new bricks after stopping the kiln,
corrosion but no replacement is done on raise the laying quality and strictly
掉砖红窑
time, causing bricks to drop in the forbid pressed repair.
Bricks dropping burning kiln.
in burning kiln
窑皮挂得不好加强配料工作，提高操作水平
The hanging of kiln coating is not good. Intensify raw meal admixture work
and raise the operating level.
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燃烧器欠佳检查燃烧器 Check the burner.
A burner is not good.
轮带与垫板磨损严重，间隙过大，窑筒体严格控制烧成带附近的轮带与垫板间
径向变形增大。隙，间隙增大时要及时更换垫板或加垫
A tyre and a liner plate are abraded 调整。
severely, the clearance is oversize, and Strictly control the clearance between a
the kiln shell radial strain increases. tyre and a lining plate near the burning
zone. If the clearance increases,
replace the liner plate or add packing
sheets for adjustment in time.
窑筒体中心线不直定期校正窑筒体中心线
The kiln cylinder center line is not Periodically calibrate the kiln cylinder
straight. center line.
窑筒体局部过热变形，内壁凸凹不平。红窑必停，对变形过大的窑筒体及时整
The kiln shell is superheated to 修或更换。
deformation, and the inside wall is rough. The burning kiln must be stopped. The
kiln cylinder with oversize deformation
shall be trimmed or replaced in time.
窑筒体受热不匀，弯曲变形过大，托轮脱正确调整托轮
空。 Accurately adjust the supporting roller.
窑筒体振动 The kiln cylinder vibrates The kiln
cylinder is heated unevenly, the bending
The kiln cylinder
strain is oversize and a supporting roller
vibrates
has come off.
大小齿轮啮合间隙过大或过小调整大小齿轮的啮合间隙
The engagement clearance of a Adjust the engagement clearance of
gearwheel and a pinion is oversize or the gearwheel and the pinion.
undersize.
大齿圈接口螺栓松动或断落紧固或更换螺栓
A girth gear interface bolt is loose or has Tighten or replace the bolt.
been broken and dropped.
弹簧板焊缝开裂重新找正、补焊
A spring lamination soldering seam Give recalibration and repair welding.
cracks.
传动小齿轮磨损严重，产生台阶更换小齿轮
A drive pinion is abraded severely, Replace the pinion.
generating steps.
基础地脚螺栓松动紧固地脚螺栓
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A foundation bolt is loose. Tighten the foundation bolt.
窑筒体开裂窑筒体振动引起见前述，对症处理
The kiln shell The kiln cylinder vibrates. See the above description and handle it
cracks. accordingly.
表面温度太高或红窑烧损窑筒体，强度和窑筒体复补，加固烧焊
刚度削弱。 Repair the kiln cylinder again and give
The surface temperature is too high or reinforcing soldering.
the red kiln burns down the kiln cylinder,
and the strength and rigidity are
weakened.
某档托轮顶力过大正确调整托轮，减轻负荷。
The propping force of some supporting Accurately adjust the supporting roller
roller is oversize. and reduce the load.
筒体钢板材质有缺陷或焊缝质量差用金属探伤器检查内部缺陷
The cylinder steel plate material has Use a metal defect detector to examine
flaws or the soldering seam quality is the internal defects.
poor.
窑筒体弯曲偏斜突然停窑后，长时间没转窑。将窑弯处做一记号，等窑转到上面时停
The kiln cylinder After stopping the kiln suddenly, the kiln 窑数分钟，使其复原。
is bent and does not rotate for a long time. Mark a bending part of the kiln and stop
deflected. the kiln for a few minutes when the kiln
turns to the mark, making it restored.
窑墩基础下沉，托轮位置发生移动根据测量数据，正确调整托轮位置
A kiln pier foundation subsides, and the Accurately adjust the position of a
position of a supporting roller is moved. supporting roller according to the
survey data.
窑中心线不直，衬瓦受力过大。校正窑中心线，调整托轮受力。
托轮衬瓦过热 The kiln center line is not straight, and Correct the kiln center line and adjust
A supporting the force on the lining tile is oversize. the force on the supporting roller.
roller lining tile is 托轮不正确歪斜，轴承推力过大。调托轮位置。
overheated. The supporting roller is out of square and Adjust the position of the supporting
the bearing thrust is oversize. roller.
轴承内冷却水管漏水，用油不当或润滑油及时换油，修理水管，清洗衬瓦。
变质，油内混有其它杂物。 Replace the oil, repair the water pipe
The cooling water pipe inside a bearing and clean the lining tile.
leaks water, use of oil is not appropriate
the lub oil deteriorates or the oil inside
has other dopants.
33 / 120
带油勺发生故障或油盘油沟堵塞。清理油沟，及时修复带油勺。
An oil dipper fails, or an oil pan or oil Clean up the oil groove and restore the
groove is blocked. oil dipper.
托轮衬瓦拉丝 A 衬瓦质量不良，有夹渣或其它杂物。改换粘度大润滑油或更换衬瓦。
supporting roller The lining tile quality is bad and it has Replace with lub oil with great viscosity
lining tile is scum or other dopants. or replace the lining tile.
drawn into wires.
油内混有铁屑，熟料粒及其它硬度较大杂换油、清洗衬瓦。
物。 Change the oil and clean the lining tile.
The oil is mixed with scrap iron, clinker
particles and other dopants with higher
hardness.
托轮径向受力过大，致使轴与衬瓦间摩擦调整托轮受力状况，更换轴承内润滑油，
力增加，油膜破坏。调大轴承冷却水量及采用其它冷却措
The supporting roller radial force is 施。
托轮衬瓦发生叫
声及产生振动 oversize, causing the frictional force Adjust the stressed state of the
between the axis and the lining tile to supporting roller, replace the lub oil
A supporting
increase and breaking the oil film. inside the bearing, enlarge the cooling
roller lining tile
water quantity of the bearing and adopt
generates sound
other cooling measures.
and vibration.
托轮轴向推力过大，使止推圈受力过大，调整托轮，减轻推力，保持托轮推力均
产生强力摩擦。匀。
The supporting roller axial thrust is Adjust the supporting roller, reduce
oversize, making the stress of the thrust thrust and keep the thrust of the
washer oversize, generating strong supporting roller even.
friction.
窑筒体局部高温辐射轴承，使润滑油粘度临时换入粘度较高的润滑油，增加隔热
变底，油膜变薄。措施。
The local high heat of the kiln cylinder Replace with lub oil with higher
radiates a bearing, making the lub oil viscosity temporarily and increase heat
viscosity drop and the oil film become insulation measures.
thin.
轴承内冷却水长时间中断，使其温度升高，恢复冷却水，保持畅通，更换新的润滑
破坏油粘度。油。
The cooling water inside the bearing has Restore the cooling water, keep it
been discontinued for a long time, unimpeded and replace with new lub
making its temperature rise and oil.
damaging oil viscosity.
冬季低温时，轴承内润滑油粘度偏高，流及时更换冬季润滑油，开加热器，对油
动性差，呈缺油状态。加热。
34 / 120
At low temperature in winter, the lub oil Replace winter lub oil in time, and turn
viscosity inside the bearing is on the high on a heater to heat the oil.
side, with poor liquidity and presenting
an oil starvation status.
慢速转窑时间过长，使油勺带油量过少，开启加油泵或临时人工加油，提高窑速。
不能满足衬瓦的润滑要求。 Turn on the oil pump or do temporary
The time of slow kiln rotation is too long, manual oiling to raise the speed of the
making the oil amount of the oil dipper kiln.
undersize and not meeting the
lubrication requirements of a lining tile.
轴承内润滑装置发生故障。及时修复、清理、补充新油。
The lubricating device inside the bearing Do restoration and straightening in
breaks down. time, and supplement new oil.
轴与衬瓦接触点不符要求。重新修刮衬瓦。
The contact point of the axis and the Fix and pare the lining tile again.
lining tile does not meet the requirement.
托轮与轮带接触托轮中心线歪斜过大，接触不匀，局部单调整托轮，减少歪斜度，增加与轮带接
面产生起毛、脱壳位压力增大。触面积。
或压溃剥伤。 The inclination of the supporting roller Adjust the supporting roller, reduce
The surface of center line is oversize, the contact is not skewness and increase contact area
contact of a even, and partial unit pressure with the tyre.
supporting roller increases.
and a tyre 托轮径向力过大。调整托轮，减轻负荷。
generates fuzz,
The supporting roller radial force is Adjust the supporting roller and reduce
shelling or
oversize. the load.
bruises.
窑体窜动性差，长期在某一位置运转，致削平台肩，保持窑筒体上下窜动灵活性。
使托轮产生台肩，一旦再窜动，破坏接触 Suppress a shoulder, and keep the
表面。 flexibility of the upward and downward
The poor axial slinging of the kiln body slinging of the kiln cylinder.
and the long-term running at one
position cause the supporting roller to
generate shoulders. Another slinging will
break the contact surface.
轮带与托轮间滑动摩擦增大。调整托轮，保证托轮位置正确。
The sliding friction between a tyre and a Adjust the supporting roller and ensure
supporting roller increases. the position of the supporting roller is
correct.
轮带侧面挡环咬托轮轴向推力过大，使轮带与侧面挡环间调整托轮，减轻推力。
毛、掉铁末、脱落。摩擦挤压力过大。 Adjust the supporting roller and reduce
35 / 120
A tyre lateral The supporting roller axial thrust is the thrust.
baffle ring bites oversize, making the frictional and
fuzz or drops compressional force between the tyre
scrap iron, and and the lateral baffle ring oversize.
sheds off.
轮带内表面与垫托轮径向受力过大，使托轮与轮带转动不调整托轮，减轻负荷。轮带与垫板间加
板间咬死正常，其间滑动摩擦力增大。润滑脂。
The internal The supporting roller radial stress is Adjust the supporting roller and reduce
surface of a tyre oversize, making the rotation of the the load. Add albany grease to the tyre
and a liner plate supporting roller and the tyre abnormal and the liner plate.
are seized. and increasing the sliding friction
between them.
轮带内表面与垫板间隙太小，温度过高或调整间隙，清理脏物。
间隙内有粉尘、油污、杂物等。 The 轮带与垫板间吹风冷却。
clearance between the tyre internal
Adjust the clearance and clear off the
surface and the liner plate is too small,
dirty.
with too high temperature, or there are
Blow air to the tyre and the liner plate
dust, greasy dirt, dopants, etc. in the
for cooling.
clearance.
掉砖红窑，窑筒体径向膨胀过大。见前述，对症处理。
The kiln shell turns red as firebricks See the above description and handle it
come off, and the kiln cylinder’s radial accordingly.
expansion is oversize.
轮带内表面与垫磨损所致。更换垫板或加垫片。

板间间隙过大，筒 Resulting from abrasion Replace the liner plate or add packing
体刚性降低 pieces.
传动大小齿轮接窑筒体窜动性差，固定在某一位置运转过铲平台肩，保持窑筒体窜动灵活性。
触表面出现台肩久。 Root out a shoulder and keep the
The clearance The axial slinging of the kiln cylinder is flexibility of the axial slinging of the
between a tyre poor and the rotation at a fixed position cylinder.
internal surface is too long.
and a liner plate
挡轮安装位置是否合适。调整挡轮位置。
is oversize, the
Check whether the installation position of Adjust the position of the thrust roller.
cylinder rigidity
the thrust roller.
declines, and the
contact surface
between a
driving
gearwheel and a
pinion shows a
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shoulder.
传动轴承摆动、振窑筒体弯曲，大小齿轮发生冲击。调直窑筒体。
动 The kiln cylinder bends, and a gearwheel Straighten the kiln cylinder.
The drive and a pinion collide.
bearing swings 大小齿轮的轮齿制造误差。修齿或更换。
and vibrates.
The gear tooth manufacture of a Fix or replace the tooth.
gearwheel and a pinion has errors
大小齿轮啮合间隙不当。调整啮合间隙。
The engagement clearance between a Adjust the engagement clearance.
gearwheel and a pinion is not
appropriate.
小齿轮轴与联轴器中心线不同心。校正中心线。
The pinion axle and the coupling center Correct the center line.
line are of disalignment.
轴承紧固螺栓或地脚螺栓松动。及时紧固。
A bearing tightening bolt or foundation Do tightening in time.
bolt is loose.
基础底板刚度不够。加固底板，提高稳定性。
The foundation mat rigidity is not Reinforce the bottom plates and raise
enough. stability.
轴承损坏 A bearing is damaged. 更换轴承 Replace the bearing.
主减速器齿轮表窑筒体振动，有冲击，超负荷。见前述。
面产生点蚀、裂 The kiln cylinder vibrates and has impact See the description above
纹、剥落等损伤 and overload.
The main
油不清洁，有杂物或粘度不够。清洗、清除杂物，换新油。
reducer’s gear
The oil is not clean, has dopants or its Clear away the dopants and change
surface
viscosity is not enough. new oil.
generates
damage such as
pitting corrosion, 齿轮表面材质疲劳，强度不够。必要时更换减速器齿轮。
cracks, flaking, The gear surface material has fatigue Replace the reducer gears when it's
etc. and its strength is not enough. necessary.
齿轮啮合不良，受力不均匀。及时调整，保证良好啮合。
The gears engagement is bad and its Make adjustment in time and guarantee
stress is nonuniform. good engagement.
主减速器壳体表油少、不清洁、冷却水中断。补加油或清洗换新油，及时恢复冷却水
面温度高或采用临时降温措施。
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The main The oil is little and is not clean, and the Add oil or clean it to change new oil,
reducer housing cooling water is discontinued. restore the cooling water or take
body surface measures to reduce heat in time.
temperature is 受窑筒体上辐射影响。加强隔热措施。
high.
Subjected to the kiln cylinder radiation Intensify heat insulation.
电动机振动地脚螺栓松动。紧固地脚螺栓。
An motor A foundation bolt is loose. Tighten the foundation bolt.
vibrates 电动机与联轴器中心线不同心。校正中心线。
The motor and the coupling center line Correct the center lines.
are of disalignment.
轴承损坏，转子与定子摩擦。更换轴承，检查、调整间隙。
A bearing is damaged, and the rotor and Replace the bearing, and check and
the stator produce friction. adjust the clearance.
电动机外壳发热接线松脱或断掉。重新接线，并要牢靠。
The motor shell The wiring is loose or broken off. Afresh connect the wiring, and it shall
emits heat. be firm and reliable.
通风不良 Bad-ventilated 采取临时降温措施，加强通风。
Take measures for temporary heat
reduction and intensify ventilation.
受窑筒体热辐射影响。加强隔热措施。
Subjected to the kiln cylinder’s heat Intensify heat reduction
radiation
转子或定子线圈损坏。拆装检修。
The rotor or stator coil is damaged. Dismantle and install it for an overhaul.
电动机电流增高窑皮增厚、增长。减少风、煤、料，处理窑皮。
The motor The kiln skin grows thick and long. Reduce wind, coal and materials, and
current treat the kiln skin.
increases. 窑内结圈。处理结圈。
Rings are formed inside the kiln. Treat the formed rings.
托轮推力方向不一致调整托轮，保持正确推力方向。
The supporting roller thrust direction is of Adjust the supporting roller, and keep a
anticoincidence. correct thrust direction.
托轮轴承润滑不良。改善润滑，加强管理。
The lubrication of a supporting roller Improve lubrication and intensify
bearing is bad. management.
窑筒体弯曲。见前述。
The kiln cylinder is bent. See the description above.
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筒体旋转受阻。检查如油勺等。
The cylinder rotation gets difficulty. Check the oil dipper, etc.
电动机本身出现故障。详细检查，更换有缺陷零件。
The electric motor fails Make detailed inspection and replace
the defective accessories.
挡轮油泵站油压油泵故障。检查油泵 Check the oil pump.
低 The oil pump breaks down.
The thrust roller 油温偏高。采取降温措施。
oil pump station’s
The oil temperature is on the high side. Take measures for heat reduction.
oil pressure is
油量调速阀未调节合适。调节油量调速阀到合适位置。
low.
The oil amount speed control valve is not Adjust the oil amount speed control
adjusted properly. valve to a proper position.
挡轮油泵站回油窑胴体轴向下滑力大。调整窑胴体轮带与托轮之间的受力状
速度过快 The kiln body’s axial downward slip 况。
The thrust roller force is great. Adjust the stressed state of a kiln body
oil pump station’s tyre and a supporting roller.
back oil speed is 截止阀工作不正常。更换截止阀。
too quick.
The working of a stop valve is not Replace a stop valve.
normal.
窑头、窑尾密封严窑头钢片与风冷套间隙过大。调整重锤，增大紧捆力。
重漏风 The clearance between the kiln outlet Adjust the heavy bob and enlarge the
The sealing of sheet steel and the air cooling set is tightening force.
the kiln outlet oversize.
and the kiln inlet
窑尾两摩擦环间隙不均或过大。检查气缸或进气系统，并及时处理 Check
leaks air
The clearance between the two friction the cylinder or the air inlet system, and
seriously.
rings at the kiln inlet is not even or give treatment in time.
oversize.
窑尾径向密封盘根失效。更换盘根。
The kiln inlet radial sealing packing fails. Replace the packing.
注：主传动、减速机、稀油站的具体维护和事故处理见设备说明书。
Note: For the concrete maintenance and accident disposal for the main drive, speed reduction unit
and thin oil station, see the equipment manual.
3.5.2窑及分解炉燃烧器 Kiln and Precalciner Burner
本项目的窑及分解炉燃烧器系统由PiILLARD公司提供，窑及分解炉燃烧器系统分别由窑燃烧器及供
油、供气系统和分解炉燃烧器及供油、供气系统组成。The kiln and the precalciner burner system for
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this project are provided by the PiILLARD company. The kiln and the precalciner burner system
consist of a kiln burner, oil and gas supply system and a precalciner burner.
3.5.2.1 主要技术性能 Main Technical Performances

序号内容技术指标
No. Contents Techincal Date
窑燃烧器输出（设计值）
1 168.5 MW
Kiln burner output(design value)
燃烧器输出（最大）
188 MW
Burner output(maximum)
燃烧器热端长度
7m
Burner hot end length
总长（约计）
12 m
Total length(approx.)
包括耐火内衬的总重量（约计）
Total weight including fire-proof 13 000 kg
lining(approx.)
耐火衬砌厚度 Refractory lining thickness 80 mm
主要空气流速 Main air flow rate 18 800 Nm3/hr
设计油流速 Designed oil flow rate 14 740 kg/hr
最大油流速 Maximum oil flow rate 16 500 kg/hr
设计天然气流量 Designed natural gas flow
19 850 Nm3/hr
rate
最大天然气流量 Maximum natural gas flow
22 600 Nm3/hr
rate
分解炉燃烧器输出（每个燃烧器的设计值）
2 Precalciner burner output(design value for 67 MW
each burner)
燃烧器输出（最大）
75 MW
Burner output(maximum)
数量 Quantity 4
燃烧器热端长度 Burner hot end length 1.1 m
耐火衬砌 Refractory lining 60 mm
主要空气流量（4 个燃烧器）
25 450 Nm3/hr
Main air flow rate(4 burners)
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No. Contents Techincal Date
4 个燃烧器用油的总流速的设计值
Design value of total current velocity for 4 23 440 kg/hr
burners’ oil consumption
4 个燃烧器用油的总流速的最大值 Maximum
value of total current velocity for 4 burners’ oil 26 400 kg/hr
consumption
天然气流量的设计值（4 个燃烧器）
Design value of natural gas flow rate (4 31 220 Nm3/hr
burners)
天然气流量的最大值（4 个燃烧器）Maximum
35 160 Nm3/hr
value of natural gas flow rate (4 burners)
窑燃烧器的一次风机
3
Primary fan for kiln burner
静压 Static pressure 20 000Pa
流量 Flow rate 20 400Nm3/hr
装机功率 Installed power 200kw
电机转速 Motor revolving speed 3588rpm
分解炉燃烧器冷却风机 Cooling fan for
4
precalciner burner
静压 Static pressure 12 000Pa
流量 Flow rate 28 400Nm3/hr
装机功率 Installed power 160kw
电机转速 Motor revolving speed 3586rpm
3.5.2.2 窑及分解炉燃烧器系统的简单描述 Simple Description of the Kiln and the Precalciner

Burner System
窑燃烧器由悬挂小车支撑，并配有电动行走装置。燃烧器可分别上、下、左、右调节3°。在本
项目中使用的燃料是天然气和原油，因此窑头平台上分别由天然气和原油的控制阀组控制燃烧器的
燃料用量。天然气的控制阀组直接和降压站的供气管道相连。原油的控制阀组直接与窑头的高压泵
的供油管线和回油管线连接。燃烧用空气的8~10%由一次风机提供，一次风机配有备用风机。
The kiln burner is shored by a hanging cart and has an electric moving apparatus. The burner can
be adjusted for 3 °up and down, left and right respectively. The fuels to be used in this project are
natural gas and base oil, therefore on the kiln outlet platform, the natural gas and crude oil control
valve train respectively control the fuel dosage of a burner. The control valve train for natural gas
is directly connected with the gas supply pipeline of a pressure reduction station. The control valve
train for crude oil is directly connected with the oil supply pipeline and crude oil pipeline for a high
pressure pump on the kiln outlet. 8~10% of combustion air is provided by the primary fan, which
has a standby fan.
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分解炉燃烧器有 4 个，直接由支架固定在分解炉炉体上。窑尾 3FL（42.040m）平面上设有

天然气和原油的主控阀组。当燃天然气时，由燃气的主控阀组分别控制 4 个天然气的独立阀组，4
个天然气的独立阀组分别控制 4 个燃烧器的燃气用量。当燃油时，由燃油的主控阀组分别控制 4
个原油的独立阀组，4 个原油的独立阀组分别控制 4 个燃烧器的燃油用量。天然气的主控阀组直
接和降压站的供气管道相连。原油的主控阀组直接与分解炉高压泵的供油管线和回油管线连接。
燃烧用空气的 4~6%由分解炉燃烧器风机提供。
当工厂采购的原油粘度偏大时，在高压泵供油系统中应启用加热器，以确保原油在燃烧器喷
嘴处的雾化。
There are 4 precalciner burners, which are directly fixed on the precalciner body with
brackets. The kiln inlet 3FL（42.040m）plane surface is equipped with main control valve train for
natural gas and crude oil. While natural gas is burned, the main control valve train for burning
gas respectively control 4 independent valve train for natural gas, and the 4 independent valve
train for natural gas respectively control the gas-burning quantities of 4 burners. While oil is
burned, the main control valve train for burning oil respectively control 4 independent valve train
for crude oil, and the 4 independent valve train for crude oil respectively control the oil-burning
quantities of 4 burners. The main control valve train for natural gas is directly connected with a
gas supply pipe line of a pressure reduction station. The main control valve train for crude oil is
directly connected with an oil supply pipe line and oil return pipe line of a precalciner
high-pressure pump. 4~6% of combustion air is provided by the precalciner burner.
If the viscosity of the crude oil purchased by the factory is on the high side, a heater in the
high-pressure pump oil supply system shall be started to ensure the atomization of the crude oil
at a burner nozzle.
3.5.2.3 启动前的准备 Preparation before Startup
a．核实所有管件、所有器械（泵，压力计）、所有控制开关、所有自动阀门的状态（正常开
启，正常关闭）都按说明书或图纸被很好的连接并符合使用条件；
a, Make sure that the states(normal opening and normal closing) of all pipe fittings,
apparatuses(pumps, pressure gauges),control switches and automatic valve are under
good connection and conform to the service conditions in accordance with the manual
or drawings.
b．核实所有电器柜总开关都已关闭、所有控制柜都停止供电、所有线路的连接都符合说明书
或图的技术要求；
b, Make sure that all electric apparatus cabinet master switches have already been shut
down, all control cabinets have been powered off and the connection of all wirings meet
the technical requirements of the manual or drawings;
c．核查所有连续式报警系统和热保护装置都已经到位，可确保不同流体的使用性能；
C. Make sure that all continuous alarm systems and thermal protection devices have all
been in place and can ensure the functional performance of a different fluid;
d．泵和鼓风机能自由地手动进行旋转，所有手动阀安装正确，调节灵活；
d. A pump and a fan can revolve freely by hand operation, and the installation of all hand
operated valves shall be exact, with flexible adjustment;
e．所有的安装符合安全要求，经过必要的安全测试。
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e. A pump and a fan can revolve freely by hand operation, and the installation of all hand
operated valves shall be exact, with flexible adjustment;
3.5.2.4 启动程序 Startup Procedure
1) 窑燃烧器的启动程序 Startup procedure of kiln burner
A．燃油 Fuel Oil
a．在启动窑燃烧器以前，按计划先启动供油的高压泵和循环系统；
a. Before starting the kiln burner, first start the oil supplying high pressure pump and
circulating system as scheduled;
b．接到点火指令后，再一次核查燃烧器的阀门位置和燃烧器位置设定已符合规定的要求，确认
点火器和喷枪在规定位置；
b. After receiving an ignition command, recheck whether the settings of the position of
burner valve and the position of a burner meet the specified requirements and confirm
whether a lighter and a blow gun are at the stipulated positions;
c．开启一次风机检查出口压力；
c. Turn on the primary fan and check the outlet pressure;
d．点火器的安全启动联锁允许点火器工作；
d. The safety starting interlock of a lighter shall allow the working of the lighter;
e．启动点火器并检查点火枪是否形成了一定能量的稳定火焰；
e. Start the lighter and check whether a firing gun has formed a stable flame with certain
energy;
f．打开窑头燃油阀组的流量阀；
f. Unbolt the flow rate valve of the kiln outlet oil-burning valve set;
g．等燃烧器火焰出现，打开中心风至规定位置 8，打开径向风和轴向风阀门并通过调节开度和
比例来稳定火焰；
g. Wait for the appearance of a burner flame, unbolt the central wind to the specified position
of 8, unbolt the radial wind and axial wind valves, and adjust the span and proportion to
stabilize the flame;
h．当火焰形成并稳定，关闭点火枪；
h. When a flame has been formed and stabilized, close the firing gun;
i．记录如下内容：每一路风的压力、阀的位置、燃油的压力，这些数据被用于以后燃烧器点火
启动参考。
i. Record the contents as follows: Air pressure on each circuit, the position of a valve, fuel
oil pressure. These data are used as references for the later ignition startup of a burner.
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B．燃气 Gas Burning
a．燃气的启动程序与燃油基本相同，所不同的是，不需要启动供油的高压泵和循环系统，而是
启动天然气降压站的供气阀门。
a. The startup procedure of gas burning is fundamentally the same as that of oil burning, but
what is different is that it does not need to start an oil-supplying high pressure pump and
circulating system, but need to start the gas supply valve of a natural gas pressure
reduction station.
b．点火枪火焰形成后，打开窑头燃气阀组的流量阀。
b. Unbolt the flow rate valve of the kiln outlet gas burning valve set after a firing gun flame is
formed.
2) 分解炉燃烧器的启动程序 Startup procedure of precalciner burner
A．燃油 Oil Burning
a．在启动分解炉燃烧器以前，按计划先启动供油的高压泵和循环系统。
a, Before starting a precalciner burner, first start an oil supplying high pressure pump and
circulating system.
b．再一次核查燃烧器的阀门位置和燃烧器位置设定已符合规定的要求；
b. Recheck whether the settings of the position of a burner valve and that of a burner have met
the specified requirements;
c．分解炉出口温度可满足点火要求，并接到分解炉燃烧器点火指令；
c. The precalciner outlet temperature shall satisfy the ignition requirement and a precalciner
burner firing command has been received;
d．开启分解炉燃烧器风机并检查出口压力
d. Start the precalciner burner fan and inspect the outlet pressure.
e．安全启动联锁允许分解炉燃烧器启动
e. The safety startup interlock shall allow the startup of a precalciner burner.
f．启动分解炉燃烧器。启动分解炉燃烧器的程序有两种选择：同时启动 2 个或同时启动 4 个。
f. Start a precalciner burner. There are two procedures for starting a precalciner burner for
selection: simultaneously starting 2 burners or simultaneously starting 4 burners.
g．打开分解炉燃油阀组的流量阀
g. Unbolt the flow rate valve of the precalciner oil burning valve train.
h．记录如下内容：每一路压力值、阀的位置、燃油的压力，这些数据被用于以后燃烧器点火启
动参考。
h. Record the contents as follows: each path pressure value, valve position, oil burning
pressure. These data are used as references for later burner ignition startup.
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B．燃气 Gas Burning
a．燃气的启动程序与燃油基本相同，所不同的是，不需要启动供油的高压泵和循环系统，而是
启动天然气降压站的供气阀门。
a. The startup procedure of gas burning is fundamentally the same as that oil burning, but
what is different is that gas burning does not need to start an oil-supplying high pressure pump
and circulating system but needs to start the gas supply valve of a natural gas pressure
reduction station.
b．启动分解炉燃烧器后，打开分解炉燃气阀组的流量阀。
b. Unbolt the flow rate valve of the precalciner gas-burning valve train after starting a
precalciner burner.
3) 加热器的启动 Heater Startup
加热器装置是被串联在高压油泵系统中，加热器的开停由出口温度控制，当油温低于或低于设定温
度时，加热器自动启停电热器。
The heater apparatus is connected in series in the high pressure oil pump system. The startup or
stopping of the heater is controlled by the outlet temperature. When the oil temperature is lower
than or higher than a preset temperature, the heater will automatically start or stop an electric
heater.
3.5.2.5启动后的调整 Adjustment after Startup
a．窑头燃烧器点火成功后，应根据窑的升温要求调节燃烧器的升温速度。而实施燃烧器的火焰
调节，应根据燃烧器的操作说明书的要求分步进行。
a. After the successful ignition of a kiln outlet burner, it is necessary to adjust the temperature
rise speed according to the kiln temperature rise requirements. But the flame adjustment of
a burner shall be done in steps in accordance with the requirements of the operating manual
of the burner.
b．要注意区分“冷窑点火”和“热窑点火”的操作。
b. It is necessary to distinguish the "cold kiln ignition" operation from the "hot kiln ignition"
operation.
c．要注意无燃料通道的供风冷却
c. It is necessary to note the air supply cooling of a no-fuel channel.
d．窑头、分解炉燃烧器的调节基本是根据系统的工艺要求和安全控制要求进行，因此应按照
Pillard 操作说明书对燃烧器及火焰形状的调节要求进行。
d. The adjustment of the kiln outlet and a precalciner burner shall be basically in accordance
with the process requirements and safety control requirements of the system, therefore it is
necessary to adjust the burner and the flame shape according to the Pillard operating
manual.
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3.5.2.6 停车及事故应急处理 Shutdown and Emergency Treatment
a．正常停车是根据窑系统的烧成情况，逐步减料和调燃烧器阀组的流量阀。当分解炉燃烧器停
车后，分解炉燃烧器风机应调整流量保持运行，直到安全温度以下。
a. The normal shutdown shall be according to the burning circumstance of a kiln system,
gradually reducing materials and adjusting the flow rate valve of the burner valve train. After
the precalciner burner stops, the flow rate of a precalciner burner fan shall be adjusted to
keep operation until reaching a safe temperature.
b．分解炉燃烧器停车后，会立即启动阀组的吹扫、保安程序。
b. After a precalciner burner stops, the purging and security procedure of the valve train will be
immediately started.
c．窑头燃烧器停车后，应保持一次风机的运转，直到安全温度以下。若长时间停窑，应拉出窑
燃烧器，以免烧坏烧嘴。
c. The operation of the primary fan shall be maintained after the shutdown of a kiln outlet
burner until reaching the low of a safe temperature. If the kiln is not in use for a long time, a
kiln burner shall be pulled out in order to prevent it from being burnt down.
d．窑燃烧器停车后，会立即启动阀组的吹扫、保安程序。
d, After a kiln burner stops, the purging and security procedure of the valve train will be
immediately started.
e．若窑头燃烧器的一次风机机械故障必须停机，可预先启动备用风机替代。若两台风机均出现
机械故障必须停机，则需启动停窑程序，然后停燃烧器并启动事故风机对燃烧器喷嘴进行冷
却。当然该种情况出现的可能性极小。
e. If a kiln outlet burner’s primary fan has to be stopped because of mechanical trouble, you
may start the standby fan in advance. If both fans have mechanical trouble and have to be
shut down, it is necessary to start the kiln stopping procedure, then stop the burner and start
an emergency fan to cool the burner nozzle. Certainly, the possibility for this circumstance
to appear is infinitesimal.
f．分解炉燃烧器的风机出现机械故障必须停机，则分解炉燃烧器将进入停车程序。
f. If a fan of a precalciner burner has mechanical trouble, it has to be shut down, and then the
precalciner burner will enter a shutdown procedure.
3.5.3 篦冷机 Grate Cooler
本项目的篦冷机由IKN公司提供，篦冷机分别由篦冷机的本体、篦床驱动系统、辊式破碎机、送灰系
统、空气炮系统及相应的控制系统组成。The grate coolers for this project are provided by the IKN
company. A grate cooler consists of a grate cooler main body, a grate bed drive system, a roll
crusher, an ash-feeding system, an air cannon system and corresponding control systems.
3.5.3.1主要技术性能 Main Technical Performances
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No. Contents Technical Index
1 生产能力 Productive capacity 11000 t/d
篦床有效面积 250m2
2
Grate bed effective area
单位篦板有效面积负荷 44 t/m2.d
3 Load on unit grate board effective
area
进料温度 1400℃
4
Charging temperature
出料温度 65℃+环境温度
5
Discharging temperature
篦冲程次数（额定） 15 次/min
床 Stroke frequency
6
Grate (rating)
bed 冲程 Stroke 140mm
篦床传液压传动 hydraulic 2 段 2 sections
动装置 drive
Grate 电动机功率 3×150 kW （其中一台备用）
7
bed
Motor power (One motor for standby)
drive
unit
熟料破型号、规格 6×4.8m， 6 个辊子,工作宽度：4.8m
碎机 Model and 6 × 4.8 m, 6 rollers, working
Clinker specification width:4.8m
crusher
出料粒径
Discharged particle 95% ＜25mm
size
8 辊的工作温度
Working temperature 150~200℃
of roller
额定速度
3~5 r/min
Rated speed
传动装置
6×18kW
Drive unit
3.5.3.2 主要结构和控制元件概述 Summary of Main Structures and Control Elements
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1) 篦冷机的本体 Main body of grate cooler
篦冷机的篦床由进口的 KIDS1#、1#段篦床、辊式破碎机后部的 KIDS2#和 2#段篦床组成，

KIDS1#、KIDS2#为固定床，1#段篦床、2#段篦床为活动床。固定床 KIDS1#共计 10 排篦板，配有
3 台冷却风机，为梁式供风，前 4 排篦板，其喷嘴底部分别设有 6 个热电偶。1#段篦床有 74 排篦板，
分成 7 个室，配 7 台风机，前面两室的喷嘴底部分别设有 6 个和 2 个热电偶。固定床 KIDS2#有 4
排篦板，2#段篦床有 31 排篦板，分成 3 个室，配 3 台风机。KIDS1#和 1#段篦床的冷却风机的风量
调节均采用变频调速，KIDS2#和 2#段篦床的风量调节采用进口风门调节。而 KIDS1#头部的篦板风
量分配靠 Y 形进风管上的翻板和风管上的调节板调节。
Grate beds of the grate cooler includes KIDS1# and 1# section grate bed at the entry and KIDS 2#
and 2# section grate bed at the back of the rolling breaker. KIDS 1# and KIDS 2# are fixed beds,
while 1# section grate bed and 2# section grate bed are movable beds. The fixed bed KIDS1# has
10 rows of grid plates in total, and it is equipped with 3 cooling fans. The beam style air supply is
adopted. 6 thermocouples have been installed at the bottom of each coanda nozzle of front 4 rows
of grid plates respectively. The 1# second grate bed has 74 rows of grate plates, and it is divided
into 7 chambers and equipped with 7 air-blowers. 6 and 2 thermocouples are equipped at the
bottom of coanda nozzle of front two chambers respectively. The fixed bed KIDS2# has 4 rows of
grate plates. The 2# section grate bed has 31 rows of grate plates, and it is divided into 3
chambers and equipped with 3 air-blowers. The frequency control is adopted for air regulation of
the cooling fans of KIDS1# and 1# section grate beds. The inlet ventilation door adjustment is
adopted for air regulation of the KIDS 2# and 2# section grate beds. While the air distribution of
the grid plate at the head end of KIDS1# is adjusted by the turning board on the Y-type air-supply
line and regulating plate on the air pipe.
篦冷机上的检修门均设有安全保护系统被联锁到系统中。
All of the access doors on the grate cooler are equipped with security protection system, and
have been interlocked into the system.
2) 篦床驱动系统 Driving System of the Grate Bed
液压系统主要由以下几个部分组成：液压泵站、1＃段篦床的驱动液压缸 1＃和 2#、2＃段篦床

的驱动液压缸 3＃、配电柜、带控制系统和操作面板的现场控制台。
The hydraulic system mainly includes following parts: hydraulic pump station, 1＃and 2#
driving hydraulic cylinders of 1＃section grate bed, 3＃driving hydraulic cylinder of 2＃section
grate bed, switch cupboard and the field control station with control system and operation panel.
液压泵站装备有 3 台驱动泵（GD）、油/水冷却器、油过滤的油温控制电路（OTC）、油罐、空
压站、液压控制台（HCB）。正常情况下，3 台驱动泵中有 2 台工作， 1 台备用。2 台工作泵中，其
中一台泵承担主要负载，另外一台承担峰值负载。在运行状态，主要负载泵和峰值负载泵的任务周
期性的变化来确保两个泵的负载均匀。3 台驱动泵之间的运行也可以互换。篦床驱动系统中的控制
系统的监控内容包括：油温、油位、油过滤器、泵阀位置、油冷却器的水量、液压油的含水量等，
并在液压控制台上均有显示。
The hydraulic pump station is equipped with 3 driving pumps (GD), the oil/water cooler, oil
temperature control circuit of oil filter, oil tank, compressed air station, and the hydraulic control
board (HCB). Under normal circumstances, 2 of the 3 driving pumps work, and 1 driving pump is
standby. One of the working pump bears major load, and the other working pump bears the peak
load. Under running conditions, the tasks of the major load pump and the peak load pump vary
periodically in order to guarantee the even load of these two pumps. Functions and operations of
these 3 driving pumps could be exchanged with each other. Monitoring contents of the control
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system of the grate bed driving system include: oil temperature, oil level, oil cleaner, pump valve
position, water quantity of the oil cooler, water content of the hydraulic oil and etc. These contents
are all displayed on the hydraulic control board.
篦床的驱动是通过液压缸 1#、液压缸 2#推动篦床 1＃，液压缸 3#推动篦床＃2 实现的。液压

缸的冲程由比例阀、电磁位移测量、控制阀等组成的油路控制系统控制，设计冲程 140mm，但运行
中的真实冲程需通过 IKN 现场调试工程师在操作面板上做出调整，并且以后也不能改变。篦床的运
行速度由液压缸的冲程次数确定。汽缸冲程次数的设定是根据实际需要，在中心控制区，设定好的
篦床移动速度通过 PLC 传输给轴向运动控制系统。轴向运动控制系统计算出速度值送给相应的电控
元件控制驱动。液压缸内的位移传感器将信号反馈给轴向运动控制系统。轴运动控制系统利用这个
信号计算出篦床的真实速度，与设定值对比，以实现运行速度的控制。篦床的额定速度是 15 次/min。
The driving of grate beds is realized by hydraulic cylinder 1# and hydraulic cylinder 2# pushing the
grate bed 1＃, and hydraulic cylinder 3# pushing the grate bed ＃2.The stroke of the hydraulic
cylinder is controlled by the oil way control system, which is composed of the proportioning valve,
electromagnetic displacement measurement and control valve and so on. The designed stroke is
140 mm. While the actual stroke in running need to be adjusted on the operation panel by IKN field
debugging engineer, and should not be changed afterwards. The running speed of the grate bed is
determined by the stroke times of the hydraulic cylinder. The number of cylinder stroke times is set
according to actual demand. In the central control area, the setting travel speed of the grate bed
will be transferred to the axial motion control system by PLC. The axial motion control system will
work out the velocity amplitude and send it to corresponding electric component control driving.
The displacement sensor in the hydraulic cylinder will send the signal to axial motion control
system. The axial motion control system will use this signal to work out the true velocity of the
grate bed, and compare it with the setting value, in order to realize the control of running speed.
The rated speed of the grate bed is 15 times/min.
3) 辊式破碎机 Coller Crusher
辊式破碎机位于 1#段和 2#段篦床之间，用于将大块熟料破碎。破碎机的辊面是曲面，并配有

辊套，共有 6 个辊子，每个辊子配有驱动电机和行星齿轮减速装置；每台电机的温度及电流和旋转
方向均被控制系统监控；每辊的轴端装有叶片，通过接近开关对转速计数，实现对速度的控制。由
集中润滑系统对辊两端的球面滚珠轴承润滑，控制系统对润滑系统的润滑时间间隔、润滑时间和油
罐的油位实施监控；轴承的温度由热电阻测温仪监控；每个辊都配有独立的水循环冷却系统，并对
回水的流量和温度实施监控，辊式破碎机的框架梁设有风冷却系统，机旁和中控均配有控制屏，在
中控和现场都能监控破碎机的运行情况。
The roller crusher is located between the 1# section and 2 # section grate beds, and is used for
breaking of big pieces of clinkers. The roll surface of the breaker is curved, and is equipped with a
roll ring. There are 6 rollers in total. Each of the rollers is equipped with drive motor and
heliocentric-type reducer. The temperature, current and rotation direction of each motor are
monitored by the control system; Blade are installed on the shaft end of each roller, and the
rotation speed of the blade is counted by the proximity switch, thus realizing the control of the
speed. The centralized lubricating system lubricates the spherical surface ball bearings at two
ends of the roller. The control system monitors the lubrication interval, lubrication time and oil
level of the oil tank of the lubrication system; The bearing temperature is monitored by thermal
resistance thermometric indicator; Each roller is equipped with an independent water circulation
cooling system, and the flow rate and temperature of the returning water are monitored; The frame
girder of the roller crusher is equipped with the wind cooling system. The control boards are
equipped at both the local and the central control; therefore, the running condition of the breaker
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could be monitored both at the central control and at the field.
4) 输灰系统 Ash Conveying System
该篦冷机的输灰系统包括两部分：第一部分是 1#段篦床底部配置的 PHD（Pneumatic Hopper

Drainage）系统。该系统是在 1#段篦床 7 个风室的底部设置了 14 个集灰箱，分属两条排灰管道，
由气力输送将灰送到集灰仓，然后通过溜子送到熟料链斗输送机。每个集灰箱的输灰时间和输灰频
次均由时间控制，集灰箱上部设有料位计，当料位计探测到的高料位信号会在中控显示，若 3 次排
料循环后仍探测到高料位，则将发出报警信号，通知需要检查处理。第二部分是 2#篦床的底部设
置的排灰系统简称滑动门（Slide Gate）系统。该系统在 2#篦床的底部的 3 个风室设置了 6 个集灰
斗并配有 6 个气动闸门，闸门打开积灰将直接落入熟料链斗输送机。闸门的开启可由料位控制和时
间控制。若采用料位控制，则控制方法如下：每个集灰斗闸门的开启时间和开启频次均由时间控制。
集灰斗上部设有料位计，当料位计探测到的高料位时闸门也会开启。时间控制将被自动重新设定。
若某料斗闸门开启时间过长将报警，必须迅速检查闸门。若 10 次循环中每次都有高料位信号，则系
统也会给出报警。若采用时间控制：则每个闸门设有固定的开启时间和延时，而实际开启时间加延
时为监控时间，若监控时间超时，则将发出报警信号，通知需要检查处理。若中间遇到高料位，闸
门也会自动被打开。
The ash conveying system of this grate cooler includes two parts: The first part is the PHD
(Pneumatic Hopper Drainage) system configured at the bottom of the 1# section grate bed. This
system sets up 14 ash-collecting boxes at the bottom of 7 air chambers of the 1# section grate bed.
The ash-collecting boxes belong to two ash pipes respectively. The ash will be transported to the
ash-collecting bin by air delivery, and then sent to the clinker bucket conveyer by the chute. The
ash conveying time and frequency of each ash-collecting box are controlled by time. The charge
level indicator is installed at the top of the ash-collecting box. The high material level detected by
the charge level indicator will be displayed at the central control. If the high material level is
stilled detected after 3 discharge circulations, the alarm signal will be issued to notify the worker to
check and handle it. The second part is the ash system installed at the bottom of the 2# grate bed,
which is called the Slide Gate system for short. This system sets up 6 ash-collecting hoppers
equipped with 6 air-operated gates at the bottom of 3 air chambers of the 2# grate bed. When the
gate valve is opened, the ash deposit will fall into the clinker bucket conveyer directly. The opening
of the gate valve could be controlled by the material level or by time. If the material level control is
adopted, the control method is as follows: The opening time and opening frequency of each gate
valve of the ash-collecting hopper are controlled by time. The charge level indicator is installed on
the top of the ash-collecting hopper, and when the charge level indicator detects the high material
level, the gate valve will also be opened. And, the time control will be reset automatically. If the
opening time of a bunker gate is too long, the alarm signal will be issued, and the gate valve must
be examined rapidly. If the signal of high material level has existed for 10 circulations successively,
the system will also issue the alarm. If the time control is adopted: The fixed opening time and
time-delay of each gate valve are set up. While the opening time plus the time-delay is the time
being monitored. If the time monitored is overtime, the alarm signal will be issued to notify the
worker to examine and handle it. If the high material level occurs between openings of the gate
valve, the gate valve will also be opened automatically.
5) 空气炮系统 Air Cannon System
在篦冷机的进料端设有 11 台空气炮，其中两台 8 升的空气炮为窑头密封装置灰斗的卸灰管清堵。

9 台空气炮为篦冷机 KIDS1#部分的清大块和过度的料堆。空气炮的运行分自动和手动两种模式。当
选用自动模式时，每台空气炮的运行会按设定的程序进行。选择手动模式，可有选择的运行。正常
情况下，选用自动模式。非正常情况下，选择手动模式。
11 sets of air cannons are installed at the feed end of the grate cooler, among others, 2 sets of
8-litre air cannons are used for blocking-clearing of the ash-discharge pipe of the ash hopper of
the sealing device of the kiln outlet.9 sets of air cannons are use for clearing large pieces and
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excessive material piles for the KIDS1# part of the grate cooler. The operation of the air cannon
has two modes, the automation and hand motion. When the automation mode is selected, each air
cannon will run according to the setting program. When the hand motion mode is selected, the air
cannons could be operated by selection. Under normal circumstances, the automation mode
should be selected. Under abnormal circumstances, the hand motion mode should be selected.
6) 控制系统组成 Composition of the Control System
控制系统是按篦冷机的功能划分成：篦床驱动系统、辊式破碎机系统、输灰系统、空气炮系统
几个独立的控制系统，并把相关联的联锁信号联系起来，组成篦冷机的控制系统。
According to functions of the grate cooler, the control system is divided into several independent
control systems: the grate bed driving system, roller crusher system, ash conveying system and
air cannon system. Relative interlocking signals of these systems are connected with each other,
thus forming the control system of the grate cooler.
3.5.3.3 开机前的准备 Preparation before Startup
1) 篦冷机的本体 Main part of grate cooler
a. KIDS1#部分的所有调节板全开，Y 形风管的所有调节板置于中间位置。
a. All adjustable plates of the KIDS 1# part and all adjustable plates of a Y-shape air duct
shall be placed at a middle position.
b. 冷却机冷却区域内的卸灰滑动门全部开着。
b. All the ash-unloading slide gate inside a cooler’s cooling realm shall be open.
c. 风机启动前应除去砌筑时留有的杂物。
c. The dopants left during masonry shall be removed before a fan starts.
d. 清除沾粘在篦缝周围的杂物，尤其注意清除掉篦缝中的焊条、钢片等。
d. Clear away the dopants stuck around a grate seam, especially the welding rods, sheet
steel, etc. dropped into a grate slot.
e. 再按风机所管辖的区域，开足风机，用软木锤敲打篦板两侧，通过振动和风机的喷吹力，进
一步清除沾粘在篦缝周围的杂物，保持篦缝清洁、整齐。但要注意敲打的力度，以免损坏篦
板。
e. Aiming at the realm controlled by a fan, turn on the fan to the full extent, use a soft wood
hammer to knock the two sides of a grate plate and by relying on vibration and the spray
blowing force of the fan, further clear away the dopants stuck around the grate slot so as
to keep the slot clean and tidy. But it is necessary to note the strength of the percussion in
order to avoid damaging the grate plate.
f. 在烘窑阶段应在 KIDS 部分覆盖上 20~30mm 厚的碎耐火砖或冷熟料，以避免烘窑的高温辐

射热损坏喷嘴。
f. At the stage of drying and heat-up the kiln, the KIDS part shall be covered with 20~30
mm-thick rubble firebrick or cold clinker to prevent the high-temperature radiant heat from
drying the kiln from damaging a nozzle.
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g. 严禁点火的油滴入未覆盖料的篦板上，以免堵死篦缝。
g. Strictly forbid the ignition oil dropping into a grate plate that is not covered with a material
in order to avoid stop up a grate slot completely.
h. 进行完上面的工作后关闭所有检修门。
h. Close all access doors after finishing the above operations.
2）篦床驱动系统 Grate bed drive system
a. 确认泵的接线和旋向正确
a. Make sure that the wiring and revolving direction of a pump are correct.
b. 确认篦床驱动系统的管路、储压罐、驱动液压缸等已清洗完毕并确认不泄漏，然后按要求重
新注油。
b. Make sure that the pipeline, pressure storage tank, hydraulic drive cylinder and so on for
a grate bed drive system have been cleaned and confirm no leakage, and then afresh
inject oil as required.
c. 液压系统脱气、篦板驱动液压缸系统的压力试验、系统中减压阀的调整完成。
c. The degassing of the hydraulic system, the pressure test for the grate drive hydraulic
cylinder system, and the adjustment of a reducing valve in the system has been
completed.
3) 辊式破碎机 Roller Crusher
a. 辊式破碎机设有远程控制面板和就地控制面板，检查控制面板上的显示信号灯是否完好。单
个启动每一个辊，检查辊的旋向，确认实际旋向三统一。即实际旋向与远程控制面板与就地
控制面板显示统一。
a. The roller crusher is equipped with a remote control panel and a local control panel.
Check whether the signal display lamp on a control panel is intact or not. Start a single
roller, check the revolving direction of the roller, and make sure that an actual revolving
direction and what are displayed on the remote control panel and on the local control
panel are unified.
b. 确认水冷却、风冷却、油润滑管线的连接完好，无泄漏。
b. Make sure that the connection of the water cooling, air cooling and oil lubrication pipe
lines is intact and they have no leakage.
c. 确认破碎辊的过载保护、速度检测、轴承的温度检测装置有效、显示正确。
c. Make sure that the overload protection of a crushing roller, speed examination and a
bearing temperature-detecting device are effective and have correct displays.
d. 确认破碎机已回复到它的运行位置，并已按规定固定。
d. Make sure that a crusher has already returned to its operating position and has been fixed
by rule.
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4) 输灰系统 Ash Conveyance System
a. PHD 系统的阀门、管线、控制信号的调试已完成并确认符号规定要求；
a. The debugging of a valve, pipe line and control signal of the PHD system has already
been completed and make sure that the debugging meets the specified requirements;
b. 确认 PHD 系统中的料位计有效，信号正常。
b. Make sure that the charge level indicator of the PHD system is effective and its signals
are normal.
c. 灰斗卸灰的滑动门轨道、导向螺栓、滑板运行正常，密封正常；
c. The unloading slide door track, guide bolt and sliding plate of an ash hopper shall function
and shall be sealed normally;
d. 确认管线连接完好，无泄漏，压缩空气的供气压力符合要求。
d. Make sure that the connection of the pipe line is intact and has no leakage, and the
compressed air supply pressure meets the requirements.
e. 确认料位计有效且信号正常，接近开关和电磁阀信号正常，控制系统显示与现场一致。
e. Make sure that the charge level indicator is available and its signals are normal, a
proximity switch and a solenoid valve have normal signals, and the control system display
is consistent with that on the site.
f. 两套输灰系统符合运行要求。
f. The two ash conveyance systems shall meet the service requirements.
a. 确认管线连接完好，无泄漏；
a. Make sure that the pipe line connection is intact and has no leakage;
b. 控制系统工作正常；
b. The control system shall work normally;
c. 压缩空气的供气压力符合要求。
c. The compressed air supply pressure shall meet the requirements.
6) 控制系统组成 Control System Composition
a. 确认控制系统信号正常，远程、就地、现场信号一致；
a. Make sure that the control system has normal signals, and its remote, local and site
signals are consistent;
b. 控制面板显示信号正确。
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b. The control panel shall display correct signals.
3.5.3.4 启动程序 Startup Procedure
在熟料的输送、余风收尘器、窑头排风机启动完毕后，篦冷机系统正常的组启动顺序如下：
冷却风机#11~#14→冷却风机#4~#10→冷却风机#1~#3→篦床＃2 的液压驱动→辊式破碎机→
篦床＃1 的液压驱动→滑动门，PHD→空气炮单元
正常的组停机顺序与上述顺序相反。
After the clinker conveyance, dust catchers and vent air fan have been started, the grate cooler
system’s normal group startup sequence is as follows:
Cooling fans #11~#14 → cooling fans #4~#10 → cooling fans #1~#3 →grate bed #2 hydraulic
drive →roller crusher →grate bed #1 hydraulic drive →slide door, PHD →air cannon unit
The normal group closedown sequence is contrary to the above-mentioned sequence.
1) 篦冷机的本体 Main Part of Grate Cooler
a. 设备启动前一定要关闭所有检修门
a. Before equipment startup, you must close all access doors.
b. 在窑的点火、烘窑阶段，如果需要开冷却风机，应该开 KIDS1#部分后面的风机，作为燃烧
用空气。
b. If at the stage of kiln ignition and drying, it is necessary to turn on cooling fans, you should
turn on those at the back of the KIDS 1# section to provide combustion air.
c. 窑在升温阶段要注意，如果喷嘴的温度上升至 80℃，应启动风机，并在最小流量下运行。
c. At the stage of kiln temperature rise, it is necessary to note that if the temperature of a
nozzle rises to 80 ℃, you should start a fan and have it run at the lowest flow rate.
d. 当 KIDS1#部分的熟料堆到 1.5m 时，应启动 KIDS1#部分的 3 台冷却风机。
d. When the clinker at the KIDS 1# part has been piled up to 1.5 m, you should start 3
cooling fans at the KIDS 1# part.
e. KIDS1#部分的冷却风机流量调节应参照 IKN 提供的流量曲线或由按 IKN 的调试工程师指定

的要求进行。
e. The cooling fan flow control of the KIDS 1# part shall conform to the flow curves that IKN
provides or to the requirements that IKN debugging engineers designate.
f. 如果熟料被吹离 KIDS 表面，应减少风机的供风量，保持住熟料在 KIDS1#上的斜坡。
f. If clinker is blown off the KIDS surface, you should slash the fan air volume to retain the
slope of the clinker on KIDS 1#.
g. 注意推动篦床的速度、风机、空气炮调节应适当，使熟料层能覆盖住 KIDS1#部分的篦板，
而不至于烧坏篦板。
g. Note that the adjustment of a speed for pushing a grate bed, of a fan and of an air cannon
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should be appropriate, making a clinker layer able to cover the grate plate of the KIDS 1#
part so as not to burn down the grate plate.
h. 在开始阶段，如果需减小 KIDS1#部分的料堆高度，可加快 1 段篦床的推动速度。
h. If at the beginning stage, it is necessary to reduce the material stack height of the KIDS
1# part, you may quicken the pushing speed of the section-1 grate bed.
i. 在操作期间，所有的冷却风机调节必须按 IKN 提供的流量曲线或由按 IKN 的调试工程师指定

的要求进行。
i. During the period of operation, the adjustment of all cooling fans shall conform to the flow
curves that IKN provides or to the requirements that IKN debugging engineers designate.
j. 当窑连续输出熟料时，篦速的调节必须按 IKN 制订的要求或按 IKN 的调试工程师现场给定的

要求进行。
j. While the kiln is outputting clinker continuously, the adjustment of a grate speed shall
conform to the flow curves that IKN provides or to the requirements that IKN debugging
engineers designate on the spot.
k. 为保证最优化的篦冷机操作，每次只能调整一个参数，等待结果，这样窑和冷却机的操作才
能稳定。
k. In order to ensure the optimal operation of a grate cooler, only one parameter may be
adjusted each time to wait for a result so that the operation of the kiln and the cooler can
be stabilized.
2) 篦床驱动系统 Grate bed drive system
a. 篦床的驱动是通过 1#、2#液压缸推动篦床 1#，3#液压缸推动篦床 2#实现的。汽缸的冲程

由比例阀、电磁位移测量、控制阀等组成的油路系统通过 PLC 实现篦床的运动控制。
a. The grate bed drive is realized by hydraulic cylinders 1# and 2# pushing grate bed 1# and
hydraulic cylinder 3# pushing grate bed 2#.The stroke of the cylinder is measured by a
proportioning valve and electromagnetic displacement. The oil route system consisting of
control valves, etc. uses PLC to realize the motion control of a grate bed.
b. 操作中只要根据篦床 4#风室的显示压力，来设定 1#篦床的速度。而两者的关系按 IKN 提供

的压力与 1#篦床速度曲线即 P~GS 曲线调节。或者按窑产量与对应的 1#篦床速度的样板表
格调节。
b. In operation, it is necessary to set the speed of grate bed 1# according to a pressure

value displayed at the grate bed 4# air chamber. The relations between the two shall be
adjusted according to the pressure and 1# grate speed curves or P~GS curves provided
by IKN or to the model table of the kiln outputs and their corresponding 1# grate bed
speeds.
c. 2#段篦床速度按照 1#段篦床速度的相关比例因子自动或手动调节。
c. The speed of grate bed 2# shall be adjusted automatically or manually according to 1#

grate bed speed-related scale factors.
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d. 在篦床运动过程中的温度、压力、油位的监控由控制系统自动实现，但控制系统一旦发出报
警，必须及时采取相应的排除措施。
d. The monitoring and control of the temperature, pressure and oil level during the process
of the grate bed motion are automatically realized by the control system, but once the
control system sends out an alarm, it is necessary to take corresponding measures in
time for troubleshooting.
a. 辊式破碎机内部的启动程序：
a. Inner startup procedure of roller crusher:
b. 启动水冷却系统→启动冷却风机→按标准操作启动辊破→由 DCS 显示辊的旋向→显示辊子

的电机电流→查看电机温度的监视→查看速度监测→查看轴承温度监测→查看水温和流量
监测
b. Starting water cooling system →starting cooling fan →starting roller crusher pursuant to
standard operation →DCS displaying the revolving direction of roller→displaying the
current of roller electric motor →looking into electric motor temperature monitoring
→looking into speed monitoring →looking into bearing temperature monitoring →looking
into water temperature and flow rate monitoring
c. 辊式破碎机在运行过程中，若遇大块、或铁块辊的电机会有过载报警，若在自动控制模式，
过载辊会自动执行过载保护操作。若在手动控制模式，必须手动执行过载保护操作。
c. If during operation, a roller crusher meets a big chunk or iron cake, the roller’s electric
motor will send out an overload alarm. In the automatic control mode, an overloaded roller
will run the overload protection automatically. In the hand control mode, hand operation
shall be used to run overload protection.
d. 辊式破碎机的控制系统设有远程控制和就地控制，轴承温度、电机温度、速度、润滑、油位、
水温、水量等均由控制系统进行实时监控，控制系统一旦发出报警，必须及时采取相应的排
除措施。
d. The control system of a roll crusher is equipped with remote control and local control. The
bearing temperature, electric motor temperature, speed, lubrication, oil level, water
temperature, water amount, etc are all under the real-time monitoring of the control
system.
a. 篦床 1#的 PHD 系统卸灰和篦床 2#的灰斗移门卸灰系统都配有自动控制系统，根据时间或

料位控制卸料，并对系统的运行实时监控。
a. The ash-unloading system of grate bed 1# PHD and the grate bed 2# ash hopper slide
door ash-unloading system all have automatic control systems. Discharging shall be
controlled according to time and charge levels and the system operation shall be under
real-time monitoring.
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b. 当篦冷机接到启动命令，该系统按规定的开机顺序启动该系统，并选择自动模式。
b. When a grate cooler receives a startup command, the system will be started according to
stipulated startup sequence and select the automatic mode.
c. 只要 2#、3#冷却风机的压力大于等于 50mbar 时，PHD 系统就能启动工作。对灰斗滑动门

卸灰系统而言，只要压缩空气供气正常系统就能启动工作。
c. As long as the pressure of cooling fans 2# and 3# is greater than or equal to 50 mbar, the
PHD system can start operation. For the ash-unloading system of a ash hopper sliding
door, as long as compressed air supply is normal, the system can start operation.
d. 运行中控制系统一旦发出报警，必须及时采取相应的排除措施。
d. Once the control system in operation sends out an alarm, it is necessary to take
measures for troubleshooting.
e. 在输灰系统工作时，有粉尘逸出。检查排障时必须戴上安全手套和防尘面具。
e. As an ash conveyance system works, dust escapes out. During inspection and
troubleshooting, it is necessary to wear safety gloves and dustproof masks.
窑系统为冷窑点火或非正常运行时可选择手动模式，窑运行正常时选择自动模式。按规定的
开机顺序启动该系统。
You may select the manual operation mode when the kiln system ignites a cold kiln or there is an
abnormal operation. When the kiln runs normally, select the automatic mode. Start the system
according to the stipulated startup sequence.
3.5.3.4.运行维护、停机维护及注意事项 Running Maintenance, Shutdown Maintenance and

Points for Attention
1) 篦冷机本体及用风 Main part of grate cooler and air use
a．正确的调节用风量，能使熟料均匀散布到后面的 1#移动篦床上。通过改变两侧的用风量能
使 KIDS1#左右的粗细料均匀分布，来回调节 Y 形风管的挡板，可调节左右边的供风。
a. Correctly adjust an air use volume to make clinker evenly spread on the 1# movable grate
bed at the back. Changing the two sides’ air use volumes can make the thick and thin
materials on the left and right sides of KIDS 1# uniformly distributed. Adjusting the baffle
of the Y-shape air duct backward and forward can regulate the air supply on the left and
right sides.
b．增加供风的一边会使料堆变得平坦，减少供风的一边会使料堆变的陡峭。
b. The side with increased air supply will make a material stack become flat while the side
with decreased air supply will make a material stack become steep.
c．当料床上的料层厚度均匀，则调节就完成，熟料的冷却也变得均匀。
c. When the material layer thickness on a bed becomes even, then the adjustment will be
terminated and the cooling of the clinker will also become even.
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d．熟料的粒度因煅烧条件的变化会改变。（如临时的冷窑或改变燃料）细的熟料流动性好，因
此，在 KIDS1#面上向下的输送速度快，KIDS1#上的保护熟料层会减薄，从而引起喷嘴的温
度提高。
d. The fineness of the clinker will vary with the change of calcination conditions, such as a
temporarily cold kiln or the alteration of fuel. Thin clinker has good liquidity, therefore, the
downward conveyance speed on the KIDS 1# surface is quicker, and a protected clinker
layer on the KIDS 1# will become thin, thus raising the temperature of a nozzle.
e．如果 KIDS1#的喷嘴温度超过 80℃，KIDS1#区的风机供风量每次按 10%的速率减少。
e. If the KIDS 1# nozzle temperature is more than 80 ℃, the air supply volume of the KIDS
1# area’s fans will be reduced at a rate of 10% each time.
f．如果 KIDS1#的风机流量减少了 30%以后，篦板温度仍不能降低，则应降低 2#段篦床的推

动速度。
f. If after the KIDS 1# fans’ flow rates have been slashed by 30%, the rate plate temperature
is still unable to be stepped down, then the pushing speed at section 2# shall be lowered.
g．如果 1#段篦床的喷嘴温度超过 80℃，则应降低 1#段篦床的推动速度。
g. If the nozzle temperature at section 1# grate bed is more than 80 ℃, then you should
lower the pushing speed of section 1# grate bed.
h．在自动模式下，篦床的推动速度由 KIDS1#后的 1#室的篦下压力控制。篦床上的料床厚度应

该恒定，并保证空气和熟料的热交换最佳为宜。
h. In the automatic mode, the pushing speed of a grate bed is controlled by the pressure
under the grate of 1# chamber at the back of KIDS 1#.The material bed thickness of a
grate bed shall be constant, and it shall be ensured that the heat exchange between the
air and the clinker will be the best.
i．如果 1#室的篦下压力增加，说明料床厚度增加，则篦床推动速度要增加。
i. If 1# chamber’s under-grate pressure is increased, it will be shown that the material bed
thickness has been increased, and the grate bed pushing speed shall be increased.
j．注意：如果通过流量控制的冷却风机的流量恒定，篦床速度控制是唯一的。如果 1#室的用
风量增加，则会引起压力增加，也会引起篦床速度加快，则无故导致料床变薄。
j. Note: If a cooling fan flow rate with flow rate control is constant, the grate bed speed
control is exclusive. If 1# chamber’s air use volume increases, it will cause pressure to
increase, and will also cause the grate bed speed to be quickened, thus leading to a
material bed becoming thin without cause.
2) 液压驱动系统 Hydraulic drive system
a．液压系统在运行时或断开后都处于高压状态，只有等关闭、卸压、冷却后才能进行维修。
a. The hydraulic system is placed in a high-pressure status while it is in operation or is

powered off. Only after shutdown, pressure unloading and cooling will repair and
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maintenance be allowable.
b．在篦床驱动液压缸脱气时，禁止从冷却机的上部或下部进入篦床和风室。
b. During the degassing of a grate bed drive hydraulic cylinder, entering the grate bed and
air chamber from the upper part or the lower part of a cooler is prohibited.
c．在液压系统脱气和进行压力测试时，油有可能喷射出来，小心受伤！戴上防护手套和防护目
镜。
c. During the degassing of the hydraulic system and a pressure test, oil may be ejected.
Take care not to get hurt! Put on protective gloves and goggles.
d．在每次计划停窑前，做好液压管路泄漏和损坏的检查工作。
d. Before planning to stop the kiln each time, check whether the hydraulic pipe line has
leakage and damage.
e．长时间停窑，应排出油/水冷却器和管道中的水，然后用压缩空气清除残余的水。而在霜冻
天气下必须做。
e. If the kiln is not in use for a long time, you should discharge the water in an oil/water
cooler and pipe line and then use compressed air to clear away the remaining water. It
must be done in frosty weather.
f．清扫液压动力机组时不要用棉线清扫容器和零件，因为细线会破坏系统。用清扫刷或无绒毛
的抹布和煤油或汽油。
f. During cleaning a hydraulic dynamic machine, do not use cotton threads to clean a
container and accessory because the fine threads will damage the system. Use cleaning
brushes or downless duster cloth added with kerosene or gasoline.
g．油过滤在第一次运行 100 小时和以后每运行 3000 小时，过滤器都需检查。如果需要，应更

换。
g. After operation for 100 hours for the first time or operation for every 3000 hours since the
first time, an oil filter shall be checked. It shall be replaced when necessary.
h．每月检查油位。如果需要，通过 10μm 的过滤器重新注油。在试运转时，经常地检查油位，

来判断油在管道、液压气缸的损失和泄漏。
h. Check the oil level monthly. If necessary, the 10 μ m filter will be used for injecting oil
afresh. Often check the oil level during a test run to judge the oil loss and leakage in a
pipeline and a hydraulic cylinder.
i．在第一次运行 500 小时后应换油；在此之后每运行 2000 小时检测油一次，如果需要，应更

换。
i. Change oil after operation for 500 hours for the first time. Examine oil once after operation
for every 2000 hours since the first time. Replace the oil if necessary.
j．注油通气阀必须每年更换一次。
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j. An oiling vent valve shall be replaced once each year.
k．油/水冷却器的维护只能在水回路无压状态进行，测压仪必须显示在 0bar。
k. The maintenance of an oil/water cooler will only be done in the status that the water loop
has no pressure, and a load cell shall be shown at 0 bar.
l．储气罐、油罐、储压罐、油泵、驱动汽缸的维护、更换必须参照相关的操作手册，按规定程
序进行。
l. The maintenance and replacement of a gas tank, oil tank, pressure tank, oil pump or drive
cylinder shall be according to a related run book and shall be done pursuant to a
stipulated procedure.
a．注意检查所有破辊轴承温度的监测，检查集中润滑的操作是否恰当，风冷和水冷的操作是否
恰当；
a. Monitor the temperatures of all crushing roller bearings and check whether the operation
of the concentrated lubrication is appropriate and the operation of the air cooling and
water cooling is appropriate;
b. 注意检查中间的辊在过流的情况下能够反转；
b. Make sure that an intermediate roller can turn over under the circumstance of
overcurrent;
c. 遇有较长的停窑时间应对辊圈和硬面进行检查，每年至少应检查一次，IKN 推荐，满负荷一
年，辊硬面应更换
c. If the kiln is not in use for a long time, we should check the roller rings and hard surfacing,
which shall be done once at least every year. IKN recommends that a roller hard surfacing
be replaced after one year of full load.
d. 齿轮装置应按规定时间和要求换润滑油
d. For a gear unit, replace lub oil pursuant to stipulated time and requirements.
e. 油量、类型、换油周期参看技术数据表，换油间隔对操作条件的影响参看齿轮装置说明书
e. For an oil quantity, type, oil changing period, refer to technical data tables. For the
impacts of oil changing intervals upon the working conditions, refer to a gear unit manual.
f. 停机换油时，由于润滑油温度高，当心烫伤，操作时必须穿戴防护用品。
f. Beware of burn when stopping the machine for oil replacement as the lub oil temperature
is high. It is necessary to wear protective supplies during operation.
g. 拆装后辊轴密封套一定要紧固。如果密封套内钻入熟料粉尘，必须清理后重新固定。
g. The dismantlement or installation of a rear roller sealing sleeve shall be fastened. If

clinker dust has entered the sealing sleeve, it is necessary to reinstall it after cleanup.
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h. 为了修理、维护需要，破碎机需拉到它的维修位置，或破碎辊磨损后需更换，此时的拆装和
复位操作必须按设备的操作说明书进行。
h. For the sake of repair and maintenance, a crusher shall be pulled to its repair position.
When a crushing roller needs replacement after abrasion, the dismantling, installing and
resetting operations shall conform to an equipment operating manual.
i. 复位后的破碎机调试前，应检查确认齿轮装置的润滑油是否加。
i. Before debugging a crusher after being reset, check whether the lub oil of a gear unit has
been added or not.
j. 复位后的破碎机应先通过试运行检查各项功能，才能投入正式生产。
j. A crusher after being reset shall first pass a test run to check various functions before
being put into formal production.
k. 如果破碎机较长时间停止工作，必须排空辊内和软管中的冷却水，以防冷却水结冰冻坏冷
却水管。
k. If a crusher is not in use for a long time, it is necessary to empty a roller and hose of
cooling water in order to prevent the cooling water from freezing and frosting a cooling
water pipe.
l. 集中润滑是为球形滚珠轴承和破碎机的迷宫密封服务的。该集中润滑的控制与破碎机一起启
动。
l. Concentrated lubrication serves the labyrinth seal of a spheroid ball bearing and a crusher.
The control of the concentrated lubrication is started together with a crusher.
m. 给集中润滑的储油器加油，必须停电源，以防旋转搅动可能会引起伤害。油的要求见技术
参数规范，油不能被污染。
m. Oiling an oil receiver in concentrated lubrication will demand the power supply to be cut
off in order to prevent revolving agitation from causing harm. For the oil requirements, see
the technical parameter specifications, and the oil shall not be polluted.
n. 如果在加油前储油器已完全空，加油后则应该保持 10min，直到泵恢复它的全部输出。
n. If before oiling, an oil receiver has been completely empty, 10 min shall be reserved after
oiling until a pump restores all its output.
o. 集中润滑通过泵和泵元件把送给润滑给油器，由给油器把油脂通过活塞的动作。将油脂慢慢
地送到给油器的各出口即分配到轴承和破碎机的迷宫密封，每个活塞的动作都有一个接近开
关监控，如果出现堵塞和储油器空，接近开关就不能探测到活塞的运动，将发出报警。此时
必须处理。
o. Concentrated lubrication uses a pump and pump elements to pass grease to an oil feeder,
which relies on the motion of a piston to slowly send grease to each outlet of the oil feeder,
namely the labyrinth seal of the bearing and the crusher. The motion of each piston has a
proximity switch for monitoring. If blockage appears and an oil receiver is empty, the
proximity switch can not detect the motion of a piston and will send out an alarm.
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Treatment shall be given at this time.
a. PHD 系统如果不再有料传输，在通常情况下冷却机操作中也能清除堵塞。气动滑动闸门在
维护期间应保持关闭，然后必须按 IKN 的操作说明书执行。
a. If the PHD system no longer has material conveyance, under a general condition, the
operation of a cooler can also clear away blockage. A pneumatic slide gate shall be kept
closed during maintenance. Then observe the IKN operating manual.
b. 冷却机操作中的清堵应注意在滑动闸门阻断热熟料、排料管内熟料冷却后进行，以免烫伤。
b. Clearing away blockage in the operation of a cooler shall be conducted after the slide gate
has blocked off hot clinker and the clinker in a discharging pipe has been cooled in order
to prevent burn.
c. 灰斗滑动门卸灰系统在维护或检查以前，压缩空气的供气开关必须关，并确保不能启动。
c. Before maintenance and inspection of an ash hopper slide door ash unloading system,
the air supply switch for compressed air shall be off and no startup shall be ensured.
d. 移门工作时，会有粉尘串出，现场工作必须穿戴防护手套和面罩。
d. While a movable door is working, dust will come out. For site work, wear protective gloves
and masks.
e. 每次停窑期间，必须检查滑板的滑轨和导向螺栓，以免磨损，必要时更换；检查滑板的泄
漏、螺旋连接、供气管线、接近开关和电磁阀。
e. During kiln closedown each time, it is necessary to check a sliding track and a guide bolt
of a slide plate in order to prevent abrasion. Replace it when it's necessary. Check
whether a slide plate has leakage. Check screwed connection, an air supply pipeline, a
proximity switch and a solenoid valve.
f. 注意检查密封，如有泄露，密封应重新调节。
f. Check sealing. If there is leakage, sealing shall be readjusted.
g. 在长时间停窑时，所有的仓斗和排料管道都需排空，以免形成涂层而堵塞管道。检查所有
仓斗是否全部清空。
g. While the kiln is not in use for a long time, all hoppers and discharging pipes shall be
emptied in order to avoid forming a coating to block a pipeline. Check whether all hoppers
are emptied.
3.5.3.5 常见故障分析及处理 Common Fault Analysis and Treatment
当生产过程中出现故障时，需根据不同的情况区别对待，重大的问题必须经过使用单位，制造
单位和设计单位共同调查、分析原因，商讨处理办法。下面对常见故障产生原因及处理方法作一简
叙：
If a fault appears in a procedure in production, it shall be differentiated according to a different
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circumstance. For an important question, a user, manufacturer and designer shall investigate and
analyze the cause, and discuss a treating way together. The causes and treatment processes of
some common faults and their causes are briefly described as follows:
Common Fault Cause Treatment Process
红河粗、细料不均匀，并被分离。 1．通过调节 KDS1#l 两侧的用风比例；
Red river Thick and fine materials are 2．减少外侧用风或增加中间的用风；
nonuniform and are separated.
3．如果是进口形状不合适，应在下次停
窑期间调成适合的形状，必要时不对称
也可以。
1.Adjust KDS 1# two sides’ air
proportions;
2.Reduce outside air or increase
intermediate air;
3.If an inlet shape is unsuited, adjust it
into a suitable shape while the kiln is
stopped next time, and unsymmetry
may also be allowable when
necessary.
堆雪人 1．细料、料粘 1．缩短空气炮运行的时间间隔，消灭大
Snowman 2．掉窑皮、结大块块；
1.Fine materials are glued; 2．当雪人是因为细料形成时，应增加
2.Kiln skins are dropped and formed KIDS1#的风机流量。
into big pieces.
3．转换空气炮开关到手动模式，选择射
击，并调整 KIDS1#区风机的供风量和比
例。
4．如果这些操作不能成功，延长操作也
无可能性，则必须停窑，冷却后人工处
理雪人。
5．必要时在停窑期间重新排列空气炮，
以便今后处理大块更有效。
1. Shorten the time interval of air
cannon operation and destroy big
pieces;
2. If the snowman is formed by fine
material, increase the KIDS 1# fan flow
rates.
3. Convert the air cannon switch into
the manual mode and select Shoot,
and adjust the KIDS 1# area’s fan air
volume and proportion.
4.If these operations are unsuccessful
and lengthening operation is also
impossible, then stop the kiln, and after
cooling, manually treat the snowman.
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5. When it's necessary, rearrange the
air cannon during a kiln shutdown so
that big pieces will be treated more
effectively from now on.
跑生料 1．窑操作不当 1．窑必须打慢车或停窑。
Kiln rushes 2．原、燃料成分突然改变，条件混乱 2．篦冷机尾部的熟料温度高并继续延
1.The kiln does not working 伸，篦板速度必须被减（转手动）或停，
appropriately. 以保护破碎机或熟料输送设备。
2. The ingredients of a raw material 1.The kiln must be set to Slow Run or
and fuel change suddenly and the Stop.
conditions are in confusion.
2. If the temperature of the clinker in
the rear of a grate cooler is high and
continues to rise, the grate plate speed
shall be reduced (Use hand operation)
or stopped to protect a crusher or
clinker conveyer.
储油器空。给储油器加油。并注意除去泵内的空气。
集中润滑的泵不 The oil receiver is empty. Inject oil to the oil receiver and remove
能工作 the air inside a pump.
A pump for 油脂内混有空气。启动中间的润滑。松开出口的减压阀，
concentrated 等待直到油内的气泡排出。
Grease inside has air.
lubrication can
not work. Start intermediate lubrication, loosen
the outlet reducing valve and wait until
the bubbles in the oil are discharged.
用了不适合的油。换油 Change oil.
Oil out of character is used.
泵元件的吸入孔被堵塞。卸下泵元件，清洁吸入孔。
Pump elements suction-eyes are Remove the pump elements and clean
stopped. the suction eyes.
泵元件的活塞磨损。换泵元件。
The piston of a pump elements is Change the pump elements.
abraded.
检查泵元件的止回阀是否有缺陷和堵换止回阀。
塞。 Change the nonreturn valve.
Check whether the nonreturn valve of
a pump elements has flaws and
blockage or not.
集中润滑系统堵润滑点、管子、给油器堵塞。 1．修理或换堵塞的给油器
塞 A lubrication point, pipe or oil feeder 2．检查止回阀，必要时更换。
The is blocked.
3．检查管路，排除堵塞
concentrated
lubricating 1.Repair or change the blocked oil
system is feeder.
blocked. 2.Inspect a nonreturn valve. Replace it
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when it's necessary.
3. Inspect a pipe line and rule out a
blockage.
PHD 系统没有料排料管堵塞。清除堵塞。
传输 The PHD system has no material Clear away the blockage.
The PHD system conveyance.
has no material
conveyance.
1．检查气缸
滑板不能到达最终的位置。 2．检查供气的管线
灰斗滑动门卸灰 The slide plate can not arrive at the
3．检查电磁阀
系统滑动故障 final position.
4．检查滑板是因为积料或大块卡住
The ash hopper
slide gate 1.Inspect the cylinder.
ash-unloading 2. Inspect the air supply pipe line.
system slides 3.Inspect a solenoid valve.
with failure.
4. Check whether a slide plate
accumulates material or is blocked by
big pieces.
滑板不能运动。 1．检查供气的管线
The slide plate can not move. 2．检查密封是否太紧
3．检查滑板是因为积料或大块卡住
1.Inspect the air supply pipe line.
2. Check whether the sealing is too
tight or not.
3. Check whether a slide plate
accumulates material or is locked by
big pieces.
3.5.4 电收尘器 Electrostatic Precipitator
3.5.4.1 设备规格、参数 Equipment Specifications and Parameters

编号 No.： 447EP1/448EP1
用途 Use：窑头废气电收尘 Electric kiln outlet gas
dust collection
型号 Model： 2×31/12.5/5×8/0.45 1/4（上进气，水
平出气）(Upper air entry, horizontal air
exit)
处理风量 Treated air volume： 1，100，000m3/h
废气温度 treated air temperature： 250（max450℃）
入口废气含尘浓度 Inlet gas dust ≤80g/Nm3
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concentration：
出口废气含尘浓度 Outlet gas dust ≤20mg/Nm3
concentration：
设计压力 Design pressure：－4000 Pa
设计阻力 Design resistance： ≤250 Pa
横断面积 Cross sectional area： 361 m2
电场风速 Electric field air speed： 0.85m/s
3.5.4.2 开停机顺序及注意事项 Startup or Closedown Sequence and Points for Attention
开机顺序：加热器先开，再按顺控开输出前端设备；通烟气加热电场，待电场内部温度高于露
点后，向电场送电。
Startup sequence: Turn on the heater first, and then follow the sequential control to turn on
the front output equipment; Send heated air for heating the electric field, and after the inner
temperature of the electric field is higher than the dew point, send electricity to the electric
field.
停机顺序：停止向电场供电，2 小时后，停振打装置，待物料送完按顺控次序停输送设备。
Closedown sequence: Stop power supply to the electric field. After 2 hours, stop a vibrating
apparatus, and after materials have been sent, follow the sequential control order to stop a
conveyer.
注意事项：Notes for Attention:
除紧急停运外，不论是第一次停运还是以后的正常停运，均应按以下要求进行。
Except for an emergency shutdown, either the first time’s shutdown or a later normal shutdown
shall conform to the following requirements.
1) 确认工艺系统已允许电收尘器停运。
1) Make sure that the process system has already allowed an electrostatic precipitator (EP)
to stop running.
2) 停止向电场供电。
2) Stop power supply to the electric field.
3) 切断主回路和控制回路的电源。
3) Cut off the power supply of the major loop and the control loop.
4) 如停机时间超过 8 小时或要进行设备检修，应将隔离开关切换到电场和变压器的高压输出均
接地的位置，并在各电控柜和高压隔离开关切换手把处挂“警示牌”，保管好安全联锁钥匙。
4) If the time for a shutdown is over 8 hours or an equipment overhaul is needed, you should
cut over the isolating link to the position for the high-voltage outputs of the electric field
and the transformer to be grounded, hang a warning sign on the changeover handle bar
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of each electric control cabinet and each high-voltage isolating link, and take good care of
the safety interlocking key.
5) 停止向电场供电后，应继续运行各振打装置和输灰装置 2-4 小时，以确保电场内和灰斗内的

粉尘彻底排出。输灰装置应在振打装置停止运行后继续运行 0.5 小时。
5) After stopping power supply to the electric field, continue to run each rapping apparatus
and ash conveyance apparatus for 2-4 hours to ensure that the dust inside the electric
field and an ash hopper has been discharged thoroughly. The ash conveyance apparatus
shall continue to run for 0.5 hour after the rapping apparatus stops running.
6) 如停机时间超过 24 小时，则在停止向电场供电的同时可切断电加热器电源。
6) If the shutdown time exceeds 24 hours, cut off the power supply to the electric heater at the time
of stopping power supply to the electric field.
3.5.4.3 电收尘器的投运 Putting Electrostatic Precipitator into Operation
1) 电收尘器投运前应提前 4 小时将全部电加热装置送电加热。投运前应将全部的振打装置和下
游的输排灰装置启动并运行正常。
1) Within 4 hours in advance before an electrostatic precipitator is put into operation, send
electricity and heat all electric heating apparatuses. Before the operation of a dust catcher,
start and normally run all rapping apparatuses and their downstream ash conveyance and
discharging apparatuses.
2) 电收尘器投运前应先通烟气加热电场，当电场内部温度高于烟气露点后才能向电场内送电。
2) Before the operation of an electrostatic precipitator, first send fumes to heat the electric
field. Only after the inner temperature of the electric field is higher than the fume dew point
will electricity be able to be sent into the electric field.
3) 确认全部的控制均已选择在自动。
3) Make sure that all the controls have already been selected at Automatic.
4) 确认全部的检查门或人孔门都已关闭。
4) Make sure that all the inspection doors or manhole doors have already been closed.
5) 按负载试运行的要求向电场供电，并观察一、二次电压、电流是否正常，电气设备有无异常
现象。
5) As required by a load test run, supply power to the electric field, and observe whether the
primary and secondary voltage, and current are normal, and whether the electric
equipment has abnormal phenomena.
6) 观察各振打装置是否运行正常，各输灰装置、锁风装置是否运行正常。
6) Observe whether each rapping apparatus, ash conveyance apparatus and air locking
apparatus run normally.
7) 观察工况参数是否正常，观察烟囱的排放情况是否达到要求。
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7) Observe whether the operating condition parameters are normal and the emission
circumstance of a stack has attained to a requirement or not.
8) 以上各项的观察应在控制室和现场分别进行，投运后一般应连续观察以上各项半小时以上，
确认均工作良好才可进入日常的巡检程序。
8) The above various observations shall be carried out respectively in the control room and
on the site. After operation, generally, you should observe the above various items
continuously for half an hours. Only after making sure that all work well will you be able to
enter a daily patrol checking procedure.
3.5.4.4 运转中的检查 Examination during Running
1) 应严格控制工艺参数，尤其是烟气的温度一定要保持在合同规定的范围内，以免使内部件产
生变形。如发现这种情况应立即调整工艺参数并停机进行检修，以免事故的扩大或难以修复。
1) Strictly control the process parameters. Particularly, the fume temperature must be kept
within in the contractual specification in order to prevent the inner parts from being
deformed. If this circumstance is found, immediately adjust the process parameters and
halt a machine for an overhaul to avoid the amplification or difficult restoration of an
accident.
2) 检查全部的振打传动装置运转是否正常；
2) Check whether all the rapping and driving apparatuses run normally;
3) 检查电控室的高、低压电控装置，尤其要监视高压电控的一、二次电压、电流值，发现不正
常应找出原因进行排除；
3) Check the high-voltage and low-voltage electric control apparatuses in the electric control
room. It is particularly necessary to keep watch on the high-voltage electric control
primary voltage and secondary voltage values, and current value. For any abnormality
discovered, find out the cause for troubleshooting;
4) 检查输灰装置和锁风装置是否运行正常；electrostatic precipitator
4) Check whether an ash conveyance apparatus and air locking apparatus run normally;
5) 观察烟囱
5) Observe whether a stack discharges smoke normally.
3.5.4.5 停机后的维护保养 Maintenance and Upkeep after Shutdown
利用电收尘器每一次停机的机会进电场内部进行检查。进入电场前应先采取切断高压电源、将
电收尘器放电极系统进行接地、挂上警示牌、打开人孔门确认内部无危险气体等安全措施。电场内
部检查的内容有：
Before entering the electric field, take such safety measures as cutting off the high voltage
power supply first, grounding the discharge electrode system of an electrostatic precipitator,
putting up warning signs, unbolting the manhole doors to make sure that there is no dangerous
gas inside, etc. The contents of the electric field internal inspection include:
1) 检查放电极和收尘极系统有无变形，极间距有无变化，放电极线是否松动或脱落，收尘极板
68 / 120
和放电极线上是否积有粉尘。
1) Check whether the discharge electrode and dust collecting electrode systems have been
deformed, the interpole gap has changed, the discharging pole wire is loose or shed off,
and the dust-collecting plate and discharging pole have accumulated dust.
2) 检查放电极和收尘极振打锤轴系统是否完好；放电极振打的拉杆部件是否正常，提升锤的提
升角度是否仍为安装时的角度，转动是否灵活。
2) Check whether the discharging pole and dust collecting rapping hammer axis systems are
intact, the tension bar parts for discharging pole rapping are normal, the lifting angle of a
lifting hammer is still the angle during installation, and the rotation is flexible.
3) 检查全部收尘极振打杆是否在一个平面上，全部振打杆的砧子是否仍在一条直线上。
3) Check whether all dust collection rapping bars are on the same plane surface and all the
rapping bar anvils are still on a straight line.
4) 检查绝缘套管内部及防尘管的内部是否有积灰、顶部挡风板和两侧边缘挡风板的位置是否正
常、内部走台上的挡风板和灰斗阻流板的位置是否正常。
4) Check whether the insides of a insulating sleeve and a dust-proof pipe have already
accumulated dust, the positions of the wind shields on the top and on the two sides are
normal, and the positions of the wind shields on the internal walking platform and the ash
hopper baffle boards are normal.
5) 检查内部走台上部和灰斗内是否有严重的积灰。
5) Check whether the top of the internal walking platform and the inside of an ash hopper
have serious accumulated ash.
6) 检查气体分布板是否变形或磨损，是否有脱落的现象或趋势。同检查放电极和收尘极振打系
统一样检查气体分布板振打系统是否完好，同时检查传动装置与振打轴之间的“接手”是否在
正常的位置上。检查分布板下部与进气口底板之间是否有积灰或卸灰不畅的情况。
6) Check whether a gas distribution board has been deformed or abraded, whether it has a
shedding-off phenomenon or trend. In the same way of checking a discharging pole and
dust-collecting pole system, check whether a gas distribution board rapping system is
intact. At the same time, check whether a “catcher” between a driving gear and a rapping
axis is at a normal position. Check whether there is accumulated ash or impeded ash
unloading between the lower part of a distribution board and an air inlet bottom board.
7) 检查箱型顶梁内的绝缘套管是否损坏，电加热器是否完好，温控器是否完好，穿墙套管是否
完好，高压导线接线是否牢固。检查绝缘棒是否完好，绝缘棒两端的全部连接是否牢固，紧
固螺栓是否有松动现象。检查箱型顶梁内部是否有积灰。
7) Check whether the insulating sleeve of a top box girder has been damaged, an electric
heater is intact, a thermostat is intact, a wall-piercing sleeve is intact, and a high-voltage
wiring connection is firm. Check whether an insulating bar is intact, all the connections at
the two ends of the insulating bar are firm, and the tap bolts are loose. Check whether the
inside of a top box girder has accumulated ash.
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8) 检查电缆进线箱，电缆终端盒、整流变压器、阻尼电阻等是否完好，全部绝缘部件是否有积
灰。检查全部接地是否良好。
8) Check whether a cable entrance box, cable terminal box, rectifier transformer, suppressor
resistor, etc. are intact, and all the insulating parts have accumulated ash. Check whether
all grounding is good.
9) 及时更换易损部件。如：收尘极和分布板振打、放电极振打、全部绝缘体、气体分布板、阻
尼电阻等有损坏应及时更换。及时运转设备的加油及调整、各种控制测试仪器的检查和调整、
接地极的检查测试和处理、电场内部、电气柜和绝缘材料处的清扫等工作。
9) Replace easily worn parts in time. If a dust-collecting pole and distribution board rapper,
discharging pole rapper, all insulators, a gas distribution board, suppressor resistor, etc,
have been damaged, replace them in time. Carry out in time the oiling and adjustment of
equipment, the inspection and adjustment of various control and testing instruments, the
inspection, testing and treatment of an earth electrode, the cleaning of an electric field
inside, electric cabinet and insulating material, etc.
3.5.5 袋收尘器 Bag filter
3.5.5.1 设备规格、参数 Equipment Specifications and Parameters

编号 No. 427BF1/427BF1
旁路放风收尘Bypass dust collection
用途 Use
型号 Model LJP5046-2×5
处理风量 Treated air volume 900，000ｍ３／ｈ
过滤面积 Filtrating area 15200ｍ２
过滤室数 Number of filtering chambers 2×5 个
滤袋规格 Filter bag specification Φ160x6000mm
入口浓度 Inlet concentration ≤60g/ Nｍ３
出口浓度 Outlet concentration ≤20mg／Nｍ３
阻力损失 Resistance loss ≤ 1700 Pa
压缩耗气量
Compressed air consumption 8 Nｍ３／min
压力 Pressure 0.3 MPa
3.5.5.2 开停机顺序及注意事项 Startup Sequence and Points for Attention
开机顺序：先启动刚性叶轮给料机、拉链机，再启动脉冲喷吹装置。
停机顺序：开机顺序的逆过程；
Startup sequence: First start the rigid rotary feeder and chain conveyance, and then start the
pulse injecting device.
Shutdown sequence: reverse process of the Startup sequence;
注意事项：Points for Attention:
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1) 排风机停后应继续让收尘器输灰系统工作一段时间；
1) After an exhaust fan is shut down, continue to let the dust catcher ash conveyance
system operate for a period of time;
2) 经常检查气压、脉冲喷吹装置、差压，避免袋子堵塞。
2) Often check air pressure, a pulse injecting device and differential pressure to avoid bag
blockage.
3.5.5.3 开机前的准备Preparations before Startup
1) 检查滤袋是否完好，如有损坏应及时更换、糊袋应及时清理；
1) Check whether a filter bag is intact. If there is damage, replace the bag in time, and a
pasty bag shall be tidied up in time;
2) 检查油雾器内是否有油；
2) Check whether there is oil inside an atomized lubricator;
3) 放出气水分离器内的水；
3) Discharge the water in air-water separator;
4) 检查袋收尘入口阀门是否打开并调整到适当位置；
4) Check whether a bag dust-collecting inlet valve has been unbolted and adjusted to an
appropriate position;
5) 检查人孔门是否密封好；
5) Check whether a manhole door has been well sealed;
6) 检查各螺栓是否松动、脱落；
6) Check whether each bolt is loose or shed off;
7) 检查是否有足够压力的压缩空气。
7) Check whether the compressed air has enough pressure.
3.5.5.4 运转中的检查 Inspection during Operation
1) 检查压缩空气压力是否正常，根据出口气体含尘浓度判断布袋有无损坏；
1) Check whether the compressed air pressure is normal, and according to the outlet gas
dust concentration, judge whether a cloth bag has been damaged;
2) 根据系统负荷状况调整挡板开度；
2) Adjust the span of a baffle according to the system loading condition;
3) 及时放空气、水分离器内的水；
3) Empty an air-water separator of water in time;
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4) 根据润滑卡片添加油雾器内的油；
4) Add oil to an atomized lubricator according to a lubrication card;
5) 根据声音判断各阀工作情况，根据压差情况调整脉冲周期；
5) Judge the working condition of each valve according to sound, and according to
differential pressure circumstance, adjust a pulse period;
6) 检查盖板是否盖严，系统是否漏风、灰斗是否积灰；
6) Check whether a cover plate is closely sealed, the system leaks air and an ash hopper
has accumulated ash;
3.5.5.5 停机后的维护保养 Maintenance and Upkeep after Shutdown
1) 检查滤袋是否正常，糊袋、破袋及时调整、更换；
1) Check whether a filter bag is normal. A pasty or damaged bag shall be adjusted or
replaced in time;
2) 提升阀密封情况，灰斗是否积灰，盖板是否变形；
2) Check the sealing circumstance of a lifting valve, and check whether an ash hopper has
accumulated ash and a cover plate has been deformed;
3) 差压取样管是否堵塞，袋笼是否完好；
3) Check a differential pressure sampling pipe is blocked and a bag cage is intact;
4) 检查各螺栓是否松动、脱落，并及时紧固、更换。
4) Check whether each bolt is loose or shed off, and tighten or replace it in time.
3.5.6.6 袋收尘常见故障处理及处理 Constant Fault and Treatment for Bag Filter
1) 排出气体含尘量超标
原因：滤袋破损；粉尘输送设备堵塞
处理方法：更换滤袋；检查恢复粉尘输送设备；
1) The dust content of a discharged gas exceeds a standard.
Cause: A filter bag is worn out; a dust conveyer is blocked.
Treatment process: Replace the filter bag; Inspect and restore the dust conveyer;
2) 排气量减少
原因：糊袋；收尘管道堵塞
处理方法：检查高压气体压力是否正常，脉冲反吹装置、差压是否正常；检查收尘管道。
2) The air displacement is reduced.
Cause: A bag is pasted; a dust collecting pipeline is blocked.
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Treatment process: Check whether the high-pressure gas pressure is normal, and
whether a pulse back blowing apparatus and differential pressure are normal; inspect a
dust collecting pipeline.
4．系统启动前的准备工作 Preparatory Work before System Startup
系统的全部设备在起动前应进行认真的检查、维修、调整工作，这不仅是在试生产阶段，在
以后的正常生产中也应遵循此生产操作规程，以确保每台设备及整套系统的安全、稳定、长期
正常运行。
系统启动前期，旁路放风不投入运行，所以该系统应与窑系统隔离。
Before startup, all the equipment of the system shall be earnestly inspected, repaired,
maintained and adjusted. Not only at the trial production stage, but also in later normal
production, it is also necessary to follow this production operating procedure so as to ensure
the safety, stability and long-term normal operation of each set of equipment and the whole
system.
Before the system startup, the bypass system is not put into operation, so the system shall be
isolated from the kiln system.
4.1 操作前的准备工作Preparatory Work before Operation
（1）在所有应该润滑的部位，按规定量、规定品位加足润滑油，并确认不漏油。
(1) To all parts that should be lubricated and the by a specified quantity and variety,
add enough lub oil, and make sure that no oil is leaked.
（2）清除各油路系统中的一切污垢，保证管路畅通。
(2) Clear away the dirt in each oil route system and ensure that a pipe line is
unimpeded.
（3）检查并清除设备内的一切杂物，关闭好检查门、清扫孔等。
(3) Inspect and clear away all the dopants inside the equipment and close an
inspection door, cleaning hole, etc.
（4）拆除膨胀节的保护连杆，检查风管连接及保温情况是否良好，管道密封是否严密。
(4) Remove the protective connecting lever of an expansion joint, and check whether
the air duct connection and thermal insulation circumstances are good or not and
whether the pipeline sealing is tight or not.
（5）检查所有设备状况良好，防护安全措施切实可靠。
(5) Make sure that all equipment conditions are good and the protective safety
measures are actually dependable.
（6）给水、排水、供气等有效无误，能满足设备或系统运行时的操作要求。
(6) Make sure that the water supply, water drainage, gas supply, etc. are available and
without any error, and can satisfy the operating requirements of the running of the
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equipment or the system.
（7）检查测量元件、控制与调节仪表、连锁与信号装置是否完好，对应是否一致，安装是
否正确，控制盘上及现场的开关是否灵活。
(7) Check whether the measuring elements, control and adjusting meters, interlocking
and signal apparatuses are intact, whether their corresponding is consistent and
installation is correct, and whether the switches on a control panel and on the site
are flexible.
（8）对设备巡视、工作平台楼梯、异常情况紧急处理等场合，均应认真清理，扫除杂物；
同时还需检查挡板、栏杆、警告牌等劳保设施是否安置妥当。
(8) For the situations such as equipment patrol checking, a working platform stairway,
emergency treatment, earnest cleanup and dopant sweeping shall be carried out.
At the same time, it is also necessary to check whether such labor protection
facilities as the baffles, rails, warning signs, etc. are installed properly.
（9）对检查中已发现的部件损坏、设备异常、水气供应不畅等情况，必须及时进行修理，
并确认完全可以立即投入正常运行。
(9) For such circumstances as parts damage, equipment abnormality, the blockage of
water and gas supply, etc, it is necessary to carry out repair in time, and make sure
that they can completely be put into normal operation immediately.
（10）防热衣、面罩、检修工具、照明用具等配备齐全，所有的生产辅助材料备量充足，保
证可以随时取用。
(10) Heatproof clothes, masks, overhaul tools, illumination appliances, etc, shall be
well-found, and all production auxiliary materials shall be ample so as to ensure
that they can be taken for use at any time.
4.2 确认事项 Matters Need to be Confirmed
(1) 确认与本烧成系统相关的其它生产车间操作前的准备工作一切就绪。
(1) Make sure that the preparatory work before operation in other workshops related to
this burning system is ready.
(2) 确认传动机构、设备旋转运行方向与工艺要求无误。
(2) Make sure that a driving mechanism and the revolving and running directions of
equipment are consistent with the process requirements without any error.
(3) 确认各种阀门、闸板等的操作位置与状态显示正确对应。
(3) Make sure that the operating positions of various valves, flash boards, etc. correctly
correspond with their status displays.
(4) 设备的单机性能要求按其说明书调试验收，试车后应确认各设备的主要监控参数（如
振动、轴承温度等）无异常，设备性能达到铭牌或生产要求。
(4) The single machine performance requirements of the equipment shall conform to
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its manual for debugging acceptance. After the trial run, make sure that the main
monitoring parameters such as vibration, bearing temperature, etc. are not
abnormal, and the equipment performance attains to the nameplate or production
requirements.
(5) 所有现场的自控元件和仪表等完好可靠，并能与中控室的显示一一对应，反应灵敏、
准确。
(5) All site automatic control components, meters, etc, shall be intact and reliable, and
shall correspond with the displays in the central control room one by one, with
sensitive and accurate responses.
(6) 系统每一机组连动、联锁，模拟各种故障停车、报警保护等检验均有效可靠。
(6) The inspection of the linkage, interlocking, shutdown simulating various faults,
alarm protection, etc. for the system’s each machine shall be effective and
dependable.
(7) 确认中央控制和机旁控制均可进行正常的开停操作，并能快速、有效、灵活地处理异
常事故。
(7) Make sure that the central control and machine-side control can be turned on and
off normally, and can treat an accident fast, availably and flexibly.
(8) 中控室、各车间、各岗位之间的通讯设施完备、联络畅通。
(8) The telecommunications facilities between the central control room, each workshop
and each post shall be complete, with unimpeded handshaking.
(9) 确认 417DA3，DA4，DA5/418DA3，DA4，DA5 处于关闭状态。
(9) Make sure that 417 DA3, DA4, DA5/418 DA3, DA4 and the DA5 are placed in off
position.
4.3 系统耐火材料的烘干 Drying of the System’s Refractory Materials
烧成系统在耐火材料砌筑完后，投料运行前，均有一个升温烘干过程，以避免直接点火开
窑、升温过快，使耐火砖、浇注料和砖缝胶泥骤然受热引起热崩裂及分层剥落，影响内衬寿命，
所以设备空载试运转结束后，或系统停车检修更换内衬后，着手实施系统耐火材料的烘干是非
常必要的。
After the laying of the refractory materials for the burning system or before operation with
lowering of charge, there is a process of temperature rise for drying to avoid direct ignition to
the kiln and too quick temperature rise, which make firebricks, poured charge and brickwork
joint puddle suddenly heated to cracks and come off by layer, influencing the life of the internal
lining, so after the no-load trial operation of the equipment or after the system has been
stopped for the overhaul and replacement of the internal lining, setting about the drying of the
system’s refractory materials is very indispensable.
4.3.1衬料烘干前的准备 Preparations before Drying Lining Materials
在遵循上述 4.1 节和 4.2 节有关内容的同时，还应做好以下准备工作：
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At the time of observing the relevant contents of the above-mentioned Sections 4.1 and
4.2, it is also necessary to complete the following preparatory work:
（1）在烧成系统的所有设备安装完毕后，应对单机空载连续运行 48 小时进行考核，在此过

程中对控制、测量、调节与联锁保护装置等也同时进行考核。若常规的系统停车检修
更换内衬，则在衬砌工作完成后，也应进行持续适当时间单机空载运行的考核。
(1) After the installation of all the equipment of the burning system , the no-load
operation of a single machine for continuous 48 hours shall be examined. During
this process, the controlling, measuring, adjusting and interlocking protective
devices, etc. shall also be examined. If the system is stopped for the routine
overhaul and replacement of the internal lining, then after the lining work is
terminated, the no-load operation of a single machine lasting for a suitable time
shall also be examined.
（2）全面检查、排除旋风筒、分解炉、回转窑、冷却机内的一切杂物，管道畅通无堵。
(2) Overall inspect and clear the cyclone, precalciner, rotary kiln and cooler of all
dopants, and the pipeline shall be unimpeded without blockage.
（3）核实耐火材料是否按设计要求施工安装，必须注意窑及烟道的热膨胀缝是否砌筑完好、
旋风筒及冷却机内吊顶砖是否吊挂牢固。
(3) Check whether a refractory material conforms to the design requirements in

construction and installation. It is necessary to note whether the thermal expansion
seams of the kiln and the smoke flue have been built well, and the ceiling bricks
inside the cyclone and the cooler have been hung firmly.
（4）打开系统中的烘干排气孔，关闭旋风预热器和分解炉所有的人孔门、清扫孔等。
(4) Open the drying air discharge holes in the system, and close all manhole doors,
cleaning holes, etc, of the cyclone preheater and precalciner.
（5）打开各级旋风筒的下料翻板阀，并用铅丝固定处于常开状态。
(5) Unbolt the discharging flap valves of all- stage cyclones and use lead wire to fix the
valves to make them normally open.
（6）关闭至原料磨管道上的热风阀，使烧成系统不受外界因素干扰。
(6) Close the hot air valves to the raw mill pipeline to make the burning system free
from outside interference.
（7）涉及到其它相关系统中的有关设备，应做好随时运行的准备，如窑头电收尘器电场内
的预电加热备妥就绪等。
(7) The relevant equipment to be involved in other related systems shall be got ready
for operation at any time. For example, the electric heating in advance inside the
electric field of a kiln outlet electric dust catcher shall be got ready.
（8）确认中控室、各系统、各岗位之间的通讯联络畅通。
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(8) Make sure that the telecommunications handshaking between the central room,
each system and each post is unimpeded.
（9）根据衬料材质、砌筑厚度、含水量、砌筑方法等实际情况，制定出切实可行的升温烘
干方案。
(9) Draw up an actually viable temperature rise drying scheme according to the actual
quality, laying thickness, water content, laying method, etc. of a lining material.
（10）燃料油或天然气准备足够。
(10) The reserves of fuel oil or natural gas shall be enough.
4.3.2预热器和回转窑耐火材料的烘干操作要求 Drying Operation Requirements for Preheater

and Rotary Kiln Refractory Materials
（1）通过调节一级旋风筒出风管上的排气阀（417DA1，DA2/418DA1，DA2）开度来控制
窑尾负压约-50~-100Pa 。如该控制有困难或系统内抽力不足，也可直接起动袋收尘器
前的引风机（327FN1，FN2/328FN1，FN2），通过调节阀门（327LDD，LDE/327LDD，
LDE）开度来控制窑尾负压。
(1) Adjust the spans of the air relief valves(417 DA1, DA2/418 DA1, DA2) of the
Class-1 cyclone air outlet conduits to control the kiln inlet negative pressure at
about-50~-100Pa.If the control encounters difficulty or the system’s internal draft is
scarce, you may also directly start the induced draft fans (327 FN1, FN2/328 FN1,
FN2) in front of a bag filter and adjust the spans of the valves(327 LDD, LDE/327
LDD, LDE) to control the kiln inlet negative pressure.
（2）要注意控制入袋收尘器的温度，若≥200℃时要开启袋收尘器前面的冷风阀（327LDK，
LDL/327LDK，LDL）。
(2) Control the temperature of a bag filter. If it is ≥ 200 ℃, open the cold air valves
（327LDK，LDL/327LDK，LDL）in front of the bag filter.
（3）起动一次风机，一次风机阀门开度可视窑内燃料燃烧状况而定。
(3) Start the primary fan. The span of a fan valve may depend on the fuel burning
conditions inside the kiln.
（4）按照实际制定的烘窑升温曲线要求，适时调节喷油量（或天然气量）及窑内通风量，
保持良好的燃烧状况。建议升温速率不高于 30℃/h，以免引起耐火材料的开裂和剥落。
(4) According to the requirements of the actually established kiln drying temperature
rise curves, opportunely adjust an oil injection quantity (or natural gas quantity) and
ventilation quantity inside the kiln, and keep a good burning condition. It is
suggested that the temperature rise rate be not higher than 30 ℃/h, in order to
prevent a refractory material from cracking and coming off.
（5）在升温的过程中，如需要调节一次风阀门的开度，应注意每次调节的幅度尽可能小，
避免一次风机吹灭火焰。
(5) If in the process of raising temperature, it is necessary to adjust the span of a
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primary air valve, it shall be noted that the span adjusted each time shall be as
small as possible to prevent the primary fan from blowing out flame.
（6）点火燃烧后，可慢慢地调整喷油（天然气）量，继续加热升温，但切记每次调节量不
要使温度急剧变化。另外烘窑操作希望长火焰稳定燃烧，防止烧成带过热或局部高温；
一般控制窑衬温度不超过 1000℃、筒体温度低于 300℃为宜。
(6) After ignition for combustion, you may slowly adjust an oil (natural gas) injection
quantity, and then go on heating to raise temperature, but you must remember that
the adjusted quantity each time will not make the temperature change dramatically.
Besides, it is hoped that in kiln drying operation, the flame will be stabilized to
prevent the burning zone from being overheated or local high temperature.
Generally, control the kiln lining temperature at not more than 1,000 ℃, and the kiln
body temperature at less than 300 ℃.
（7）适时调整系统的通风量，以控制和保持预热器及回转窑内各部位相应合适的温度。若
窑尾温度过高，一级旋风筒出口温度偏低时，可适当加大通风量；若窑尾温度偏低，
一级旋风筒出口温度偏高时，可通过适当关小通风量来调节，必要时还可启动三次风
管高温调节阀适当的开度。注意上述调整通风量的过程中一定要保持火焰的稳定和良
好的燃烧状况。
(7) Opportunely adjust the ventilation quantity of the system to control and keep the
corresponding suitable temperature of the preheater and each part inside the rotary
kiln. If the kiln inlet temperature excessively high but the Class-1 cyclone outlet
temperature is on the low side, you may appropriately enlarge the ventilation
quantity. If the kiln inlet temperature is on the low side but the Class-1 cyclone
outlet temperature is one the high side, you may turn down the ventilation quantity
appropriately for adjustment, and you may also appropriately open the tertiary air
duct high temperature regulating valve when it's necessary. Note that in the
process of the above-mentioned adjustment of a ventilation quantity, you must
keep the stability and the good burning condition of the flame.
（8）窑头进风量不足时，可起动冷却机 KIDS1#部分后面的冷却风机，同时关闭窑头罩和冷

却机的人孔门；另外也可加大一次风阀门的开度。当冷却风机气流过大时，也可启动
熟料电收尘器的引风机，通过改变风机前阀门的开度来控制窑头负压在-20~-50Pa。
(8) When the kiln outlet’s incoming air volume is scarce, you may start the cooling fan
behind of the cooler KIDS 1# part, and at the same time, close the manhole doors
of the kiln outlet hood and the cooler. Moreover, you may also enlarge the span of a
primary air valve. When the cooling fan air flow is oversize, you may also start the
induced draft fan of the clinker EP and alter the span of a valve in front of the fan
control the kiln outlet negative pressure at -20~-50Pa.
（9）在整个升温烘干过程中，应根据窑尾温度，用辅助传动慢转窑，大体要求如下：
(9) In the whole process of temperature rise for drying, you should use auxiliary drive
to slowly rotate the kiln according to the kiln inlet temperature. The general
requirements are as follows:
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窑尾温度（℃）转窑量（圈）旋转间隔时间（分）

Kiln inlet Revolution of Revolving time interval
temperature kiln (min)
Below 100 以下 0 不慢转 No slow rotation
100～250 1/4 60
250～450 1/4 30
450～650 1/4 10～15
Above 650 以上 1 连续慢转 Continuous slow
rotation
注意：天气下雨时应根据实际情况相应地缩短慢转时间间隔。
Note: While it is raining, you should correspondingly shorten a slow rotation time
interval according to an actual circumstance.
（10）当一级旋风筒出口温度达到 300℃左右时，要使这个温度持续保持时间不得少于 24 小

时，使得系统内衬中的水分能充分蒸发干燥。对已经生产过的窑，保温时间不必过长。
(10) When Class-1 cyclone outlet temperature attains to about 300 ℃, it is necessary
to make this temperature sustain a time not less than 24 hours so as to make the
moisture in the system’s inside lining be able to fully evaporate. For a kiln that has
undergone production, its heat insulation time shall not be too long.
（11）在烘窑的前面阶段及窑尾温度在 250℃以下时，可打开旁路放风系统的阀 417DA3，

DA6/418DA3 ， DA6 ，以帮助旁路放风装置内的耐火材料的干燥。 417DA4 ，
DA5/418DA4，DA5 必须关闭。等到窑尾温度在 250℃以上时，应关闭 417DA3，
DA6/418DA3，DA6，使旁路放风系统与窑系统隔离。
(11) At the front stage of kiln drying and when the kiln inlet temperature is lower than
250 ℃, you may unbolt the bypass system’s valves 417 DA3, DA6/418 DA3, DA6
so as to help dry the refractory material in the bypass apparatus.417 DA4, DA5/418
DA4, DA5 shall be closed. When the kiln inlet temperature is more than 250 ℃, you
should close 417 DA3, DA6/418 DA3, DA6 so as to isolate the bypass system and
from the kiln system.
（12）当一级旋风筒出口温度达到 300℃左右，并保温 24 小时以上时，一般可以接着进行投

料运转，一方面能充分利用系统内的烘干蓄热量，减少燃料消耗；另一方面可使内衬
不必经受时热时冷的应力损失，并缩短点火至投料的烘窑时间。但若有必要进行检查
烘干后内衬的情况，可以分步减少燃料供给直至熄火，调节系统通风量，力求使内衬
得以缓慢渐冷，万万不可骤冷。待完全冷却后进入预热器及回转窑，全面认真地检查
烘干后内衬的情况，如发现有大面积衬砖剥落、炸裂且深度超过耐火砖厚度的三分之
一，应考虑其重新更换。补砖时要注意不使经烘干的内衬再次受潮，更换部分不必再
次进行单独烘干，可随以后的正常点火操作同时进行，酌情考虑适当延长烘窑升温时
间。
(12) When the Class-1 cyclone outlet temperature attains to about 300℃ and if the
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temperature has been kept for more than 24 hours, generally, you may carry out
operation with lowering of charge immediately, on one hand, being able to make full
use of the drying heat storage in the system and reducing fuel dissipation, and on
the other hand, being able to make the inside lining not experience stress loss due
to the change from cold to heat or from heat to cold and shorten the kiln drying time
from ignition to the lowering of charge. But if it is necessary to inspect the inside
lining after drying, you may can step by step reduce fuel supply until flameout.
Adjust the system’s ventilation quantity to try hard to make the inside lining turn cold
slowly and gradually. Never attempt to give sudden cold. After the complete cooling,
enter the preheater and rotary kiln to overall and earnestly check the circumstance
of the inside lining. If it is found that the lining bricks have large-scale flaking and
cracks whose depth of 1/3 of the thickness of a firebricks, replacement shall be
considered. During repairing bricks, take care not to make the dried inside lining
affected with damp again. A replaced part need not be dried alone again, and it
may be dried with the normal ignition operation later. Appropriately lengthening the
kiln drying time shall be considered.
（13）上述这种烘干方法，一是对于以后系统耐火材料大、中检修更换、重新烘干具有一定
的适用性，二是操作要求不可能完全与实际情况一一吻合，因而可以根据现场操作或
初次点火取得经验加以适当修整。
(13) The above-mentioned method has certain compatibility for the later major or
medium overhaul, replacement, and re-drying of the system’s refractory materials.
As the operating requirements do not completely fit together with the actual
circumstances one by one, you may acquire experience for appropriate trimming
according to site operation or the first-time ignition.
4.3.3 三次风管耐火材料的烘干 Drying of Refractory Materials of Tertiary Air Duct
三次风管耐火材料的烘干可采用两种方案：一是辅助烘干，二是单独烘干。
For the drying of a tertiary air duct refractory material, two schemes can be adopted. One is
auxiliary drying, and the other is independent drying.
5.3.3.1 辅助烘干 Auxiliary Drying
辅助烘干是从窑头罩抽取冷却熟料后的热风进行烘干，条件是预热器及窑烘干后投料，必须以
低产量操作。这种方式烘干周期较长，窑低产量操作时间长，其优点是能确保三次风管尽可能烘干，
且温度变化缓慢；同时烘干不需另增热源，可和冷却机耐火材料烘干同时进行。
Auxiliary drying is extracting the hot air of cooled clinker from the kiln outlet hood for drying, with
the condition that after the drying of a preheater and the kiln, lowering of charge has to be
operated with low output. This drying mode has a longer drying period, and its operating time of
low kiln output is long. Its merit is that it can ensure that a tertiary air duct can be dried as far as
possible, and the temperature changes slowly, and that drying does not need to increase heat
sources, and it can be used together with the drying of cooling fan refractory materials.
（1）预热器及窑耐火材料烘干后，继续升温到投料状态，稳定后开始逐步增加投料。
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(1) After the drying of a preheater and kiln refractory material, go on to raise
temperature the status for lowering of charge. After being stabilized, start to
increase lowering of charge gradually.
（2）窑以低产量操作，平衡稳定后，通过调节三次风管闸阀，逐步加大窑头罩三次风抽风
量，控制进分解炉三次风温度。
(2) The kiln shall be operated at low output. After being balanced and stabilized, adjust
a tertiary air duct gate valve, gradually enlarge the kiln outlet hood tertiary air
ventilation quantity and control the temperature of the tertiary air entering the
precalciner.
（3）当三次风温度 500℃时，应持续恒温一段时间，以便使内衬中的水分能充分蒸发干燥。

然后继续升温超过 600℃。
(3) When the tertiary air temperature is 500 ℃, keep it for a period of time in order to
make the moisture in the inside lining be able to evaporate well. Then go on to raise
the temperature to more than 600 ℃.
（4）逐步加大进分解炉的生料量，且密切监测炉内温度变化，随时调节三次风管热风阀开
度、喂煤量和生料量。
(4) Gradually increase the quantity of raw meal entering the precalciner, closely
monitor the temperature change inside the furnace and adjust the span of a tertiary
air duct hot air valve, coal feeding amount and raw meal quantity at any time.
（5）不断增加燃料量、喂料量，保证风、燃料、料的良好配合，达到正常操作。
(5) Continuously increase an amount of fuel and feeding quantity, and ensure that the
good proportions of air, fuel and charge satisfy normal operation.
5.3.3.2 单独烘干 Independent Drying
此种烘干方法适宜于三次风管内耐火材料水分偏高的场合，随之带来的麻烦是要增加烘干热源。
This drying method is suitable for the situation in which the refractory material moisture is on the
high side inside a tertiary air duct, but the trouble brought immediately is to increase drying heat
sources.
（1）在窑头罩中适当位置架设一个钢架或冷却机篦床上铺设冷熟料后，铺适量干燥木柴，
浇少量柴油。
(1) Spread an appropriate amount of dry firewood and sprinkle a little amount of diesel
oil after at an appropriate position of the kiln outlet hood install a steel frame or
laying cold clinker on the grate bed of a cooler.
（2）依靠系统内抽力或窑尾高温风机来控制三次风管内的通风量。
(2) Rely on the system’s internal draft or the kiln inlet high-temperature fan to control
the ventilation quantity of a tertiary air duct.
（3）点燃木柴，并不断从窑头罩人孔门或冷却机人孔门增添木柴，旺火直至三次风管内耐
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火材料烘干。如温度偏低，则适当延长恒温时间。
(3) Light the firewood, add firewood continuously from a kiln outlet hood manhole door
or cooler manhole door, and keep the vigorous fire until drying the refractory
material inside an air duct. If the temperature is on the low side, then appropriately
lengthen the time of the constant temperature.
（4）烘干后熄灭热源，控制三次风管内通风量至最低值，切记保温渐冷。
(4) After drying, put out a heat source, control the ventilation quantity inside a tertiary
air duct to the minimum value and have to remember thermal insulation and
gradual cold.
（5）完全冷却后清理灰渣，全面检查烘干后衬砖的情况，如耐火砖崩裂剥落严重应考虑重
新更换。
(5) After complete cooling, clear away ash dirt and overall inspect the lining bricks after
being dried. If the cracking and peeling off of the firebricks are severe, replacement
shall be considered.
4.3.4 篦式冷却机耐火材料的烘干 Drying of Refractory Materials of Grate Cooler
篦式冷却机耐火材料的烘干可借助于熟料散热，不需要进行单独烘干并为此设置特别烘干装
置，但烘干操作应统筹考虑烧成系统的运行情况。
For the drying of a grate cooler refractory material, you may make use of the clinker heat transfer
by radiation and do not need to carry out independent drying, so no special drying apparatus will
be set up. But for the drying operation, you should overall consider the running circumstance of
the burning system .
（1）尽可能采用长时间自然通风干燥。
(1) Adopt long-playing natural draft drying as far as possible.
（2）为防止冷却机耐火材料温度骤增，窑低产量运转应不少于 48 小时，操作可兼顾三次风

管耐火材料的辅助烘干同时进行。
(2) In order to prevent the temperature of a cooler refractory material from increasing
suddenly, the low-output operation of the kiln shall not be less than 48 hours.
During operation, simultaneously give consideration to the ancillary drying of a
tertiary air duct refractory material.
（3）如果窑的运转负荷在投料初期就较高，也可采用加快推动速度,加大供风的操作方法，
来减慢烘干速度。
(3) If the operation load of the kiln is high at the early stage of lowering of charge, you
may also adopt the operating methods of quickening a pushing speed and
enlarging air supply so as to slow down a drying speed.
（4）若操作运行前确认冷却机耐火材料有必要进行强制烘干，还可采用在篦床上焚烧木柴
的办法，但必须事先在篦床上铺设冷熟料或耐火砖，防止局部过热造成篦板变形。
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(4) If before operation, it is necessary to compulsorily dry a cooler refractory material,

you may also adopt the method of burning firewood on the gate bed, but you will
have to spread cold clinker or firebricks on the grate bed in advance so as to
prevent local overheating from resulting in grate plate deformation.
4.3.5 衬料烘干操作的注意事项 Points for Attention of Lining Material Drying Operation
（1）稳定燃烧的火焰，火焰长、细，完全燃烧。
(1) Stabilize the flame, and the flame shall be long and thin, with complete combustion.
（2）防止烧成带耐火材料经受急剧的局部过热。
(2) Prevent a burning zone refractory material from experiencing sharp local
overheating.
（3）防止由于窑筒体不均匀受热变形及热膨胀，造成对支承装置不良影响。
(3) Prevent the kiln cylinder from deformation and thermal expansion because of the
kiln body being subjected to uneven heating, which cause bad impacts on a
supporting apparatus.
（4）随时注意监控窑筒体、窑尾及一级旋风筒出口的温度。
(4) Monitor the temperatures of the kiln body, the kiln inlet and the Class-1 cyclone
outlet at any time.
（5）密切监测窑托轮、液压挡轮、减速机等的轴承润滑状况和轴承温度。
(5) Closely monitor the bearing lubrication condition and bearing temperature of a kiln
supporting roller, hydraulic thrust roller, speed reduction unit, etc.
（6）系统升温情况不得较大地偏离拟定的烘干升温曲线要求，并注意适时慢转窑。
(6) The system’s temperature rise shall not considerably deviate from the determined
requirements of the drying temperature rise curves, and take care to slow down the
kiln in good time.
（7）烘干过程中，一定要注意喷油（天燃气）量、各类风门开度的调节幅度不得过大，以
免造成超温超载而损坏内衬或设备。
(7) During a process of drying, you must note that the amplitudes of accommodation of
an oil(natural gas)injection quantity and the spans of various throttles shall not be
oversize in order to prevent overheating and overloading from damaging the inside
lining or the equipment.
（8）烘窑时间，切记由于窑内温度及二次风温较低，燃料燃烧状态不稳定，有爆燃回火或
突然熄灭的危险。需注意安全。
(8) During kiln drying, remember that as the temperature inside the kiln and the
secondary air temperature is lower and the fuel calcinating status is unstable,
having the hazards of deflagration or sudden extinguishment. It is necessary to pay
attention to safety.
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5.投料试生产 Commissioning with Lowering of Charge
5.1第一次投料运转 First operation with Lowering of charge
烧成系统耐火材料烘干结束后，如确证没有必要熄灭进行内部检查，一般接着进行投料运转。
操作时应持稳妥、积极的态度，既要做好充分的准备，又不可过于紧张，不敢大胆操作；要力争抓
住时机，较快地达到稳定燃烧，挂好窑皮，提高产量。经验证明：对于窑外分解窑，产量过低反而
易出工艺故障，产量高时却有利于稳定操作，故应打破陈规，如无设备故障，应力争稳定地突破“操
作死区”，在初次点火投料后 3～5 天内基本上达到正常生产。
If after the drying of a burning system ’s refractory material ends, it is certainly unnecessary to put
out the flame for an internal check, generally, operation with lowering of charge shall be carried out
immediately. During operation, you should have a steady and progressive attitude, make full
preparations, should not be too nervous to operate boldly, work hard for grabbing an opportune
moment, realize stable calcination quickly, hang the kiln skin well and raise the output. Experience
proves that if the precalcining kiln outside has too low an output, a process fault is easily led to,
while if the output is high, it will be advantageous to stable operation, so you should smash
conventions. If there is no equipment failure, you should contend for stably breaking through the
"dead zone of operation". Normal production shall be basically reached in 3-5 days after the first
ignition and lowering of charge.
5.1.1投料前的进一步确认工作 Further Confirmation before feeding
（1）记录烘干后耐火材料的情况。
(1) Record the circumstances of a refractory material after being dried.
（2）确认检查门、人孔门、清扫门等全部关闭。
(2) Make sure that all the inspection doors, manhole doors, cleaning doors, etc. have
been closed.
（3）确认各级旋风筒锥部吹堵的压缩空气管路畅通。
(3) Make sure that the compressed air pipe line of the conic sections of all-level
cyclones are unimpeded.
（5）进行系统各部位温度的检查，投料前 1 小时内要拆除各级旋风筒下料翻板阀的固定铁

丝，并调整妥当。
(5) Inspect the temperature of each part of the system. Within one hour before
lowering of charge, remove the fixed iron wires on the discharging flap valves of
all-level cyclones and make good adjustment.
（6）确信系统所有机电设备、各种计测仪表能够正常连续工作。
(6) Make sure that the system’s all electromechanical equipment and various meters
can work continuously and normally.
（7）核实油库中的油（或天然气来源）、均化库中生料能满足生产初期的要求储量。
(7) Make sure that the oil(or natural gas source) in the bulk plant and the raw meal in
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the homogenizing storage can satisfy the demanded reserves at the initial stage of
production.
（8）选择好熟料输送线路并确信链斗输送机能长期正常运行。
(8) Select a correct clinker conveyance route and make sure that a chain bucket
conveyor can run for a long time and normally.
（9）若烘窑前就计划准备一次投料运转，最好预先在冷却机的 KIDS1#部分覆盖上碎耐火

砖或冷熟料 20~30mm，以避免烘窑的高温辐射热损坏篦板喷嘴。
(9) If before drying the kiln, an operation with lowering of charge is planed and
prepared, it will be best that the KIDS 1# part of a cooler will be covered with broken
firebrick or cold clinker with thickness of 20~30 mm to prevent the high-temperature
radiant heat of drying the kiln from damaging a grate plate nozzle.
（10）原料粉磨与废气处理、生料均化与入窑等其它相关车间应做好随时负载运行的准备、
通讯联络顺畅。
(10) The raw mill and waste gas treatment, raw meal homogenization and kiln feeding,
and other related workshop shall be got ready for load running at any time, and
their telecommunications handshaking shall be smooth.
（11）准备好各种清理、捅料、检修、安全防护等设施与设备，保证能随时取用。
(11) Get ready various facilities and equipment for cleanup, charge-poking, overhauling,
safety protection, etc. and ensure that they can be taken for use at any time.
（12）旁路放风系统已与窑系统隔离。
(12) Make sure that the bypass system has been isolated from the kiln system.
5.1.2投料操作 Operation of Feeding
5.1.2.1 开始喂料 Beginning Feeding
（1）增加窑头喂油（天然气）量，按照点火升温曲线继续升温。
(1) Increase the kiln outlet oil(natural gas)feeding quantity and go on to raise
temperature according to the ignition-temperature rise curves.
（2）按启动顺序起动冷却机的各台风机、熟料电收尘器引风机以及其它设备。注意风机起
动前应关闭相应的调节风门。
(2) Follow the startup sequence to start each fan of a cooler, clinker EP induced draft
fans and other equipment. Note that the corresponding damper shall be closed
before the startup of a fan.
（3）调节系统通风量及窑头燃烧器燃烧的一、二次风量，监测系统各部位的温度和压力。
(3) Adjust the system’s ventilation quantity and the primary and secondary air volumes
of the kiln outlet burner and monitor the temperature and pressure of each part of
the system.
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（4）控制窑尾温度 950～1000℃ ，一级旋风筒出口温度 360～400℃时开始投料。
(4) Control the kiln inlet temperature at 950-1000 ℃. When the class-1 cyclone outlet
temperature is 360-400 ℃, start feeding.
（5）开始以总喂料量的 20～30％喂料。
(5) To begin with, feed 20-30% of the total feeding capacity.
（6）系统投料后，及时将窑的辅助传动改为主传动，并采取低速转窑的方案，防止大量生
料涌入烧成带。尽可能保证首批物料的烧成，以避免物料生烧引起扬尘，从而降低窑
内的能见度，给操作观察窑内状况和进一步加料带来困难。喂料之初，烧成热耗约为
1100～1300kcal/kg.cl。
(6) After the feeding for the system, change the ancillary drive of the kiln into main
drive and assume the scheme of rotating the kiln at an idle speed to prevent a great
deal of raw meal from swarming into the burning zone. Possibly ensure that the first
batch of charge will be burned to prevent incomplete calcination from resulting in
rising dust, which lowers the range of visibility inside the kiln and brings difficulty to
the operating observation of the condition inside the kiln and further charge. At the
early stage of feeding, the burning heat loss is about 1100-1300 kcal/kg.cl.
（7）密切观察窑内状况，注意窑尾，一级旋风筒出口的温度和压力，随时调节风、燃料、
料的匹配。
(7) Closely watch the condition inside the kiln. Note the temperature and pressure of
the kiln inlet and the Class-1 cyclone outlet, and adjust the matching of air, fuel and
charge at any time.
5.1.2.2 加料操作 Charging-up Operation
（1）根据窑内及预热器情况，逐渐加快窑速，并相应逐渐加料至设计能力的 50%左右，燃

料量随喂料量逐渐增加，加油（天然气）的操作应缓慢、稳定。
(1) According to the circumstances inside the kiln and the preheater, speed up the kiln
by degrees, and correspondingly and gradually feed about 50% of the designed
capacity. The fuel quantity shall be increased by degrees with the feeding quantity,
and the operation of adding oil(natural gas) shall be slow-moving and stabilized.
（2）加料幅度不宜大，可控制≤40t/h，每次加料为 5~10 t 左右。
(2) The charge span shall not be big, and it may be controlled at ≤ 40 t/h. The charge
each time shall be about 5~10 t.
（3）加料过程中，窑尾温度应控制在 950～1100℃，一级旋风筒出口温度在 320～380℃。

若窑尾温度低于 950℃时应减缓或停止加料。
(3) In the charging process, the kiln inlet temperature shall be controlled at 950-1100
℃, and the Class-1 cyclone outlet temperature, at 320-380 ℃.If the kiln inlet
temperature is lower than 950 ℃, you should decelerate or stop charge.
（4）根据加料量、加燃料量及系统温度、压力的变化，及时调整风量。在此期间，应注意
86 / 120
系统各部位的温度、压力变化，不要破坏窑内稳定；同时还要严密注意各级旋风筒下
料翻板阀的动作，加强巡回检查，发现堵塞情况要及时果断处理。
(4) According to a charge quantity, fuel quantity and the system’s temperature and
pressure change, adjust an air volume in time. During this period, you should note
the temperature and pressure change of each part of the system and not break the
stability inside the kiln. At the same time, rigorously note the movements of all-
stage cyclone discharging flap valves, intensify patrol inspection, and for a
discovered blockage circumstance, handle it resolutely and in time.
（5）调整火焰活泼有力，明亮完整，不冲刷耐火砖或窑皮，初次投料开始到挂窑皮结束约
需 48 小时。
(5) Adjust flame to alacrity, vitality, brilliancy and integrity. Do not scour the firebricks or
the kiln skin. It takes about 48 hours from the first lowering of charge to the
completion of hanging the kiln skin.
（6）在分解炉未投入运行时，窑运行时的喂料量控制不能超过设计能力的 50％。但应该尽

快过渡。
(6) Before the precalciner is put into operation, the feeding capacity during the running
of the kiln shall be controlled at not more than 50% of the designed capacity. But
the transition shall be done as soon as possible.
5.1.2.3 冷却机的操作 Operation of Cooler
（1）冷却机的操作应按 IKN 的操作手册执行。窑在升温阶段要注意，如果篦板喷嘴的温度

上升至 80℃，应启动风机，并在最小流量下运行。
(1) The operation of a cooler shall conform to the IKN run book. At the stage of the kiln
being heated, it shall be noted that if the temperature of a grate plate nozzle rises to
80 ℃, you should start a fan and make it run at the lowest flow rate.
（2）窑内熟料开始卸落到篦床时，当 KIDS1#部分的熟料堆到 1.5m 时，应启动 KIDS1#部

分的 3 台冷却风机。
(2) When the clinker inside the kiln starts to be unloaded to the grate bed and when the
clinker at the KIDS 1# part has been piled up to 1.5m, you should start 3 cooling
fans at the KIDS 1# part.
（3） KIDS1#部分的冷却风机流量调节应参照 IKN 提供的流量曲线或由按 IKN 的调试工程

师指定的要求进行。
(3) The flow control of a cooling fan at the KIDS 1# part shall conform to the curves of
discharge that IKN has provided or to the requirements that the IKN debugging
engineers have designated.
（4）如果熟料被吹离 KIDS 表面，应减少风机的供风量，保持住熟料在 KIDS1#上的斜坡。
(4) If the clinker is blown off the KIDS surface, you should slash a fan air volume and
keep the clinker slope on KIDS1#.
87 / 120
（5）注意推动篦床的速度、风机、空气炮调节应适当，使熟料层能覆盖住 KIDS1#部分的

篦板，而不至于烧坏篦板。
(5) Note that the adjustment of a grate bed pushing speed, fan and air cannon shall be
appropriate, making the clinker layer able to cover the grate plate of the KIDS 1#
part so as not to burn down the grate plate.
（6）在开始阶段，如果需减小 KIDS1#部分的料堆高度，可加快 1 段篦床的推动速度。
(6) If at the beginning stage, it is necessary to reduce the height of the charge at the
KIDS1# part, you may speed up the pushing speed of section 1 of the grate bed.
（7）当窑连续输出熟料时，篦速的调节必须按 IKN 制订的要求或按 IKN 的调试工程师现场

给定的要求进行。
(7) While the kiln is continuously outputting clinker, the adjustment of a grate speed
shall conform to the requirements that IKN has drawn up or to those an IKN
debugging engineer gives on site.
（8）为保证最优化的篦冷机操作，每次只能调整一个参数，等待结果，这样窑和冷却机的
操作才能稳定。
(8) In order to ensure the optimized operation of a grate cooler, you may only adjust
one parameter each time and wait for a result so that the operation of the kiln and
the cooler will be stabilized.
（9）加料、加燃料的同时，逐渐加大各室风量,一般原则如下：
冷却机加风顺序：先高温段、后低温段；
冷却机减风顺序：先低温段、后高温段；
在投料初期，高温段风机风门相对大些，低温段风机风门相对小些，并与熟料电收尘
器引风机一起按窑头罩负压-20~-50Pa 来调节风门。
(9) At the time of charging and adding fuel, enlarge the air volume of each room by
degrees. The general principles are as follows:
Cooler air-increasing sequence: High-temperature zone first, low-temperature later;
Cooler air-decreasing sequence: low temperature zone first, high-temperature later;
At the initial stage of feeding, a high-temperature zone fan air cock shall be a little big
relatively, and a low-temperature zone fan air cock shall be a little small relatively. An
air cock shall also be adjusted together with a clinker EP induced draft fan according
to the kiln outlet hood negative pressure -20~-50Pa.
（10）熟料应均匀散开并能保持一定的厚度；根据篦床上熟料红亮程度、熟料分布情况、IKN
的推荐数据及窑与分解炉的风量要求，分别调节各风室风量，从而尽可能提高二、三
次风温，不至于造成风量过大吹穿料层短路。
(10) Clinker shall be evenly spread out and keep certain thickness. According to the
brightness of the clinker on the grate bed, the distribution of clinker, and the data
88 / 120
and the air volume requirements for the kiln and precalciner recommended by IKN,
adjust the air volume of each air chamber so as to raise the secondary and tertiary
air temperatures as far as possible and to prevent an excessive air volume from
blowing through a charge layer and from causing a short circuit.
（11）当窑的产量达到正常指标时，要检查冷却机出口熟料温度并依此来调节冷却风量；当
总的冷却风量超过窑和分解炉燃烧的需要时，应通过篦冷机废气引风机在控制窑头罩
负压的基础上将多余废气排出。
(11) When the output of the kiln attains to a normal index, check the cooler outlet clinker
temperature and depend on this to adjust a cooling air volume. When the general
cooling air volume runs over the demands of the kiln and the precalciner, discharge
the redundant gas on the basis of the grate cooler Vent air fan controlling the kiln
outlet hood pressure .
（12）当冷却机废气温度超过 300℃时，可打开冷风阀掺冷风，并根据温度调节阀门开度。
(12) When the cooler waste gas temperature exceeds 300 ℃, you may unbolt a cold air
valve to vent cold air and adjust the span of the valve according to the temperature.
5.1.2.4分解炉投料运行 Precalciner Operation after Feeding
在稳定运行 2～4 小时后，一般可进行分解炉的燃烧器的启动操作。
Generally, you may carry out the startup operation of a precalciner burner after stabilized
operation for 2-4 hours.
（1）注意进入分解炉内的热风温度要达到 600℃以上。若温度偏低时，可调节冷却机的操

作，尽可能使三次风温大于 600℃。
(1) Note that the temperature of the hot air entering the precalciner shall attain to over
600 ℃. If the temperature is on the low side, you may adjust the operation of a
cooler and make the tertiary air temperature exceed 600 ℃ as far as possible.
（2）起动分解炉燃烧器系统，确保分解炉内喷油（天然气）正常燃烧，并进一步缓慢提高
三次风管热风阀的开度，增加三次风量。
(2) Start the precalciner burner system, ensure the normal combustion of the oil
(natural gas) inside precalciner, further and slowly increase the span of a tertiary air
duct hot air valve and raise tertiary air volumes.
（3）逐步加大喂料量，严密监视炉内的温度变化。
(3) Gradually enlarge the feeding quantity and closely monitor the temperature change
in furnace.
（4）窑喂料量增加 300～350t/h 左右。
(4) The kiln feeding quantity shall be increased to about 300-350 t/h.
（5）逐渐增加窑速，最终为 3～3.5r/min 之间。
(5) Increase the kiln speed by degrees, and its final speed shall be 3-3.5 r/min.
89 / 120
（6）加大烧成系统的排风量，最终使一级旋风筒出口负压约 5000～5800Pa，CO在 0.5%

以下，O2在 3.5%左右。
(6) Increase the air discharge volume of the burning system and finally, cause the
Class-1 cyclone outlet negative pressure to be about 5000-5800 Pa, CO to be
below 0.5% and O2 to be about 3.5%.
（7）调整窑与分解炉的喷油（天然气）的比例，增加分解炉的喷油（天然气）量，最终热
耗为 730Kcal/kg.cl 左右,窑与分解炉的燃料耗用比例是：
窑﹕分解炉=35～40﹕60～65
(7) Adjust the ratio of the oil (natural gas) injection of the kiln to the precalciner,
increase oil(natural gas) injection quantity of the precalciner and finally, cause the
heat loss to be 730 Kcal/kg.cl, The fuel consumption ratio of the kiln to the
precalciner shall be:
Kiln﹕Precalciner=35-40 ﹕ 60-65
（8）根据综合判断、及时加料加油（天然气），最终窑喂料量加料至 680～710t/h。
(8) Add charge and oil (natural gas) in time according to comprehensive judgment. The
final kiln feeding quantity shall go to 680-710 t/h.
（9）加料同时，增加系统排风量与冷却机各室风量，增加冷却机篦床速度，调节三次风管
热风阀至最佳状态。
(9) At the time of charging, increase the air discharge volume of the system and the air
volume of each chamber of a cooler, increase the cooler grate bed speed and
adjust a tertiary air duct hot air valve to an optimum condition.
（10）分解炉投料过程中，由于总喂料量大幅度增加，窑内工况变化大，操作应密切注意系
统温度、窑负荷电流、窑尾与分解炉的压力变化，密切观察窑内情况，及时调整各种
参数，加料量、燃料量、排风量调整幅度不宜过大，处理好风、燃料、料、窑速的平
衡，稳定系统热工制度。
(10) As during a process of feeding for the precalciner, the general feeding quantity is
significantly increased and the operating conditions inside the kiln changes
considerably, in operation, you should closely note the system temperature, the kiln
load current, the kiln inlet and precalciner pressure changes, closely observe the
condition inside the kiln and adjust various parameters in time. The adjustment
range of a charging quantity, fuel quantity or air discharge volume shall not be
oversize. Handle well the balance of air, fuel, charge and a kiln speed and stabilize
the system’s hot engineering system.
（11）烧成系统各部位的主要操作参数大体如下：
z 一级旋风筒出口温度： 290～350℃
z 一级旋风筒出口O2含量： 3%左右
z 一级旋风筒出口 CO 含量： <0.2%
90 / 120
z 分解炉内温度： 850～900℃
z 窑尾温度： 1050～1150℃
z 窑尾O2含量： 1.0～2.0%
z 烧成带温度： 1350～1500℃
z 窑头罩负压： -20~-50Pa
z 二次风温度： >950℃
z 三次风温度： >860℃
烧成带的窑筒体温度： 250～400℃（视筒体冷却风机的开停而定）
(11) Generally, the main operation parameters for each part of the burning system are
as follows:
* Class-1 cyclone outlet temperature: 290-350 ℃
* Class-1 cyclone outlet O2 content: 3% or so
* Class-1 cyclone outlet CO content: <0.2%
* Temperature inside the precalciner: 850-900 ℃
* Kiln inlet temperature: 1050-1150 ℃
* Kiln inlet O2 content: 1.0-2.0%
* Burning zone temperature: 1350-1500 ℃
* Kiln outlet negative pressure: -20~-50Pa
* Secondary air temperature: >950 ℃
* Tertiary air temperature: >860 ℃
Kiln body temperature of burning zone: 250-400 ℃(depending on the

startup and shutdown of a kiln body cooling fan)
（12）系统热工制度稳定后，确认各类计测仪表、机电设备正常，即可投入中控回路自控操
作（包括篦冷机“三元”控制、喂料仓料位控制及窑头负压控制等）。
(12) After the system’s thermal regulation has been stabilized and after making sure that
various meters and electromechanical equipment are normal, automatic control
operations (including cooler "ternary" control, feeding bin charge level control, kiln
outlet negative pressure control, etc.) with central control loops may be put into use.
（13）系统操作完全正常后，可根据窑尾热料的氯离子检出情况或根据业主多年的生产经验，
确定何时投入旁路放风系统。
(13) After the system operation is completely normal, determine when to put the bypass
system according to the detection circumstance of kiln inlet hot charge chlorine ions
or according to the owner’s production experience of many years.
91 / 120
5.2 投料操作原则 Principles for Operation with Feeding
带分解炉的大型回转窑在操作上是比较复杂的，尤其是从点火到正常运行的投料过程中，烧
成系统工况变化更为频繁，所以要保证系统投料一次成功有必要强调和遵循以下几项原则：
The operation of a large rotary kiln with a precalciner is comparatively sophisticated. Particularly
during the process of feeding from ignition to normal operation, the burning system ’s operating
condition changes are more frequent, so it is necessary to ensure that the lowering of charge of
the system will be successful at a time and to emphasize and keep to the several principles as
follows:
（1）控制住窑尾温度 950～1000℃，一级旋风筒出口温度 320～360℃，并能平衡稳定一

段时间后才开始投料。
(1) Control the kiln inlet temperature at 950-1000 ℃ and the Class-1 cyclone outlet
temperature at 320-360 ℃, and balance and stabilize the temperature for a period
of time before starting feeding.
（2）随时监测系统主要控制点的温度和压力，因为这是运转操作中调节燃料、料、风的主
要参数。
(2) Monitor the temperature and pressure of a main control point of the system at any
time, because these are the main parameters for adjusting fuel, charge and air in
operation.
（3）系统投料后在生料进入烧成带之前，将采取“留火等料”的操作方式，既要保证烧成带有
一定的高温，砖面发红，又要防止过高温度使耐火砖烧融；既要保证挂好窑皮且致密
平整、使熟料结粒细小均匀，又要严防结大块跑生料，所以采取略低 KH 值与 SM 值
的配料方案、严格控制生料化学成分、稳定烧成温度在 1400℃左右、调整良好的火焰
形状与燃烧状态。
(3) After the system’s feeding and before raw meal enters the burning zone, adopt the
operating mode of "keeping fire and waiting for charge", not only for the purpose of
ensuring that the burning zone has a certain high temperature and the brick face
gets red, but also for the purpose of preventing the excessive high temperature
from making the firebricks melted, and not only for the purpose of ensuring that the
kiln coating will be hung well and it will be compact and neat, but also for the
purpose of strictly preventing big pieces from running to raw meal, so adopt the
admixture scheme with slightly low KH value and SM value, strictly control the raw
meal chemical compositions, stabilize the burning temperature at about 1400
℃,and adjust flame to a good shape and burning status.
（4）从熟料进入冷却机开始到正常生产的整个操作过程中，应保证冷却机的冷却效率，控
制合适的冷却风量和篦床速度，尽可能地提高二、三次风温，这对确保窑内燃烧气氛
和烧结能力，以及分解炉顺利点火投料并较快地达到正常运行尤为重要。
(4) During the whole operation process from clinker entering a cooler begins to normal
production, you should ensure the cooling efficiency of the cooler, control a suitable
cooling air volume and grate bed speed, and the secondary and tertiary air
92 / 120
temperature as far as possible, which is particularly important to ensuring the

burning atmosphere and sintering capacity inside the kiln, and that the precalciner
will be smoothly ignited for lowering of charge and reach normal operation
comparatively fast.
（5）操作应持稳妥、积极的态度，敢于大胆操作，善于抓住时机，力争较快地突破易使系
统热工制度紊乱的“操作死区”，达到正常的稳定运行。
(5) During operation, you should have a steady and progressive attitude, do bold
operation, be good at grabbing an opportune moment, and try hard for fast breaking
through the “operation dead zone” easily making the system’s thermal regulation
messy to reach normal and stable operation.
（6）另外，具体操作中尤其需要注意以下三点：
z 风、燃料、料、窑速要平衡匹配，调节幅度不宜过大。
z 篦床上有热熟料时，应极力避免停止冷却风，即使窑与篦床停止运行，也应将篦床
上的熟料（至少是高温段）完全吹冷后才能停风。
z 加强现场巡回检查，密切注意预热器各部位的压力监测，发现积料堵塞情况要及时
果断处理。特别强调清料工作要安全、仔细，严防烫伤等意外事故。
(6) Moreover, in concrete operation, particularly note the following 3 items:
* Air, fuel, charge and a kiln speed shall be matched well and their amplitudes of
accommodation shall not be oversize.
* When there is hot clinker on the grate bed, you should make every effort to avoid
stopping the cooling air. Even if the kiln and the grate bed stop running, you should
also blow the clinker (at least the high-temperature zone) on the grate bed
completely to cold before stopping air air.
* Intensify the site patrol inspection, closely monitor the pressure of each part of the
preheater and for an accumulated-charge blockage circumstance discovered, treat it
resolutely and in time. It is specially accentuated that the charge cleaning shall be
safe and careful. Take strict precautions against an accident such as a scald.
5.3 旁路放风的投入运行 Putting Bypass System into Operation
系统内有害成分Cl-的富集有个时间过程，因此点火期间可不开启旁路放风系统。但要关注Cl-的
含量。何时开启旁路放风可采用两种方式：（1）参考工厂原有生产线，窑点火后旁路放风系统投运
（2）通过C6 旋风筒下料管热料的分析，监控Cl-的含量，当热料中的Cl-的含量超过 2.0%将
的时间。
启动旁路放风系统。
The enrichment inside the system of the harmful component Cl- has a time process, so during an
ignition period, the bypass system need not be started. But you shall pay attention to the Cl-
content. For when to start the bypass system, you may adopt two modes:(1)making reference to
the time for a bypass system to be put into operation after a kiln ignition for the original production
line in the factory;(2)Analyzing the hot charge of a C6 cyclone discharging pipe to monitor and
control the Cl- content. When the Cl- content in the hot charge exceeds 2.0%, start the bypass
93 / 120
system.
旁路放风系统操作中的注意事项：Points for attention in the operation of the bypass system:
（1）旁路放风系统启动后，尽快将放风比例调整到 10%，然后在根据热料中的Cl-的含量逐

步扩大放风比例。设计中正常的旁路放风比例约为 22%左右，实际放风比例应视热料
中的Cl-的含量定。
(1) The air proportion shall be adjusted to 10% as soon as possible after the startup of
the bypass system, and according to the hot charge Cl- content, enlarge the air
proportion gradually. The regular bypass air proportion in the design shall be about
22%, but the actual air proportion shall depend on the hot charge Cl- content.
（2）旁路放风的比例是通过调节旁路放风系统排风机（427FN1/428FN1）的转速和旁路放
风风管上调节阀（417DA3/418DA3）的开度联合控制的。
(2) A bypass air proportion is jointly controlled by adjusting the revolving speed of the
bypass system fan （427FN1/428FN1） and the span of the bypass air duct
regulating valve(417 DA3/418 DA3).
（3）旁路放风系统中，袋收尘器（427BF1/428BF1）的进风管道上设有测温点，正常的温
度为 180~200℃，由此温度控制二次冷却风机（417FN3/418FN3）的转速，当温度高
于 180℃时，将提高转速，当温度低于 150℃时，可降低转速。
(3) In the bypass system, the air inlet pipeline of the bag filter (427 BF1/428 BF1) is
equipped with temperature measuring points. The normal temperature shall be 180~
200 ℃, which will control the revolving speed of the secondary cooling fan (417
FN3/418 FN3). When the temperature is higher than 180 ℃, the revolving speed will
be raised, while the temperature is lower than 150 ℃, the revolving speed will be
lowered.
6．系统起动及停车操作 Startup and Shutdown Operation of the System
6.1 正常点火操作 Normal ignition operation
正常点火操作，不存在耐火材料烘干及挂窑皮操作，是指短时间停机后重新起动的操作过程。
即使有时在窑内、分解炉内、三次风管内以及预热器局部更换了耐火内衬，也不需要特殊的操作，
只需升温时间适当延长，开始投料时补挂窑皮便能顺利运转，操作方法基本相同。
A normal ignition has no refractory material drying and no kiln coating hanging operation, meaning
that it is an operation process of re-starting after a short-time shutdown. Even if sometimes inside
the kiln, the precalciner, the tertiary air duct and the preheater, fireproof inside linings are replaced
locally, no special operation will be needed. It is only necessary to lengthen the temperature rise
time appropriately. Going on to hang the kiln coating when starting lowering of charge will be able
to lead to a smooth operation. The operation methods are fundamentally the same.
6.1.1正常点火操作前的准备 Preparations before Normal Ignition Operation
（1）确认各种计测仪表、显示报警装置处于可工作状态。
(1) Make sure that various meters and displaying alarms are placed in workable states.
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（2）确认各种风机的风门、各类阀门、三次风管热风阀等操作灵活，并处于下限位置。
(2) Make sure that the air cocks of various fans, various valves, tertiary air duct hot air
valves, etc. are operated flexibly and are placed at the lower limit.
（3）确认操作要求、控制程序与选择设备一一对应。
(3) Make sure that an operation requirement, control procedure and the selected
equipment shall be of one-to-one correspondence.
（4）所有自控回路的自动、手动选择开关置于操作要求位置。
(4) All the automatic and manual selection switches for automatic loops shall be set to
the positions as required in operation.
（5）检查所有润滑点的润滑情况，冷却用水、排水情况符合要求。
(5) Check the circumstances of all lubrication points and make sure that cooling water
and water drainage meet the requirements.
（6）检查所有检查门，清扫孔关闭。
(6) Make sure that all inspection doors and cleaning holes have been closed.
（7）检查预热器上升烟道及废气管道，清除系统中积料。
(7) Check the preheater ascension smoke flue and the waste gas pipeline, and clear
away the accumulated charge in the system.
（8）确认系统各部位下料翻板阀，活动件能活动灵活自如。
(8) Make sure that the discharging flap valve of each part and movable parts of the
system can be moved flexibly.
（9）检查窑液压挡轮，其它设备传动、制动装置等处于可工作状态。
(9) Make sure that the kiln hydraulic pressure thrust rollers, other equipment drive,
arrests, etc are be placed in workable states.
（10）确认有足够点火用燃料，点火装置可靠、齐备。
(10) Make sure that there is enough ignition fuel and the ignition apparatuses are reliable
and ready.
（11）检查冷却机及熟料链斗输送机运转可靠，尤其是篦板完好。
(11) Make sure that the operation of a cooler and a clinker chain bucket conveyor is
reliable, and a grate plate is intact.
（12）检查窑内、预热器和分解炉，冷却机、燃烧器、三次风管的耐火材料状况和窑皮状况
并确认符合要求；了解窑、三次风管、冷却机内的物料残留量；仔细落实点火的必要
条件，制定出切合实际的点火升温曲线。
(12) Check the refractory material condition inside the kiln, preheater and precalciner,
cooler, burner and tertiary air duct and the kiln coating condition, and make sure that
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they meet the requirements. Understand the residual quantity of charge inside the
kiln, tertiary air duct and cooler. Carefully carry out the necessary conditions for
ignition and draw up practicable ignition heating curves.
（13）联系熟料入库号及进行熟料输送路线选择。核实储油库中的储油量（或天然气的供应
量）、均化库中生料能满足生产初期的要求储量。
(13) Contact the number for clinker to enter the storage and select the clinker
conveyance path line. Make sure that the oil storage quantity in the oil tank (or
natural gas supply quantity) and the raw meal in the homogenizing storage can
satisfy the demanded reserves at the initial stage of production.
（14）确认熟料电收尘器及其引风机、冷却机风机、一次风机等关键设备能够长期连续运转。
(14) Make sure that such key equipment as a clinker EP, cooling fan, primary fan, etc. can
operate for a long time and continuously.
（15）窑及分解炉的高压油泵及循环系统的设备、控制元件能够长期连续运转。
(15) The high-pressure oil pumps of the kiln and precalciner, and the equipment, control
elements of the circulating system shall be able to operate for a long time and
continuously.
（16）对设备巡视、工作平台楼梯、异常情况紧急处理等场合，均应充分清理，扫除杂物；
同时还需检查挡板、栏杆、警告牌等劳保设施是否安置妥当。
(16) To the situations such as equipment patrol inspection, working platform stairways,
abnormal circumstance emergency treatment, etc. full cleaning shall be done and
dopants shall be cleared away. It is also necessary to check whether such labor
protective facilities as inspection baffles, railings, warning signs, etc. have been
installed properly.
（17）检查清扫、捅料、检修、照明、安全保护等用具准备齐全。
(17) Make sure that appliances for cleanup, charge-poking, overhauling, illumination,
safety protection, etc are in readiness.
（18）确认综合检查结果，烧成系统所有设备可以运转，通知现场岗位工人及中控室操作人
员。
(18) Confirm the comprehensive inspection results. Make sure that all equipment in the
burning system can operate and notify the site workers and central control room
operators.
6.1.2 正常点火操作 Normal Ignition Operation
结合前述烧成系统耐火材料的烘干操作和第一次投料运转，正常点火操作方法基本上与此
类同，不再赘述。不过以下几点需引起注意：
Based on the above drying operation of a system refractory material and the operation with
lowering of charge for the first time, the normal ignition operation method is basically similar to this,
and no unnecessary details are given. However, the following several points shall need attention:
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（1）根据实际情况控制升温速率，防止温度骤变。
(1) Control a temperature rise speed according to an actual circumstance and keep the
temperature from chopping about.
（2）预热器虽然都是固定的壳体，但投入使用前最好先进行通风试运转，持续时间不要少
于 8 小时。在试运转中和试运转后，要详细检查各部位的异变情况。
(2) Although the preheater is a fixed housing body, but before use, it is best to first do a
ventilation trial operation with duration not less than 8 hours. During and after the
trial operation, it is necessary to check each part in detail for a changed
circumstance.
（3）在窑运行稳定 2～4 小时后，就可启动分解炉燃烧器的运行，无需待三次风管耐火材料

的烘干。
(3) After the kiln operation has been stabilized for 2-4 hours, you may start the running
of a precalciner burner and do not need the drying of a tertiary air duct refractory
material.
6.2 正常操作原则Rules of Normal Operation
带分解炉的大型回转窑需达到优质、高产、低消耗和长期、安全、稳定运转的目的，必须做到“五
稳”（即喂料稳定、燃烧稳定、排风稳定、窑速稳定、一级旋风筒出口温度稳定），因而有必要强调
和遵循以下几个操作原则：
For a large rotary kiln of with a precalciner, you need to attain to the aims of fine quality, high
output, low dissipation and long-run, safe and stable operation and have to attain "five
stable"(namely stable feeding, stable calcination, stable air ventilation, a stable kiln speed and a
stable Class-1 cyclone outlet temperature), as a result, it is necessary to accentuate and keep to
the following several operating principles:
（1）注意把握好点火关。正确地制定不同情况下的“点火升温曲线”做好开车前的各项准备，
其要点是让系统热工制度符合喂料量递增所需的热量。
(1) Grasp the ignition operation. Draw up with accuracy the "ignition heating curve"
under a different circumstance, make various preparations. Its key point is to let the
thermal regulation of the system match the heat quantity needed for an increasing
feeding capacity.
（2）以炉为主，稳定窑头，稳定风、料，同步调整窑速和燃料量为操作指导思想，综合判
断工况条件，实现安全稳定运行。
(2) Regard the furnace as the main part, and regard the stabilizing of the kiln outlet, air
and charge and the synchronization of a kiln speed and fuel quantity as the
operating guideline. Comprehensively judge the operating conditions and realize
safe and stable operation.
（3）整个运转过程中，应保证冷却机的冷却效率，尽可能地提高二、三次风温，降低熟料
出料温度，控制合适的冷却风量，在此期间，还应重视合理地配用一次风量和轴径向
风比例，控制好风、燃料比例及配合，从而保证其燃烧效率和理想的火焰形状。
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(3) During the whole operation process, the cooling efficiency of a cooler shall be
ensured. Raise the secondary and tertiary air temperatures as far as possible and
lower clinker discharging temperature and control a suitable cooling air volume.
During this period, you should also value the reasonable coordination the ratio of a
primary air volume to the axial and radial air, well control the ratio and matching of
air to fuel, thus ensuring its combustion efficiency and an ideal flame shape.
（4）掌握好三次风量和窑内通风量的比例，掌握好分解炉用燃料量和窑头用燃料量的比例。
对于控制参数的调节，应稳宜慢，切忌大起大落；应综合兼顾，处理准确、果断、有
效。
(4) Grasp the ratio of a tertiary air volume to a kiln-inside ventilation quantity and the
ratio of a precalciner fuel quantity to and a kiln outlet fuel quantity. For the
accommodation of the control parameters, it shall be stable and slow. Avoid
considerable fluctuation. It is necessary to synthesize and give attention to every
side, and give treatment accurately, resolutely and effectively.
（5）在系统长期运转中有效地控制烧成带温度，窑尾温度，六级筒下料温度，五级筒下料
温度，各旋风筒锥体负压、一级筒出口废气成份等重要参数，并密切监视本系统主机
设备的安全报警。
(5) During the system’s long-run operation, effectively control such important
parameters as the burning zone temperature, kiln inlet temperature, Class-6 cylinder
discharging temperature, Class-5 cylinder discharging temperature, each cyclone
conic body negative pressure, Class-1 cylinder outlet waste gas compositions, etc,
and closely monitor the safety alarm of the system’s main equipment.
（6）有较好技术和责任心的操作人员，通过勤看火、勤观察、勤检查、勤联系，在各种情
况发生时能迅速综合判断，采取正确的应变措施，使系统工作状态时时稳定在理想的
操作控制范围内。
(6) Operators with better technique and sense of responsibility shall see the fire
frequently, observe frequently, check frequently and contact frequently. Under
various circumstances, they shall be able to synthesize and judge quickly, assume
exact emergency measures and make the system’s operating state always
stabilized in an ideal operational control range.
（7）具体操作中还需注意以下几点：
(7) In a concrete operation, it is also necessary to note the following several points:
a．根据一级旋风筒出口废气分析来控制系统足够的通风，其风量不宜过大、过小，
从而保证窑炉燃料完全燃烧，同时监测废气温度及 CO 的含量来保证收尘器的正
常工作。
a. According to Class-1 cyclone outlet waste gas analysis, control the enough airing
of the system. Its air volume shall not be oversize or undersize to ensure the
complete combustion of the kiln fuel. Monitor the waste gas temperature and CO
content in the meantime to ensure the regular work of a dust catcher.
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b．冷窑点火或废气温度过低，均不能接通电收尘器的高压。
b. For cold kiln ignition or if the waste gas temperature is too low, the high voltage of
an electric dust catcher shall not be connected.
c．检查冷却机风室有无漏风及串风现象。
c. Check whether a cooler air chamber has air leakage.
d．操作中若有掉篦板现象发生，要及时停窑处理，防止篦板掉入破碎机中，造成破
坏事故。
d. If in operation, a grate plate has dropped, it is necessary to stop the kiln for
treatment in time so as to keep the grate plate from dropping into a crusher, which
may result in a breakage accident.
e．密切监测烧成带窑筒体温度不得超过 400℃，保护窑皮和筒体。
e. Closely monitor the burning zone’s kiln body temperature. It shall not be more than
400 ℃ so as to protect the kiln coating and body.
f．进行熟料质量检验，生料与热料的品质检验，并根据反馈数据，实施各部分控制
参数的调整。
f. Examine the quality of clinker, raw meal and hot charge, and according to the
feedback data, carry out the adjustment of the control parameters of each part.
g．密切注意窑尾负压与各级旋风筒负压来检查预热器有关部位是否积料、堵塞、结
皮，一旦发生应及时处理，特别注意清扫工作要安全、仔细，严防烫伤等意外事
故。
g. Closely note the kiln inlet negative pressure and all- stage cyclone negative
pressure to check whether a relevant part of the preheater has accumulated
charge, blockage and surface crusting. Once it occurs, you should handle it in time.
In cleaning work, particular attention shall be paid to safety and carefulness. Take
strict precautions against an accident such as a scald.
h．原料粉磨系统的开停及有关风门等设备的操作，应预先和中控操作人员联系并同
意后方可进行。
h. For the operations of the startup or slowdown of a raw mill system, relevant air
cocks, etc, you should contact an operator for central control in advance and get
approval before doing so.
6.3 正常停车 Normal Shutdown
系统停车前事先把停车计划通知到原料粉磨、油库、高压泵房等车间，使其作好充分的准备，
并随时联系，以便相互配合。原则上希望系统停车后，能做到窑空、生料库空、运输设备空，但主
要还应当根据生产需要，停窑时间长短及工艺装备所限来决定生料库是否排空和库仓内生料的剩余
量。另外，原料粉磨系统需要关闭热风阀或使热风改向时，一定要与中控操作员联系并征得准许后
方可进行有关设备的操作。注意不要没有准备而使烧成系统的气流突然变化、干扰窑的工作状况。
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Before the system shutdown, notify the workshops for the raw mill, crude oil tank, high-pressure
pump house, etc, of a shutdown plan, make them make full preparations and make contacts at any
time in order to get mutual coordination. In principle, it is hoped that after the shutdown of the
system, the kiln, raw meal storage and transport equipment will be empty, but mainly according to
production demands, the time length for stopping the kiln and the limitation of the process
equipment, you will be expected to decide whether to empty the raw meal storage and determine
the remaining quantity of the raw meal in the silo. Moreover, when the raw mill system needs to
close a hot air valve or makes the hot air change its direction, you must contact an operator for
central control and get permission before operating related equipment. Take care not to make the
air flow of the burning system change suddenly, which interferes with the operating condition of
the kiln.
本系统停车时，有自动调节回路的设备一般都应切换成手动位置，正常停车的顺序是：炉、窑
减燃料、减料；减小旁路放风量；切断旁路放风系统；先停炉、停料、后停窑、具体操作步骤如下：
When this system is shut down, generally, the equipment that has an automatic regulating loop
shall be changed over to a manual position. The normal shutdown sequence shall be: the furnace
and kiln reducing fuel and charge; reducing the bypass air volume; cutting off the bypass system;
first stopping the furnace, stopping charge, and then stopping the kiln. The concrete operation
steps are as follows:
6.3.1分解炉的停车操作 Shutdown Operation of Precalciner
（1）根据热耗与温度，逐步减燃料、相应减料。
(1) Reduce fuel and correspondingly reduce charge gradually according to heat loss
and temperature.
（2）根据O2含量的变化，调节窑尾高温风机转速和阀门开度。
(2) Adjust the revolving speed of a kiln inlet high-temperature fan and the span of a
valve according to the change of the O2 content.
（3）当分解炉内温度下降到 820℃左右时，这时适当减料。当分解炉内温度下降到 800℃

以下，适时停止分解炉燃烧器的燃料供应。但保持分解炉燃烧器冷却风机的运行，调
小风量冷却喷嘴。
(3) When the temperature inside the precalciner descends to about 820 ℃, reduce
charge appropriately. When it descends to below 800 ℃, stop fuel supply to the
precalciner burner in good time. But keep the running of the precalciner burner
cooling fan and turn down the air volume for cooling the nozzle.
（4）同时调整一级旋风筒出口负压与系统排风量，减少冷却机各风室的风量。
(4) At the same time, adjust Class-1 cyclone outlet negative pressure and the air
discharge volume of the system to reduce the air volume of each air chamber of the
cooler.
（5）同时降低入窑喂料量，维持在 SP 窑操作状态。
(5) At the same time, lower the feeding quantity into the kiln and maintain the mode of
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operation for the SP kiln.
（6）根据分解炉内温度变化和窑内情况，随时调节三次风管热风阀开度至合适状态。
(6) Adjust the span of the tertiary air duct hot air valve to a suitable status at any time
according to the temperature change inside the precalciner and the condition inside
the kiln.
（7）适当地降低窑速来保持正常烧结，同时调整窑头燃料供给。
(7) Properly lower the kiln speed to keep normal sintering and at the same time, adjust
the kiln outlet fuel supply.
6.3.2.窑的停车 Kiln Shutdown
（1）继续逐步减料。
(1) Go on to reduce charge gradually.
（2）同步缓慢降低窑转速，调整系统排风量和冷却机各室的风量。
(2) Simultaneously and slowly lower the kiln revolving speed and adjust the system’s air
discharge volume and the air volume of each chamber of the cooler.
（3）当窑尾温度偏高，一级旋风筒出口温度降低时，可以全闭三次风管热风阀。
(3) When the kiln inlet temperature is on the high side and the Class-1 cyclone outlet
temperature is lowered, you may shut the tertiary air duct hot air valves completely.
（4）随时调节窑头燃料供给量，既保证相应的烧结温度，又不要使窑尾温度和一级旋风筒
出口温度过高。
(4) Adjust the kiln outlet fuel supplies at any time in order to ensure a corresponding
sintering temperature and not to make the kiln inlet temperature and Class-1 cyclone
outlet temperature excessively high.
（5）当一级旋风筒出口温度下降到正常偏下且不再回升时，应立即停料。逐级翻动下料翻
板阀，清理各级旋风筒内的积料，必要时用吹堵系统清理。若停料后，一级旋风筒出
口温度过高，可打开一级筒人孔门或冷风阀。
(5) When the Class-1 cyclone outlet temperature descends to a normally low and no
longer rises, you should stop feeding immediately. Step by step, turn over the
discharging flap valves and clear away the accumulated charge inside all-stage
cyclones, and use a blockage-blowing system for cleanup when it's necessary. If
after stopping charge, the Class-1 cyclone outlet temperature is too high, you may
unbolt the Class-1 cylinder manhole door or cold air valve.
（6）窑开始慢转。当窑内物料基本排空时停燃料、停一次风机，同时起动事故风机以冷却
保护燃烧器不被灼伤。待燃烧器冷却至一定程度后，拉出窑头罩，切忌一次风量过大，
使窑皮骤冷垮落。
(6) The kiln begins to run slowly. When the supplies inside the kiln basically empty, stop
fuel and the primary fan, and at the same time, start the accident fan to cool and
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protect the burner from scald. Pull out the kiln hood after being cooled to a certain
extent. Prevent by all means a primary air volume from being oversize, which makes
the kiln coating become suddenly cold and collapse.
（7）减风或停止窑尾高温风机。注意此刻一定要使窑内温度缓慢下降，保护好窑皮和内衬。
注意一级旋风筒出口温度高于 100℃时，应慢转窑尾高温风机，防止叶片变形。
(7) Reduce air or stop the kiln inlet ID fan. Note at this moment that you must make the
temperature inside the kiln drop slowly and protect the kiln coating and inside lining
well. Note that when the Class-1 cyclone outlet temperature is higher than 100 ℃,
you should slow down the kiln inlet high-temperature fan to prevent the vane from
being deformed.
（8）停窑操作过程中，窑慢转间隔要求大体如下：
0～1 小时，连续慢转
1～3 小时，每隔 15 分钟转 1/4
3～6 小时，每隔 30 分钟转 1/4
6～12 小时，每隔 60 分钟转 1/4
12～24 小时，每隔 120 分钟转 1/4
24 小时以后，根据窑内温度情况而定
(8) During the process of kiln shutdown operation, the intervals for the kiln to rotate
slowly are as follows:
0-1 hour, continuous slow rotation
1-3 hours, rotating by 1/4 every 15 min
After 24 hours, they shall depend on the temperature circumstance inside the
kiln.
6.3.3 冷却机的停车操作 Shutdown Operation of Cooler
（1）根据窑、分解炉、预热器的风量要求，及时调整冷却风机的转速和风门开度。
(1) According to the air volume requirements of the kiln, precalciner and preheater,
adjust in time the revolving speed of a cooling fan and the span of an air cock.
（2）窑缓慢减速、同步降低篦床速度，当窑停止向冷却机卸料后，应停止篦床推动，以保
持熟料层。若冷却机检修，则应排净篦床上物料后才停车。
(2) Slow down the kiln and simultaneously lower the grate bed speed. After the kiln stops
unloading charge to the cooler, you should stop pushing the grate bed to keep the
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clinker layer. If the cooler is overhauled, you should empty the grate bed of charge
before a shutdown.
（3）篦床停止运行后，应将篦床上的熟料完全吹冷后方可停冷却风机，以保护篦板。若需
排净篦床上物料时，也应在冷却风机运转时进行。
(3) After the grate bed stops running, you should blow the clinker on the grate bed to
completely cold before stopping the cooling fan to protect the grate plate. Emptying
the grate bed of supplies shall be done while the cooling fan is running.
（4）熟料破碎机位于 1#篦床之后，1#篦床停机后停熟料破碎机，然后再停 2#篦床，但水

冷、风冷系统要等设备冷却到安全温度以下才能停。
(4) The clinker crusher shall be located behind the 1# grate bed. After the 1# grate bed
stops, stop the clinker crusher and then stop the 2# grate bed, but the water cooling,
and air air cooling systems shall be stopped only after the equipment is cooled to
below a safe temperature.
（5）待各风室内的细碎熟料全部排空后，才可停卸灰系统。
(5) Only after all the fine crushed clinker of each air chamber has been emptied may
you stop the ash-unloading system.
（6）停冷却机各部分的润滑系统。
(6) Stop the lubricating system of each part of a cooler.
（7）各冷却风机全部停止后，停熟料电收尘器及其引风机。注意引风机停车前，一定要控

制住窑头负压，以免热气体从窑头罩冒出、发生伤人事故。
(7) After each cooling fan stops, stop the clinker EP and its induced draft fan. Note that
before stopping the induced draft fan, you must control the kiln outlet negative
pressure in order to prevent hot gas coming out from the kiln hood from injuring a
person.
（8）待熟料电收尘器回灰及设备内的余料排净后相继停止熟料输送系统。
(8) After the back ash of the clinker EP and the remaining charge inside the equipment
are emptied completely, go on to stop the clinker conveying system.
6.3.4 其它 Others
（1）待预热器、窑、冷却机停机后，才能停止系统内的其余辅助配套设备，才能停气、停
水。
(1) Only after stopping the preheater, kiln and cooler may you halt the other auxiliary and
matching equipment in the system, and air and water supply.
（2）关闭各种计测仪表、电气设备。
(2) Shut down various meters and electric equipment.
（3）记录停机时间和停机情况，报告生产调度。
103 / 120
(3) Record the shutdown time and circumstance and report to production dispatching.
6.4 故障停车和重新起动 Trouble halt and restart
6.4.1 故障停车 Trouble halt
故障停车包括设备故障停车和工艺故障停车两种。对于设备故障停车，一般说来其停车顺序、速度
均取决于设备之间的联锁关系或 PC 控制，不能在现场人为地加以干涉，而工艺故障停车在许多情
况下其停车顺序、时间都可以人为地加以选择，也往往需要对 PC 控制解锁来灵活实施处理故障的
手段，但不管发生哪一种故障，我们建议其操作处理原则必须遵循以下步骤：
Trouble halt include equipment trouble halt and technology trouble halt. For equipment trouble
halt, generally its sequence and speed of halt depends on connection or PC control between the
equipments. No interference is allowed onsite. For technology trouble halt, the sequence and time
of halt allows casual selection in many circumstances, but it often requires unlocking PC control to
flexibly implement the means of trouble shooting. No matter what kind of trouble happens, we
suggested that principle for its operation and treatment shall follow these steps:
（1）根据仪表的显示及报警，对故障原因、排除故障所需时间，对工艺生产、设备安全的
影响程度及时作出准确的判断，并找出有效的处理办法。
(1) According to display and alarming of the instruments, make timely judgment about
cause of the trouble, time for trouble shooting, degree of impact upon technology
production and safety of the equipment, and then find the effective solution.
（2）尽可能在中控室进行处理，尽可能快地恢复正常生产。
(2) Try to make treatment in the central control cabinet and recover the normal production
as soon as possible.
（3）设备单机停车。
(3) Halt of single equipment.
（4）分系统停车。
(4) Halt of sub-system.
（5）全系统停车。
(5) Halt of whole system.
此外，无论任何原因造成的停窑，都必须使窑系统的冷却过程尽可能缓解，尽量减少进入系统
的冷风量，以避免窑皮和内衬受骤冷损坏。当停窑时间估计不超过 4 小时，且故障能很快排除，可
实行保温措施，间隔或连续地在窑头喷入少量燃料，从而为系统重新起动，尽快投入正常运转创造
条件。
Additionally, halt of kiln due to any reason shall mitigate the cooling process of the kiln system
as possible and reduce the cold air amount into the system, so as to avoid any damage of abrupt
cooling down incurred to the kiln surface and lining. When the time for halt of kiln is estimated less
than 4 hours and the trouble can be eliminated immediately, heat conservation measures can be
implemented. Small amount of fuel is sprayed in into the kiln outlet at interval or continuously, so
104 / 120
as to create condition for restart of the system and quick commencement of normal operation.
6.4.2 重新起动 Restart
在重新起动窑时，要注意窑温的变化，要判断是采用直接喷入燃料或通过点火喷入，防止未燃烧的
气体积存在窑内和预热器的管道内引起爆燃。为此应当遵循下列操作原则：
When the kiln is restarted, change in temperature of the kiln should be noticed. Judgment
shall be made whether the fuel is sprayed in directly or sprayed through ignition, so as to prevent
the gas not combusted accumulating in the kiln and the pipe of preheater and thus inducing
explosion. Therefore, following operational principles shall be followed:
（1）短时停窑后，重新给窑升温时，应确保窑温度可满足燃料直接燃烧要求，才能直接喷入，
否则要点火助燃。
(1) After short-time suspension of the kiln and heating of the kiln is made anew, it shall be
ensured the temperature of the kiln can satisfy requirement of direct combustion of the
fuel before it is sprayed in directly; otherwise combustion shall be promoted by ignition.
（2）喷燃料时，必须调整风量，避免产生还原气氛。
(2) When fuel is sprayed, air volume shall be adjusted to avoid production of reducing
atmosphere.
（3）若窑的温度较低或在调整火焰时，燃料增加要缓慢，不要突然增加。
(3) If temperature of the kiln is low or when the flame is adjusted, increase of the fuel shall
be slow rather than abrupt.
（4）若需要调节一次风和二次风时，要缓慢地进行，切忌猛增猛减。
(4) Adjustment of primary air and secondary, if any, shall be conducted slowly. Sharp
increase or decrease is forbidden.
（5）分解炉的投入应视故障停车时间的长短和重新起动时的系统工况条件酌情而定。
(5) Input of the precalciner shall be determined as per time of the trouble halt and system
working conditions in time of restarting.
（6）若故障停车时进行窑慢转而造成冷却机一段篦床上堆积物料过多，重新起动时要进行篦
板的检查，并在起动初期尽快送出堆积熟料。
(6) In trouble halt, if slow rotation of kiln causes excessive accumulation of materials on a
stretch of grate bed on the cooler, inspection to the grid plate shall be conducted in
restarting and accumulated clinker shall be sent out at the beginning of starting.
（7）故障停车较长时间后的冷窑重新起动，重新点火、升温、投料可参考前述有关条文并酌
情调整。
(7) Restarting, re-ignition, reheating and material inputting of cold kiln after long time of
trouble halt can refer to relevant articles afore-mentioned and are subject to proper
adjustment.
105 / 120
7. 常见故障及处理 Common troubles and handlings
（1）窑头燃烧器系统 Burner system of the kiln outlet
常见故障可能的原因或现象主要操作处理

Common fault Possible cause or phenomenon Main operational handlings
1.火焰分叉 1．燃烧器管头部有杂物清除 Clear
Forking of There is impurity at the inlet of

flame the burner
更换 Replace
2．燃烧器管口变形
Nozzle of the burner deforms
2. 火焰形状不 1．径、轴向风比例不佳调节燃烧器上相应阀门
佳
Poor proportion between radial Adjust corresponding valve on the burner
Poor shape of and axial airs
适当调节一次风进口阀开度
flame
2．一次风过大过小
Properly adjust openings of the primary
Excessive high or low volume air inlet
of primary air
3．燃烧器出口风速低
减小管道及阀门的压力损失
Speed of air at the burner outlet
Reduce pressure loss in the pipe and the
is low
valve
窑炉用风配合不当调总排风量或适当关小三次风阀
Air used for the kiln oven is Adjust rotation speed of main ventilation
poorly matched fan at the kiln inlet of opening of the valve
3. 窑尾温度偏
低系统排风量不够，窑内燃烧不充调窑尾主排风机转速或阀门开度
分
Temperature of Adjust rotation speed of main ventilation
the kiln inlet is System has insufficient fan at the kiln inlet of opening of the valve
relatively low ventilation amount and
combustion in the kiln is
insufficient
窑尾负压过大清理系统结皮堵料
Negative pressure of the kiln Clear away crusting blockage of the

inlet is too large system
二次风温偏低适当关小冷却风机阀门开度
Temperature of the secondary Properly reduce opening of valve of the
106 / 120

air is relatively low cooling fan
1．风机润滑不良 a．起动备用风机。系统继续运行
Fan lubrication is poor Start the backup fan and the system go
on operating
2．轴承温度超限
b．备用风机不能启动，则关闭窑头所用燃
Temperature of the bearing
料的流量阀。
goes beyond limit
４.一次风机停
If the backup fan cannot start, shut off
车 3．电气故障等
flow valve for the fuel used at the kiln
Primary fan Electric trouble, etc. outlet.
halt
c．现场全开燃烧器的外流风阀，紧急启动
事故风机，或酌情考虑是否拉出燃烧器。
Outflow valves of the burner onsite are

opened. Make emergent start of the
accident fan or, in necessary situation,
consider whether to pull out the burner.
d．窑尾主排风机慢转，系统保温冷却。
Main ventilation fan of the fan kiln inlet
rotates slowly and the system is cooled
and conserves heat.
e．窑连续或间隔慢转
The kiln slowly rotated in succession or at

interval
５.窑头燃油/燃 1．备用系统故障 a．停窑、停料、停分解炉燃料，否则会出

气供应断现生烧料，还会使窑温降低过快，重新起
backup system trouble
Supply of fuel 动困难。
oil/fuel gas at 2．电气故障
Stop operation of kiln, or supply of
the kiln outlet
Electric trouble material or precalciner fuel; otherwise
breaks off
raw meal will be produced and
3．CO 气体严重超标
temperature of the kiln will be reduced
CO gas exceed the standard too fast, making it easy to restart.
seriously
b．调整系统风量及冷却机冷却风量、慢转
窑。
Adjust air volume of the system and

cooling air amount of the cooler, and
slowly rotate the kiln.
107 / 120

c．停篦床。
Halt the grate bed
d．查明故障，尽快处理。Locate the trouble

and make treatment as soon as possible.
（2）分解炉燃烧器系统 Precalciner burner system

1.分解炉燃烧 1．分解炉内温度过低适当关小三次风管阀门开度，调慢篦床速
器熄火 Temperature in the 度，加大高温区冷却风量，减小低温区冷却
Precalciner precalciner is too low 风量。
burner Properly reduce opening of the Tertiary Air
2．三次风过大
extinguishes Duct., slow down speed of the grate bed,
Excessive volume of tertiary
increase cooling air volume in the
air
high-temperature zone and reduce
cooling air volume in the low-temperature
zone.
2.分解炉内温喂入的燃料量过大适当减小燃料喂入量
度过高 Excessive amount of Properly reduce feeding amount of the
Temperature feeding fuel fuel
in the
precalciner is
too high
3 分解炉燃烧（故障原因同窑头燃烧器） a.减窑喂料量
器断油或断气 (cause for trouble is the Reduce kiln feeding amount
Precalciner same as the kiln outlet b.关闭三次风管热风阀开度。
burner breaks burner)
Shut off the tertiary Air Duct and opening
supply of oil
of the hot air valve.
or gas
c.根据煅烧情况，温度变化来控制窑燃烧器
燃料量和窑速。
Control fuel amount of kiln burner and kiln
speed according to calcinations situation
and change of temperature.
d.调整窑尾主排风机转速或阀门开度及冷
却机冷却风量。
Adjust rotation speed of main ventilation
fan of the kiln inlet or opening of the valve
108 / 120

and cooling air volume of the cooler.
e.加强监视窑尾、旋风筒、下料翻板阀的工
作情况，定时清吹，防止积料。
Intensify monitoring over working of the
kiln inlet, cyclone and feeing flap valve.
Make regular blow-out, so as to prevent
material accumulation.
（3）烧成通风系统和生料系统 Burning ventilation system and raw meal system

1.风机润滑不良； a.停料、停分解炉燃烧器，必要时也停窑
Poor lubrication of the fan; 头燃烧器，注意保温操作。关闭三次风。
1.窑尾主排风 2．轴承温度超限； Halt material supply and precalciner

机停车 burner. If necessary, halt the kiln outlet
Temperature of the bearing
burner also and pay attention to heat
Halt of main exceeds the limit;
conservation operation. Shut off the
ventilation fan
tertiary air.
of the kiln
inlet b.窑筒体间隔或连续慢转，酌情拉出燃烧
器，防止弯曲变形。
Kiln cylinder slowly rotates at interval of
in succession. Pull out burner properly
according to situation, so as to prevent
distortion and deformation.
c.减冷却机篦速直至停止,减冷却风量，注
意窑头负压的变化。
Reduce speed of the cooler gate bed till
it stops. Reduce the volume of cooling
air. Pay attention to change of negative
pressure at the kiln outlet.
系统漏风大造成超负荷加强预热器系统监测，严防堵料，定期清
Large air leakage of the 理。
system causes super load Intensify monitoring over the preheater
system. Strictly prevent material
blockage and make clearing regularly.
电气故障等查明故障原因，尽快进行处理
Electric trouble, etc. Find out cause of the trouble and make
treatment as soon as possible.
109 / 120

a.密切注意窑头罩的负压变化。严防风机
发生热变形。
2.熟料电收尘 Pay close attention to change in

器引风机停车 negative pressure of the kiln hood.
（同上）(Same as above)
Fan halt Strictly prevent deformation of the fan in
caused by EP heat.
for the clinker b.估计排除故障时间较长，则应减料、减
燃料，直至停止。
If estimated time for trouble shooting is
long, reduce the material and fuel, till it
halts.
c.减小冷却机低温区冷却风量，甚至停止
低温区冷却风机。
Reduce cooling air volume in the
low-temperature zone of the cooler, till
cooling fan in the low-temperature zone
halts.
d.观察篦床上熟料的冷却情况，严防篦板
烧坏。
Observe cooling of clinker on the grate
bed and strictly prevent the grid plate
from being burnt down.
e.根据系统操作难易，对设备安全的影响
程度以决定是否停窑。
According to hardship of the system
operation and degree of impact upon
safety of the equipment, decide whether
to halt the kiln.
f.查寻原因，排除故障。
Find out the cause and shoot the
trouble.
1．斜槽透气层糊死或破损； a.如供料系统故障能很快排除，不会造成
3.生料喂料系 Ventilation layer of the chute is 系统过长停料，则可停分解炉燃烧器,调
统停车 agglutinated tightly or 整系统各部分风量，实施保温操作。
Halt of raw damaged; If trouble of the feeding system can be

meal feeding 2．斜槽供气风量或风压不足； eliminated immediately and no
system long-term material supply of the system
Air supply or air pressure of
is caused, the precalciner burner can be
the chute is insufficient;
halted. Adjust air volume of each part of
110 / 120

3．各管道阀门控制位置不对； the system and implement
heat-conservation operation.
Control position of the pipe
valve is improper; b.如故障造成系统过长时间停料，严重影
响窑系统的操作，则参照前述“正常停车”
4．罗茨风机故障等。
有关部分实施停窑。
Roots blower trouble., etc.
If the trouble results in too long-term
material halt of the system and seriously
impacts operation of the kiln system,
halt the kiln in reference to relevant part
in aforesaid “Normal Halt”.
（4）窑及预热器系统 Klin and Its Preheater System

Common fault possible reasons or phenomena main operating handlings
1.窑尾温度下降过大，燃料喂 a.减少喂料量和增加燃料喂入量。
入量过小； Reduce material feeding amount,
The temperature in the klin increase fuel feeding amount.
inlet decreases too much, fuel b.减慢窑转速。
1. 跑生料
feeding amount is too little;
Leakage of raw Slow down the turning speed of klin.
meal 2.预热器塌料，生料窜入烧成
c.当生料已窜入烧成带时，应适宜减少喂
带；
料量，待窑电流及烧成带温度上升或呈上
The material of the preheater 升趋势时，适时增加喂料，提高窑速，然
collapses, the raw meal 后调整燃料喂入量。注意加料、加燃料幅
enters into burning zone; 度不宜过大。
3.窑电流下降，烧成带温度及 If the raw meal enters into the burning
NOx 浓度降低，窑头负压波 zone, it’s should to reduce the material
动，窑内发浑，冷却机篦床速 feeding amount, after the klin current
度偏快，窑头、冷却机冒灰。 and the temperature of the burning zone
The current of the klin raises or has the tendency to raise, then
decreases, the temperature of increase material feeding amount, raise
burning zone and the NOx the rotation speed of klin, adjust fuel
concentration decreases, the feeding amount. Be aware of the added
negative pressure of kiln feeding amount of material and fuel can
outlet fluctuates, the speed of not be too much.
graterplate of the cooling
machine is a little faster, the
kiln outlet and cooling
machine generates ash.
1.烧成带温度或窑筒体温度变 a.调整火焰，窑内热负荷不宜过高。
111 / 120

化急剧。 Adjust flame; the heat load within the klin
The temperature of burning should not be too high.
zone or the temperature of b.适当减慢窑速，修补平整窑皮，待窑内
2.掉窑皮
cylinder of klin changes 正常时缓慢恢复窑速。酌情开停筒体冷却
klin coating
sharply. 风机。
falls down
2.原窑皮完整性不好。 Properly slow down the turning speed of
The integrality of the original klin, repair and level the klin coating,
klin coating is not good. slowly restore the turning speed of the
3.窑电流短时间内异常迅速地 klin after the inner of the klin is normal.
高出正常值，筒体局部高温。 Start and stop the air cooling machine of
cylinder based on actual situation.
The klin current quickly
exceeds the normal value in c.掉窑皮筒体温度严重超限时，应停窑。
short time; the temperature in If the temperature of the cylinder from
local of cylinder is very high. which the klin coating falls, then the klin
4.可见窑皮，呈暗红色。 should be stopped.
The klin coating is seeable

and the color is wine.
1.传动齿轮及托轮轴承润滑不 a.立即停分解炉及窑头燃烧器，停料，减
良磨损严重。少冷却机冷却风量，调整熟料电收尘器引
The lubrication of driving gear 风机转速，防止太多的冷风入窑，使窑内
3. 回转窑停车
and the bearing of supporting 保温。
rotary klin is
stopped roller are not good and are Stop the reduction furnace and kiln outlet
worn seriously. burner immediately, stop feeding
2.液压挡轮系统故障。 material, reduce the cool air amount of
the air cooling machine, adjust the
The Hydraulic thrust roller
turning speed of the induced draught fan
system failure.
of the clinker EP to prevent too much
3.窑头、窑尾密封圈损坏，漏
cool air enters into klin, keep the
风严重。
temperature of the klin.
The seal rings at the kiln
b.减小窑尾主排风机转速或阀门开度，注
outlet and kiln inlet are
意防止废气温度超限。
damaged and the air leakage
Reduce the turning speed of main air
is serious.
exhauster in the kiln inlet or the opening
4.大小齿轮、托轮与轮带接触
of the valve, and be aware of avoiding
不良。
the temperature of the exhaust gas goes
The contact between big and beyond limitation.
small gears, supporting roller
c.用辅助传动慢转窑，注意窑尾积料。
and tyre is not good.
Use associate driving device to turn the
5.电机故障。Engine failure.
kiln slowly, be aware of the material
112 / 120

accumulations in the kiln inlet.
d.降低冷却机篦床速度，但不要使热熟料
烧坏篦板。
Slow down the speed of the grater bed of
cooling machine, but don’t make the hot
clinker to burn out the grater board.
e.如较长时间不能排除故障，应考虑全系
统停车。
If the failure can not be eliminated after a
long period of time, it’s should be
considered to stop the whole system.
f.查明原因，进行处理。
Find out the reason and handle it.
1.窑尾排风量突然下降。 a.塌料严重按窑跑生料故障处理，参见前
4. 预热器塌料 The exhaustion amount in the 述。但注意窑头负压的调整，严防热气流
the material of kiln inlet suddenly decreases. 冲出伤人。
preheater 2.清理旋风筒或管道堵塞时突 If the falling of material is serious, then
collapses 然冲料表现为锥体负压突然降 handle the failure as same as the failure
低。 of outputting raw material, refers to the
above mentioned process. But pay
The material is suddenly
attention to the adjustment of the
pushed out while cleaning the
negative pressure of kiln outlet to avoid
cyclone or pipe, showing that
the hot airflow rushes out and hurt
the negative pressure
people.
suddenly decreases.
b.对于较小程度塌料，一般不作特别处理，
3.窑尾温度下降幅度很大。
可适当增加窑头燃料喂入量，酌情调整操
The temperature in the end of
作。
klin decreases greatly.
For slight falling of material, in ordinary,
4.窑头负压减少，可能显正压。
there is no need to take special handling,
The negative pressure of kiln it’s can properly increase the fuel feeding
outlet decreases and maybe amount and adjust operation
shows positive pressure. correspondingly.
1.分解炉温度偏高，物料粘性 a.根据各级旋风筒负压显示，判断堵料位
增大，逐渐积存在锥部，未及置。
时清堵。 Judge the material blocking position
5. 预热器堵塞
停车 The temperature inside based on the display of negative
reduction furnace is a little pressure of different level cyclones.
the preheater
higher, the stickiness of b.如堵料严重，防堵清吹系统已失灵则应
is blocked and
material is increased which 人工捅料，此时特别注意人身安全。
stopped
113 / 120

makes materials gradually If the material blocks seriously and the
cumulates in the cone part anti-block and cleaning and blowing
and haven’t been cleaned in system is fail, then it’s should to poke the
time. blocked material manually, in this case,
2.旋风筒锥部物料垮落，下料 it’s should pay much attention to
管堵塞。 personal safety.
The material in the cone part c.如无法排除故障，须停料、停燃料、停
of cyclone falls down and 窑。严禁在堵料停窑四小时之内用拉大窑
blocks the material feeding 尾排风的方法处理堵料。具体停车顺序基
pipe. 本上可参照“正常停车”。
3.下料翻板阀长期窜风，下料 If the failure can not be eliminated, it’s
管本身结皮。The feeding flap must to stop feeding material and fuel,
valve leaks air for a long time, stop klin. It’s forbidden to handle the
the feeding pipe forms blocked material by increasing
agglomeration. exhaustion of kiln inlet within 4 hours
after the klin stopped due to material
blockage. The concrete stopping
sequence can basically refer to “normal
stopping”
d.排除堵塞基本操作步骤：
Basic operating steps for eliminating
blockage:
(1)确认堵料位置，从相应最高的观察孔观
察。
Identify the blocking position and
observe from the corresponding highest
inspection hole.
(2)从堵塞的那级旋风筒开始将其以下的
下料翻板阀用铁丝全部吊开。
Hoist up the all feeding flap valves
hereinafter the blocked cyclone by using
iron wire.
(3)根据堵料位置，用高压风管捅料棒从物
料的上面向下处理，尤其要清除结皮。
Based on the blocking position, poke
from up-down by using material poking
stick for high pressure wind pipe,
particularly to clean up the formed
agglomeration.
(4)处理故障时不能转窑，同时要通知有关
114 / 120

岗位注意安全，防止冲料凶猛、烫伤人。
The klin can not be turned while handle
faults, at the mean time, notice relative
posts to pay attention to safety to avoid
the material rushes out and scald
people.
(5) 清理堵料前，下级旋风筒所有孔洞均
须关闭。
Before clean blocked material, all holes
in different level of cyclones must be
closed.
(6) 关闭空气炮系统 Shut off air canon
system
（7）堵料清除完毕后要仔细检查 Carry
out detailed check after the blocked
material is cleaned up.
下料翻板阀动作不灵活、卡死调整翻板阀，使其灵活。
the feeding flap valve cann’t Adjust the feeding flap valve to make it
move freely or is deadly moves freely.
blocked
有害成分超标检查有害成分含量 check the content of
the harmful components harmful components
exceed indexes 增加旁路放风的比例 raise the proportion
of bypass ventilation
（5）冷却机及冷却风机系统 Cooling Machine and Air Cooling Machine System

1. 液压系统故障 hydraulic a.按“正常停车”顺序停窑。
system failure Stop klin based on the sequence of
1. 冷却机篦床 2 ．熟料破碎机故障 clinker “normal stop”.
停车 crusher failure b.继续通风冷却熟料，调整熟料电收尘器
Grater bed of 3.电气故障 electrical failure 后引风机转速，使风改变流向，减小入窑
cooler stop 二次风量。
Continue ventilation to cool clinker,
adjust the turning speed of the backward
induced draught fan of clinker EP, and
change the flow direction of the wind so
115 / 120

as to reduce the secondary air volume.
c.如有人在冷却机内作业应禁止窑头喷燃
料保温。
It’s forbidden to spay fuel into kiln outlet
to keep its temperature while there is
someone working within the cooler.
篦板损坏继续把熟料送空，也可停止篦床，注意尽
grater board damaged 量不让篦板掉入破碎机中，捡出篦板。
Continue to output clinker till it is
finished, it’s also can stop grater bed, be
aware of don’t letting grater board drops
into crusher as much as possible, pick
up grater board.
2. 冷却机篦下 1.篦板坏，漏料多。 a.检查篦床上熟料冷却情况和漏料温度。
风室堵死 The grater board is damaged Check the cooling situation of clinker in
the air and leaks lots of materials. grater bed and the temperature of
chamber leaked clinker.
2.熟料中细料过多。
under the b.及时更换损坏零件。Replace damaged
There is too much fine stuff in
grater of cooler parts in time.
the clinker.
is deadly d.按控制要求停窑。Stop klin according to
3.冷却机篦下压力增高。
blocked control requirement.
The pressure under the grater
of cooler increases.
4.风室内风温升高。
The air temperature inside the
air chamber increases.
3. 冷却机进料 1.熟料结大块或掉大块窑皮。 a.加大冷却风量和熟料电收尘器引风机排
口堵塞 The clinker agglomerates in 风量。
the feeding big block or big block drops Increase cooling air amount and the
opening of from klin coating skin. exhaustion amount of induced draught
cooler is 2.冷却机进料口结皮堆料。 fan of clinker EP.
blocked b.提高篦床速度。
The feeding opening of cooler
agglomerates which results in Increase grater bed speed.
material accumulation. c.防止窑不正常运转，检查熟料化学成分
3.篦床故障停车而窑仍运转下并予以控制。
料。 Avoid abnormal running of klin, check
The grater bed is stopped due the chemical component of clinker and
to fault whereas the klin still make control of its.
works and feed material. d.停窑，从冷却机侧部清理检查口及时人
116 / 120

4.预热器塌料或清理堵塞时突工捅料排除。
然垮落冲料。 Stop klin, clean the inspection hole from
The material of preheater falls the side of cooler and poke the material
down or suddenly collapses and eliminate blockage in time.
while clean blockage. e.重新启动。Restart
5.二次风温偏低。Secondry air
temperature is a little lower.
4. 篦床上出现见篦冷机部分 3.5.3.5 见篦冷机部分 3.5.3.5
“红料流” See the part of grate cooler See the part of grate cooler 3.5.3.5
"Red material 3.5.3.5
flow" occurs
on the grate
bed.
5．堆“雪人” 见篦冷机部分 3.5.3.5 见篦冷机部分 3.5.3.5
Forming the See the part of grate cooler See the part of grate cooler 3.5.3.5
snowman 3.5.3.5
熟料粒度过细提高窑头温度，检查熟料率值 SM 是否过
The particle size of the clinker 大
is too small. Increase the temperature of kiln outlet,
and check to see whether SM, one of the
6. 篦板温度偏
modulus values of clinker, is too big or
高
not
Higher
篦床上出现“红料流” 参见上述
temperature of
the grate plate "Red material flow" occurs on See above.
the grate bed.
风室冷却风量过大，熟料层被减小该风室风量，适当减慢篦速
吹穿 Decrease the air volume of this air
The cooling air volume of the chamber, and slow down speed of the
air chamber is too big, and the grate appropriately
clinker layer is blown through.
风室冷却风量过小，不足以充开大该风室风量，适当加快篦速
分冷却熟料 Increase the air volume of this air
The cooling air volume of the chamber, and accelerate speed of the
air chamber is too small to grate appropriately
cool the clinker completely
篦床上有大块熟料适当加快篦速
Large-size clinkers appear on Accelerate the speed of the grate
the grate bed appropriately
117 / 120

篦床速度过快，料层过薄适当减慢篦速
The speed of the grate bed is Slow down the speed of the grate
too fast, and the material bed appropriately
is too thin
冷却风量不够适当增加有关风室的风量
7. 冷却机出料 Insufficient cooling air volume Increase the air volume of relevant air
温度偏高 chambers appropriately
Higher 篦床速度过快适当减慢篦速
temperature of The speed of the grate bed is Slow down the speed of the grate
the material too fast appropriately
discharged
篦床上出现“红料流”或熟料结参见上述
from the cooler
大块 See above.
“Red material flow” or large
clinker block occurs on the
grate bed
1.熟料层太厚。 a．检查篦板与压力设定值比较是否合
8. 冷却机的冷 The clinker layer is too thick. 适。如有必要的话，改变压力设定值
却风量不够加快篦速。
2.篦床速度之间的比率不当，使
Insufficient 得二段低压不能通过熟料层。 Check to see whether the setting value
cooling air of the pressure is proper for the grate
The second-section low
volume of the plate. Change the setting value of the
pressure could not get
cooler pressure and accelerate the speed of
through the clinker layer due
the grate if necessary.
to improper rate between
speeds of grate beds. b．改变篦床速度之间的比率，加快二段
篦速，减薄熟料层。
3.熟料在篦床上局部堆积。
Change the rate between speeds of
Clinker deposit on part of the
grate beds, accelerate the grate speed
grate bed
of second-section, and thin down the
clinker layer.
c．增加相应风室的风量。
Increase air volume of relevant air
chamber.
1.风机润滑不良 a．如果篦板下面的一台风机跳停，其相
9. 冷却风机停 Lubricant starvation of the fan 应的篦板驱动在 5 分钟后必须停止（防止
车 Coanda 喷嘴的冷却缝被细的熟料堵塞），
2．轴承温度超限
其后按正常停车处理
Shutdown of Over-limit bearing
the cooling fan If tripping of a fan under the grate plate
temperature
occurs, the corresponding drive of the
3.电机故障等
grate plate must be stopped after 5
118 / 120

Motor failure and etc. minutes, in order to prevent the cooling
seam of the Coanda nozzles from being
blocked by fine clinkers. The normal
shutdown process should be abided by
afterwards.
b．如果篦板下的所有的冷却风机跳停，
相应的篦床应在 1 分钟内停止，再过 5 分
钟停窑。
If tripping of all cooling fans under the
grate plate occurs, the corresponding
grate bed must be stopped within 1
minute, and the kiln must be shut down
after 5 minutes.
c.注意窑头的负压变化，随时调整熟料电
收尘器后引风机的转速。
Pay attention to variation of the negative
pressure of the kiln outlet, and adjust the
rotation speed of the exhauster behind
the electric precipitator of clinker at all
times.
a.断开所有设备的启动开关。
Cut off start switches of all equipments.
b.事故风机及窑辅助传动接通保安电源，
10.全厂停电紧急启动间隙慢运转。
Blackout of the Switch on emergency power for the

whole plant emergency fan and auxiliary drive of the
kiln, and start up interval slow running
urgently.
c.拉出窑头燃烧器。
Haul out the burner from kiln hood.
d.注意窑尾风机的间隙慢运转。
Pay attention to the interval slow running
of the fan of kiln inlet.
e.注意窑系统冷却要缓慢，并为可能短时
间来电重新启动创造可能性。
Make sure that the kiln system is cooled
slowly, and create possibility for restart
due to possible power-on within a short
period of time.
119 / 120

f.恢复运行应先适当清理预热器下料管及
窑尾烟室积料。
Clean up material deposits in
discharging pipe of the preheater and
smoke chamber of the kiln inlet before
restoring the system to normal
operation.
120 / 120

Clinker Burning System

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Clinker Burning System

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HOFUF CEMENT PLANT 5th & 6th EXTENSION PROJECT Burning System

本系统的核心部分：烧成窑尾、烧成窑中、烧成窑头的主机分别由 SINOMA 提供了在线旋喷

本操作手册仅限于 HOFUF CEMENT PLANT 5TH/6TH EXTENSION PROJECT 2×10000t/d

book provided by equipment supplier will be finalized.

2．生产工艺流程简述 Brief Description of Production Process Flow

2.1 生料入窑 Feeding Raw Meals into the Kiln

2.2 生料预热与分解（烧成窑尾）Preheating and precalcining of Raw Meals (Calcinating Kiln

正常情况下，系统的总阻力损失为 5800~6500Pa，出一级筒飞灰量约 70g/Nm3，废气温度为

两根外径为 Φ3000mm 的三次风管（437TD1，TD2/438TD1，TD2），一端与篦冷机的前端两侧

Φ6.2×92m 的回转窑，斜度为 4%，三档支撑，窑尾配有汽缸压紧式密封装置，并配有两台空压

2.4 熟料冷却与废气处理和窑头燃烧系统（烧成窑头）Clinker cooling, exhaust treatment and

2.5 Clinker Conveyance

2.6 Bypass and Returned Ash Conveyance

3. Operation Instructions of Major Equipment Units of the Burning system

3.1 General Description

3.4 Operation Mode

3.5 主要设备单元的操作规程 Operating Instructions of Main Equipment Units

3.5.1 回转窑 Rotary kiln

3.5.1.1设备概述 Equipment Summary

3.5.1.2主要技术性能 Main Technical Performances

3.5.1.3 主要结构和控制元器件概述 Summary of Main Structures and Control Components

2）传动装置 Drive unit

1PQ4560-6CM90-Z 1050 1197 120~1197~1504 1LG4223-4AA 54 1770

3）支承装置 Supporting Unit

4）液压挡轮装置 Hydraulic thrust roller unit

5 个行程开关的的动作分别代表窑的 5 个位置，由 5 个行程开关的信号分别控制挡轮油泵站的

5) Sealing Device of the Kiln Outlet

6) Sealing Device of the Kiln inlet

3.5.1.4 开机前的准备 Preparations before Startup

1）窑体 Kiln body

2）托轮 Supporting roller

a, Confirm whether each part’s bolts are loose or not.

b, Confirm whether a shaft temperature detection apparatus is intact or not.

3）传动装置 Drive unit

a, Check the engagement, abrasion and lubrication circumstances of a gearwheel or a pinion.

c, Check the oil amount of an oil tank;

d, Confirm whether each part’s bolts are loose or not.

h Check whether each valve or pipeline is normal and leaks oil.

4）液压挡轮 Hydraulic thrust roller

5）窑头罩 Kiln hood

b Check whether the kiln hood rubs with a revolving part.

3.5.1.5开停机顺序及注意事项 Startup and Shutdown Sequence and Matters Need Attention

1）开停机顺序遵循的原则 Principles to be followed for startup and closedown sequences

2）开停机顺序 Sequences for Startup and Closedown

A）开机顺序 Sequence for startup

B）停机顺序 Sequence for Closedown

3）注意事项 Points for attention

d. Do not start an oil pump and drive unit without oil.

e, Confirm the position of a clutch.

3.5.1.6 运转过程中的检查 Inspection During Operation

1）传动装置的检查 Drive unit inspection

b, Check whether there are abnormal vibration, noise and odor;

c, Check whether the foundation bolts are loose.

b, Check whether there are abnormal vibration and oil leakage;

b, Check whether there is a swinging phenomenon.

D.传动大、小齿轮及轴承 Driving Gearwheel, Pinion and Bearing

c, Check the radial and axial swing circumstances of a gearwheel;

2） 轮带及支承装置的检查 Inspection of tyre and supporting apparatus

is abnormal noise, and whether a baffle block or baffle ring is available;

f, Check whether the supporting roller bearing temperature rise is normal;

i, Check whether the foundation has dither and local settlement.

3） 液压挡轮及挡轮油泵站Hydraulic thrust roller and thrust roller oil pump station

d, Check whether the oil temperatures at all points are normal;

g, Check whether each part has oil leakage;

2）轮带及支承装置的检查 Inspection of tyre and supporting apparatus

3）液压挡轮及挡轮油泵站Hydraulic thrust roller and thrust roller oil pump station

4）窑筒体的检查 Inspection of kiln Shell

a、确认轮带的内径与轮带下垫板外径之间的间隙达 20mm 时，应做相应的处理。

b、轮带发现断面磨损了 10% （这时应对其应力及刚度核算），或表面磨成锥形、多边形，以及

c、当托轮厚度磨损了 10% ，挡轮的轮缘厚度磨去 20% ，或托轮表面磨成锥形、多边形或其

d、传动齿轮的齿厚磨损了 30%或 0.5 模数时；或轮缘具有不可恢复的损伤时需更换；

j、检查窑、窑头罩等处的耐火材料，掉砖必须补，蚀薄大于 1/3 必须更换。

轮带内表面与垫磨损所致。更换垫板或加垫片。