5,000 TPD CMIC CEMENT PLANT

PROJECT IN CAMBODIA

391--RAW MEAL TRANSPORT AND STORAGE

411--RAW MEAL TRANSPORT TO KILN FEED

431--KILN FEED

操作说明书

Operation Specification

中信重工工程技术有限责任公司

CITIC HIC Engineering&Technology Co.,Ltd

二零一七年三月
March 2017
 5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

目 录
Catalog
第一章 前 言............................................................................................................................... 1
Chapter 1 Preface ............................................................................................................................ 1
第二章 工艺流程及工艺设备介绍 ................................................................................................ 3
Chapter 2 process flow and equipment introduction......................................................................... 3
2.1 生料均化库系统介绍 Raw homo silo system introduction ................................................ 3
2.2 工艺流程简介 Process introduction.................................................................................... 4
2.3 工艺设备 Equipment .......................................................................................................... 4
第三章 启动前的准备工作 ........................................................................................................... 5
Chapter 3 Preparation before start up............................................................................................... 5
3.1 生料均化库装料前的准备工作 The raw meal preparation before filling the raw meal silo.
................................................................................................................................................. 5
3.2 生料入窑调试前的准备工作 The preparation for raw material into the kiln prior to
commissioning ......................................................................................................................... 8
3.3 设备空载试车 Equipment no-load test ............................................................................. 10
3.4 投料试生产前的确认事项 Checklist before load test and commissioning ....................... 11
第四章 系统的开停顺序说明和投料试生产 .............................................................................. 13
Chapter 4 system startup-stop sequence decription and commissioning test run ............................. 13
4.1 系统的开停顺序说明 System startup-and-stop sequence description ........................... 13
4.2 投料试生产 Commissioning test run .............................................................................. 17
第五章 系统运行检查、常见故障及处理 .................................................................................. 19
Chapter 5 system running inspection, common fault and treatment ................................................ 19
5.1 系统运行检查 System running inspection ...................................................................... 19
5.2 常见故障及处理 Common fault and treatment ................................................................ 20
5.3 日常维护 Daily maintenance ........................................................................................... 22
5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第一章 前 言

Chapter 1 Preface

本调试操作说明书仅供 5,000 TPD CMIC CEMENT PLANT PROJECT IN

CAMBODIA 系统操作时使用。
This commissioning manual only used for homo silo system of 5,000 TPD CMIC
CEMENT PLANT PROJECT IN CAMBODIA.
5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA 项目生料均化系
统采用 IBAU 型中心室均化库(简称 IBAU 伊堡库)，伊堡库是一种连续操作的均
化库，正常运转时可上部连续进料，下部连续出料。其原理侧重于库内重力混合
作用，基本不用或减小气力均化作用，以简化设备和节省电力。在混合室或均化
室库内，设有一个轮流充气区，向搅拌仓内混合进料，而多料流式均化库则有多
处平行的料流，漏斗料柱以不同流量卸料，在产生纵向重力混合作用的同时，还
有径向混合作用。本调试操作说明书是在简单介绍各系统主要工艺过程、主要选
用设备的基础上，根据各系统的要求和特点，为保证系统的正常运行和生产而提
出的主要操作事项。操作人员在全面掌握本说明书中各项操作要领的同时，还必
须通晓系统中每一台设备的性能、维护保养和操作安全等方法与要求，必须熟知
中控操作的方法与步骤、以及各仪表测点指示参数正常工作的范围及报警点以及
在报警时应采取的措施及步骤，以便在实际生产操作中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处理。系统中每一台设备的性能和维护操作等
方法与要求，请参阅各相应设备供货厂商提供的单机使用说明书。
5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA project raw
material homo system uses IBAU type central chamber homo silos (abbreviation
IBAU), IBAU is a continuous operating homo silo. In normal operation the upper can
continue feed the lower can continue discharge. The operating principle focuses
gravity mixing in silo. It is nearly never use or to reduce pneumatic homo action to
simplify the equipment and save power. There is a gas-filled region in turn in the
mixing chamber or homo silo which can provide mixed feed for stirred bin. And
multi-material flow homo silos have many parallel material flows. Funnel material
column will discharge with different flow to produce longitudinal gravity mixing
effect, meanwhile, it also produce radial mixing effect. The debugging operating
manual is a brief introduction of the main process for each system and main

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

equipment used. It is mainly operation item which can ensure the normal operation
and production according to the requirements and characteristics of each system. The
operator should completely know each operating essentials in the manual ，
meanwhile ， he must proficient each equipment performance in the system,
maintenance and operational safety methods and requirements. Must know operating
methods and procedures，each instrument measuring point indicating parameter work
range and alarm point and measures and steps to be taken at alarm point. It is
convenient to resolve various problems appeared and to fix problems flexibly
according to the actual situation. Each equipment performance, maintenance and
operation methods and requirements in the system please refer to stand-alone
equipment instruction manual provided by the respective equipment suppliers.
编制本操作说明书的基本依据是各类设计文件，同时结合以往生产调试的经
验。在实际生产中，如本操作说明书所述与实际情况有偏差时，或者对所述内容
有疑问时，请与我院派往现场的调试技术人员进行协商解决，并根据实际情况进
行修改。
The operating manual is compiled basically based on types of design documents
and combined with previous production debugging experiences. In actual production,
the operating manual content may has a little bit deviation with the actual situation, or
have questions about the content, please contact our institute commissioning and
technical personnel dispatched to the work site to settlement in negotiation way, and
to modify it according to the actual situation.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第二章 工艺流程及工艺设备介绍

Chapter 2 process flow and equipment introduction

本系统采用一座Φ18mIBAU 型生料均化库对生料进行均化，选用固体流量
计对入窑生料进行计量，生料经空气输送斜槽、斗式提升机送入窑尾预热器内。
This system uses a Φ18mIBAU homo silo to homo raw meal, selects solid flow
gauge to measure feed raw meal. Raw meal is delivered to air slide through air and
transported to pre-heater through bucket elevator.

2.1 生料均化库系统介绍 Raw homo silo system introduction

2.1.1 设置均化库的目的：
2.1.1 Homo silo establising purpose:
作为生料磨与窑之间的缓冲环节，即：
Used as buffer between raw mill and kiln, that is to say:
a.作为生料磨与窑之间的缓冲环节，它既是生料均化装置，又是来自原料粉
磨系统的生料的储存装置，其工艺特点是：使生料均化连续化，即在成分波动较
大的出磨生料进库的同时，可从库底不断卸出成分均匀的生料，供窑使用，保证
熟料烧成系统的连续运转。
a. Homo silo which is a buffer between raw mill and kiln is both raw material
homogenizing equipment and raw material storage device from raw material grinding
system. And its process characteristic is: let raw material continously homogenizing,
that is to say, when volatile raw meal from mill enters to silo, uniform raw meal can
be unloaded continously to kiln. In this way, clinker burning system can be running
continuously.
b.稳定生料的化学成分，缩小其波动范围，保证熟料质量。
b. Stable chemical composition of raw materials, reduce its range, ensure the
quality of clinker.
2.1.2 均化库的能力
2.1.2 Capaciy of homo silo
均化库规格： Φ18×67.7m ，有效容量为：Q=12000t

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

Homo silo size: Φ18×67.7m, effective capacity: Q=12000t

2.1.3 生料均化库系统的主要设计技术经济指标
2.1.3 Main technical and economic indicator of homo silo system
连续三天计算，出库生料的 CaO 标准偏差 S≤±0.2%.
Standard deviation S for CaO of material from silo can not excess 0.2% for three
days consecutive calculation.

2.2 工艺流程简介 Process introduction

库底中心设置一个大型圆锥，通过它可将库内荷载传递到库壁,结构合理。
库壁与圆锥之间形成环形区，并将其分为 6 个充气区，由 6 个气动流量控制阀控
制卸料量，生料经斜槽进入库底中心称重仓内。生料在称量仓经过再一次搅拌均
化后，从卸料器卸出，经冲板流量计计量后，由空气输送斜槽(431-AS1)送入斗
提机(431-BE1)，最后送入窑尾预热器中。或者由空气输送斜槽(431-AS1)送入斗
提机(391-BE1)，最后返回生料均化库中。
There is a large cone in the center of silo bottom. This cone which structure is
reasonable can transfer load in silo to silo wall. In this way, a annular region is formed
between silo wall and cone having 6 aeration zones controlled by 6 flow control
valves to discharge. Raw meal will enter into bottom center weighing bin through air
slide. Raw meal will be discharged from weighing bin stirring and homogenization
once again. And then enter to bucket elevator (431-BE1)after passed through impact
flow meter through air slide(431-AS1), finally enter to pre-heater. or return to
homosilo.

2.3 工艺设备 Equipment

本系统所有工艺设备主要技术参数见设备表。
Equipment technical please see the equipment list.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第三章 启动前的准备工作

Chapter 3 Preparation before start up

本系统起动前应进行认真的检查调整工作，不仅在调试阶段，而且在正常生
产中也应作为生产操作规程的一部分被认真执行，以确保各设备的安全运行和系
统的稳定生产。
The system should be carefully checked and adjustment before starting work, not
only in the installation and commissioning phase, and in normal production should
also serve as part of the production rules to be seriously implemented, In order to
ensure stable production of all equipment and systems.

3.1 生料均化库装料前的准备工作 The raw meal preparation before filling

the raw meal silo.

生料均化库能否达到设计要求，在很大程度上取决于施工及安装质量。为保
证生料均化库一次投料成功，并能长期安全运行，在库准备投料前，必须对均化
库的施工、安装情况作全面的检查，在装料之前处理存在的隐患。否则一旦库已
投料，就可能影响到均化库的均化效果、使用寿命，从而影响整条生产线的正常
运转，因此应对库装料前的准备工作引起足够的重视。
Raw meal silo if or not can meet the design requirements, It depends largely on
the quality of construction and installation. In order to ensure feeding success of raw
meal silo, And also can long-term safe operation, Before the raw mill filling into the
raw meal silo, Construction and installation of the meal silo must have a
comprehensive examination, The security risks must be excluded before loading
process. Otherwise, if the meal silo is feeding, It may affect the meal silo effect,
service life, Thus affecting the normal operation of the entire production line, So the
filling meal prepared work of the meal silo must be seriously enough.
3.1.1 均化库建成之后，应尽可能除去库内的凝结水，天气干燥时应打开均
化库各门孔，必要时打开库底罗茨风机，库顶除尘风机。并检查均化库的施工质
量，确保库不漏渗雨水，同时要严防杂物入库，保持库内清洁。
3.1.1 After the meal silo is completed, the condensation water should be
removed as far as possible ,all the doors hole of the meal silo should be open in dry
weather, Open the Roots blower of the bottom silo and dust blower top of the meal

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

silo if necessary. And check the construction quality of the meal silo. Ensure that the
meal silo does not leak rainwater, To prevent debris while in storage, Keep the meal
silo clean.
3.1.2 经制造厂充气检查合格的充气箱抵达现场后，在进均化库安装之前仍
需对充气箱进行检查，凡怀疑密封胶已干脱或其它原因漏气的充气箱均需拆下充
气层，重新涂上密封胶再装上充气层。充气层有损坏的均需更换。
3.1.2 After the inflatable tank which have already inflatable checked by the
manufacturer arrived at the site, Prior to installation into the meal silo plenum boxes
still need to be checked, Where doubt sealant has dried off or other reasons are
required to remove the tank leak inflatable layer, Recoated with sealant and then
mounted on pneumatic layer. Inflatable layer of damage required to be replaced.
3.1.3 经检查后的充气箱可根据图纸要求，在均化库安装就位，充气箱的安
装斜度必须满足图纸要求，再按图纸要求把充气箱和管道联结起来，安装过程或
安装完毕后，应检查充气管道阀门是否运转灵活，开关状态是否满足工艺要求，
充气管道内应无电焊渣及其余堵塞物，并清除库内所有杂物。由于斜槽、充气箱
等都采用尼龙或涤纶织物做充气层，很容易被电焊或电焊渣烧坏，以及机械损伤，
故应仔细检查，如有损坏者应及时更换或修补。
3.1.3 Inflatable box which has been checked should mounted on the correct place
of the meal silo according to the requirements of the drawings, Inflatable box
installation slope must meet requirements of the drawings according to the drawing,
Then connect the plenum boxes and duct together according to the drawing, Inflatable
pipe valve should be checked the operating flexibility before installation or after
installation, Whether the switch state meet the technical requirements, Whether the
inflatable pipe have welding slag or the other obstruction. And remove all debris in
the meal silo. Because of the slide and inflatable box both adopted inflatable nylon or
polyester fabric as layer fabrics, It can easily be burned welding or welding slag, as
well as mechanical damage, so it should be carefully examined, If damage should be
replaced or repaired.
3.1.4 投料前，必须对库充气系统进行一次全面检查，开启罗茨风机及管路
阀门向库内送风。逐个检查每一个充气箱、管道接头及焊点的密封情况，可以用
肥皂水涂在检查部位，如该处漏气，将会出现肥皂泡。漏气的充气箱如在拧紧螺
栓后仍未解决问题，则需拆开充气箱检查处理。处理完毕后再安装好充气箱进行

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

检查。管道在连接处漏气时，需打紧活接头或弯头，或采取其它措施来处理，必
须强调，在库内充气层已装上的情况下，不宜再在库内使用电焊或气焊处理管道
漏气问题，以免烫坏充气层。
3.1.4 Before feeding the raw meal, The pneumatic system of the raw meal silo
must have a comprehensive inspection, Roots blower and pipeline valve open air flow,
And then check each inflatable box, each pipe joints and weld joints sealed case, You
can check the site with soap water applied, If the leakage, Soap bubbles will appear.
Inflatable tank leak after tightening the bolts as problem is not resolved, The
Inflatable box need to open check and processing. Disposed the above mistake, after
installing the boxes to be checked. If the pipeline leak at the connection time, Need
open the union or elbow, Or take other measures to deal with, It must be emphasized,
In the case of the raw meal silo has been installed on the inflatable layer, It is not
appropriate to use welding or gas welding processing pipeline leak problem in the silo,
in order to avoid scorch pneumatic layer.
3.1.5 在确认库内充气系统无问题之后，再次清除库内杂物，然后用微膨胀
水泥将库内引入管道的各预留孔封死。因预留孔数量多，直径小，堵死时必须谨
慎，杜绝投料后库预留孔向外喷灰现象。
3.1.5 After confirming inflation system in the raw meal silo no problem, Again
cleared dirty material of the silo, Then seal all holes which introduced into pipes the
respective with expansive cement. Care must be taken when sealed, Because holes for
quantity and Small diameter, To prevent ejectors outward phenomenon of the
reserved hole when the meal silo working.
3.1.6 在投料前，应开启罗茨风机向库内送风 1—2 周，以便干燥充气材料，
同时可带走库内湿气，防止生料在库壁结料。
3.1.6 Before feeding, Roots blower to the silo should be open for 1-2 weeks, So
as to dry inflatable material and carry away moisture,Prevent raw materials junction
and compaction in the library wall.
3.1.7 上述各项准备工作均已完成后，可以封好库侧人孔门，作好装料运转
的准备。
3.1.7 After the above preparations have been completed, You can seal the silo
side Manhole,Make preparations for feeding operation.
3.1.8 长期投产以后的每次清库，若需更换库底充气系统中的部分充气层、

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

充气箱或充气管道等，则也应遵守上述准备工作中的一些具体事项。
3.1.8 For each clearing silo after long-term production, If need replace the
pneumatic layer Inflatable box or inflatable pipelines of the silo bottom portion the
pneumatic system, It should also comply with some of the specific issues of above
preparatory work.
3.1.9 生料均化库设备的安装及运行前的检查与确认均应按照设备制造厂的
操作说明书要求进行。
3.1.9 The installation and operation requirements of the raw meal silo equipment
check and verify should be carried out the manufacturer's operating instructions
before the equipment.

3.2 生料入窑调试前的准备工作 The preparation for raw material into the

kiln prior to commissioning

窑喂料系统是稳定预热器窑热工制度，确保熟料的产质量，提高窑运转率的
重要环节之一。缩短生料入窑的调试周期，争取一次投料成功，将为完成烧成系
统的调试工作打下良好的基础，因此应重视生料入窑调试前的准备工作，全面检
查该系统设备加工及安装情况。
Kiln feed system is one of the important part for stable preheater kiln thermal
system, ensure the production of clinker quality and improve kiln operation rate.
Shorten the Installation and commissioning cycle of raw material into the kiln, Strive
for the first feeding success, Will create a good foundation for complete the
commissioning of the firing system,Therefore, much attention should be paid for the
commissioning preparation work of raw material enter into the kiln, The
comprehensive inspection system equipment for processing and installation.
3.2.1 在计量仓安装完毕之后，需对该系统充气箱及充气管道的密封性进行
检查及处理，以确保不漏气。应检查充气箱内充气材料有无损坏，充气材料是否
干燥，若潮湿应开启罗茨风机吹干。检查仓内是否有杂物，检查各人孔门及检修
门是否密封良好。
3.2.1. After the Measurement bin is installed, You need to inspect and process
the inflatable sealing systems and inflatable tank and pipeline,make ensure air
tightness.The inflatable box should be checked for its inflatable material damage and
inflatable material is dry, If it is wet, then turn dry the bin wall use Roots blower.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

Check whether there is debris in the measurement bin,Check each of the manhole and
each of the access door is sealed.
3.2.2 检查计量仓进出料管、进出风管的软接头，确保计量仓不受外力影响，
以保证系统计量精度。还需对计量仓荷重传感器作一次静态校正，未装料时读出
荷重传感器测出的重量，然后比较计量仓设备重，从而检查计量仓是否独立，并
检查计量仓支座是否找平。有条件时，应对计量仓荷重传感器进行一次加码标定。
3.2.2. Check out the measurement bin feeding/discharging material tube,
inlet/outlet air duct soft joints, Ensure the measurement bin Free from external
influence , To ensure that the system measurement accuracy. We also need for a static
correction of the measurement bin load sensor, Reads the instrumentation value of the
load sensor before material is feed, ,So as to check whether the independent the
measurement bin, And check bottom supports of the measurement bin is leveling. We
also should overweight calibration once the measurement bin load sensor when
conditions.
3.2.3 计量秤及荷重传感器运行前的检查与确认按设备制造公司提供的操作
说明书要求进行。
3.2.3 Check and confirm of the measurement scales and weight sensor before
running must comply with the operating instructions company requirements which
provide by device manufacturer.
3.2.4 斗式提升机运行前的检查与确认按设备制造公司提供的操作说明书要
求进行。
3.2.4 Check and confirm of the bucket elevator before running must comply with
the operating instructions company requirements which provide by device
manufacturer.
3.2.5 检查各种阀门是否动作灵活，开关状态是否满足工艺要求，各仪表与
电器执行元件的接线是否正确。
3.2.5 Examine the various valves are flexible action, whether the switch state
meet the technical requirements, instrumentation and electrical wiring for each
actuator is correct.
3.2.6 检查袋式收尘器的袋室、灰斗等部件内的杂物是否清除干净；检查各
滤袋捆扎是否完好、且没有破洞和裂口、滤袋是否拉紧和挂直，各风管、阀门、
排灰阀、人孔门等设备部件连接处应检验其严密性，若发现接口严密性差，应需

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

整形或及时更换密封填料。
3.2.6 Check the bag filter bag room and dustbin and other components inside the
hopper is cleaned; Check the bag banding is intact without holes and cracks, The bag
is tighten and hang straight, Each air pipes, valves, ash valve, Manhole equipment
parts connections should test its air tightness, If you find the interface air tightness is
poor, You should be finishing equipment shapes replace plastic sealing packing.
3.2.7 更为详尽的每台单机设备安装后与调试使用前的检验要求参见相应的
设备产品说明书。
3.2.7 More detailed inspection requirements of separate device after the
installation and testing prior to commissioning requirements need refer to the
appropriate device data sheet.

3.3 设备空载试车 Equipment no-load test

3.3.1 润滑加油，确保各加油点、润滑点均不被遗漏。注意使用相应的正确
油号的润滑油，其油路应畅通，油压符合说明书要求。
3.3.1. Lubricating stations and lubrication piping fill oil and grease, Ensure that
the each refueling point, lubrication points are not be missed. Note that the the type
and grade of oil and grease use is correct, Its passage should be smooth and unblock,
Oil pressure comply with the specification requirements.
3.3.2 检查设备冷却用的给排水管路畅通，水压满足设计要求，电路接线正
确无误。
3.3.2 Check water drain line for the cooling equipment smooth and unblock,
Water pressure meet the design requirements, Circuit wiring is correct.
3.3.3 限制操作，严禁非作业 员随意动手和开启按钮，确保人身安全。
3.3.3 Limiting operation, The behavior of non-workers random touch and the
open button. Ensure personal safety.
3.3.4 本系统每台设备逐个进行空载试运转，应根据相应设备的说明书及验
收标准进行。
3.3.4 The no-load test run for each device individually, It should be carried out
according to the instructions and acceptance criteria corresponding device.
3.3.5 特别强调：每台罗茨风机要至少进行 8 小时的连续运转、并利用管路
上阀门将风机出口压力调至设计压力，观察罗茨风机轴温情况、出口管道内空气

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

温度、电机电流大小等，以便判断和确认罗茨风机能否保证长期安全运转，另外
应记录每台罗茨风机在正常工作状态时的出口静压，供以后判断均化库与计量仓
内物料的情况时参考。
3.3.5 With particular emphasis on: Each roots blower to be continuous operation
at least eight hours,And make outlet pressure adjusted the fan design pressure by
virtue of the pipeline valve,Observe carefully for the bearing temperature of the Roots
Blower, Pipe outlet air temperature,Motor current, etc.In order to determine and
confirm the roots blower can have a long-term safe operation,It should also be
recorded the outlet static pressure of each roots blower in normal working condition,
For later reference when judging the materials positions within the homogenization
silo and the measurement silo.
3.3.6 对各分组设备联动试车，要观察其开停顺序是否满足工艺联锁要求，
尤其是库底气动阀是否按分区、定时的充气程序开闭。
3.3.6 Linkage test for each Grouping Devices,
To observe the opening stop order meets the process interlock requirements,In
particular, whether the silo bottom pneumatic valve partition can meet the
requirement of Partition,as well as the timing of the opening and closing of a
pneumatic program.
3.3.7 在袋式收尘器及其风机试车期间，可调整各收尘点通风管道上手动碟
阀的开度至某一位置，保证各点收尘通风维持一定的微负压值；待投料生产后，
其阀门开度可能会随各点收尘情况再进行整定。
3.3.7 During the commissioning of the bag filter and its’ fan, Adjust the degree
opening of manual butterfly valve of the ventilation ducts on each collecting point to a
certain position,To ensure that collecting dust ventilation points maintain a certain
slightly negative pressure value, Until after the feed production, Its valve opening
may then change with each point collecting case.

3.4 投 料 试 生 产 前 的 确 认 事 项 Checklist before load test and

commissioning

3.4.1 确认所有设备润滑加油点的油量与油质情况符合规定要求，并且不漏
油、不堵塞。
3.4.1 Make sure that the oil quantity, oil pressure and oil situation of all
equipment lubrication point and refueling point is subject to the requirements, and not

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

oil leakage, not oil plug.

3.4.2 确认所有设备所需供水、供气的管路通畅，压力满足设计和运行要求。
3.4.2 Make sure that the water supply tube line and air supply tube line of all
equipment is smooth and no block, Pressure to meet the design and operational
requirements.
3.4.3 确认本系统中所有设备完好无损，旋转方向正确无误，无异常故障；
各种阀门动作灵活准确，调节控制量与实际操作要求相符，各种仪器仪表指示和
信号联络有效无误。
3.4.3 Confirm all devices in the system is intact, The rotational direction is
correct, No abnormal failure; A variety valve action is Flexible and accurate,
Adjusting the control amount consistent with the actual operating requirements,
Various Instrumentation instructions and signal contact is effective and correct.
3.4.4 确认集中控制完全满足工艺开停与联锁要求，各操作岗位和生产车间
通讯联络畅通。
3.4.4 Confirm centralized control technology fully meet the process opening stop
and interlock requirements, The Communications unimpeded of Each operation and
production workshop.
3.4.5 与中控室、相关电气室联系，确认所有设备已经做好供电的准备，随
时可以按操作要求投入运行。
3.4.5 Contact with the control room and the related electrical room, Make sure
that all equipment is ready to power supply, Ready to be put into operation according
to operational requirements.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第四章 系统的开停顺序说明和投料试生产
Chapter 4 system startup-stop sequence decription and
commissioning test run

4.1 系 统 的 开 停 顺 序 说 明 System startup-and-stop sequence

description

本系统各分组设备的开停顺序操作见窑尾电气室操作说明部分，其一般原则如
下：
Open stop order for each Grouping device of Process Systems operating system, see
the kiln tail electrical room section operating instructions，the general principles are
as follows:
4.1.1 收尘系统总是先于库底充气、生料输送和入窑喂料开机，并在生料输送和
窑喂料的有关设备停机后才允许停收尘系统。
4.1.1 Dust collection system is always started up before inflatable system at the
bottom of silo,raw material conveying and feeding power into the kiln, and stopped
after the related equipment of raw material conveying and kiln feeding.
4.1.2 库底卸料阀的开关取决于计量仓内生料量的多少，卸料量可根据实际生产
情况随时调节。
4.1.2 Unloading valve switch at bottom of silo depends on raw material quantity in
measuring bin. Unloading quantity can be adjusted at any time based on actual
production conditions.
4.1.3 生料库库底轮流分区充气顺序由顺序控制器控制。各区延时时间应在调试
时间结合生料物性、供气罗茨风机压力等因素来调整，以达到最佳均化效果。
4.1.3 Alternate and zone inflatable sequence are controlled by sequence
controller.Delay time for each zone can be adjusted combined with raw material
nature and pressure of roots fan to achieve the optimum homogenizing effect.
4.14 411-3B1 储料仓部分，收尘系统依然是先于仓底充气、生料输送和入窑喂料
开机，并在生料输送和窑喂料的有关设备停机后才允许停收尘系统。
4.14 411-3B1 storage silo part, dust collection system is still started before inflatable
system in bottom of bin,raw material conveying and feed to kiln, and stopped after the
related equipment of raw material conveying and feed to kiln.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

本系统各分组设备的开停顺序简图如下：
The system grouping equipment start-and-stop sequence diagram is as follows:

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

4.2 投料试生产 Commissioning test run

本工程设置的 IBAU 库是一种耗气量少、操作简单、经济性较好的均化储库，但由于其

均化原理是以料流漏斗重力混合为主要手段，因而对消除低频和较长周期的成分波动往往不
易达到理想效果，所以对整个生料制备系统作为一条均化链，控制各环节合理匹配和均化质
量，就显得极为重要。对此均化库在投料试生产和以后正常生产中的使用应特别注意以下几
点：
IBAU silo used for this project is a small air consumption, simple operation and better
ecomomy homo silo. Its working priciple is using material funnel gravity mixing as the main
method. It is difficult to achieve desired effect to eliminate the low-frequency and longer-cycle
component fluctuaiton. So it is very important to take the whole raw material preparation system
as a homogenization link to control all aspects in reasonable match and homogenization. To this
issue, you should pay particular attention to the following points during silo commissioning test run
and normal operation.
4.2.1 入库生料成分波动必须围绕着煅烧要求控制指标波动、且标准偏差不大于 1.5%，波
动周期平均最长不应超过 6 小时，每小时生料 CaCO3 标准偏差的绝对波动值尽可能控制在
0.8%范围内。
4.2.1 The raw material entered into silo which fluctuates must around burning required control
indicators, and standard deviation is less than 1.5%. The maximum fluctuation cycle should not be
more than six hours. Raw material CaCO3 standard deviation absolute value should be within range
of 0.8% per hour.
4.2.2 严格控制入库生料水分在 0.5%以下，最大不应超过 1.0%，因为生料水分低于 0.5%
时，生料具有良好的流动性能，环形区料流漏斗重力混合效果才能充分体现出来；当生料水
分增大时，其流动性能变差，即容易使生料“结粒”而在充气层表面形成“死料”，还在一
定程度上减少了各个分区的单位时间卸料量，从而削弱了平均均化周期较长时的均化效果。
上述情况在增湿塔回灰直接输送入库时应尤为注意。
4.2.2 Raw material moisture should be strictly controlled below 0.5%, and the maximum
should not exceed 1.0%. When raw material moisture is less than 0.5%, it has good flow properties,
material funnel gravity mixing effect in annular region can be fully reflected. When raw material
moisture is increased, its flow properties will be worse, that is to say, raw material is easy to
“become particle” on the inflatable layer surface to form “dead material”, to some extent, discharge
amount of each partition of unit time will reduce. Thus homogenizing effect of longer average
period will be weakened. In the above case, when conditioning tower return ash directly delivery to
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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
silo you should particularly pay attention to.
4.2.3 应始终保持库内料面高度不低于其最小允许值，一般要求库内最低料位不低于库直
径的 1 倍，以便充分发挥 IBAU 库的重力混合作用，确保均化效果。
4.2.3 Material level in silo should be always above the minimum allowable value. Generally
the minimum material level in silo can not less than one time of the diameter of silo to fully play the
gravity mixing action of IBAU silo to ensure homogenizing effect.
4.2.4 均化库首次装料、烧成系统停机时间较长和每次清库后的重新投料，都不允许库内
一下子存储过多的生料，以免造成“压库”等现象。所以本系统投入生产运行，应与原料粉
磨系统、烧成系统统筹调度计划是非常必要的。
4.2.4 For the first time of homo silo material loading, burning system stopping time is longer
and material will be feeded again after each time silo clearing. Do not allow the silo to store so
mahy raw material at one time to prevent raw material engross. So when this system put into
operation it is necessary to integrated schedule with raw material grinding system and buring
system.
4.2.5 根据生产调度，争取不定期地在某一段时间内大幅度地降低和提高库内料面高度，
从而减少库壁处生料易受潮结块或粘壁的可能性，这也是本说明书生产操作要求所推荐的。
4.2.5 Material level in silo shall be dramatically reduced and improve for a certain period
irregularly according to production schedule. Thus, damp raw material at silo wall can be reduced.
This is also the manual production operation requirements recommended.
4.2.6 应重视罗茨风机供风质量变化的影响，当供气中含有较多水分，不仅会堵塞充气层，
而且会渐渐提高可能积存在充气层表面“死料”的含湿量，并逐步增大“死料”堆积面积，
从而造成充气分布不均和排料不畅；另外供气中若含有部分油滴微粒将是绝对不允许的，同
时还应加强罗茨风机出口压力的巡视监控，否则会造成充气无力，达不到预期的均化作用。
4.2.6 Pay attention to the impact of roots fan air supply changes. When gas contains more
moisture will block inflatable layer and gradually improve moisture of dead material on inflatable
layer surface, so accumulated area of dead material will be increased gradually to result in uneven
distribution and material discharging not smooth. Moreover, particles of oil drop contained in gas
supply is absolutely not allowed. Meawhile you shoud strongen roots fan outlet pressure monitoring,
or inflate will weaken can not achive the desired homogenization effect.
4.2.7 要防止生料中各种异物混入进库，以免引起堵料和损坏充气层。
4.2.7 You should prevent various foreign matter together with raw material entering into silo
to block material and damage inflatable layer.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

第五章 系统运行检查、常见故障及处理
Chapter 5 system running inspection, common fault and treatment

5.1 系统运行检查 System running inspection

5.1.1 库底充气管路是否有漏气或堵塞现象，库底孔洞和设备部件连接处有无冒灰。
5.1.1 Whether inflatable pipeline in bottom of silo is leaking or clogging, whether silo bottom
holes and equipment components are ash raising or not.
5.1.2 库底充气气动阀动作是否灵活正常，有无损坏。
5.1.2 Silo bottom inflatable pneumatic valve movement is flexible and damaged or not.
5.1.3 观察空气输送斜槽、斗式提升机的运行情况，无刮壳、卡斗声响。
5.1.3 Observe air slide, bucket elevator running condition, shall be without scraping and
getting stuck sound.
5.1.4 观察压缩空气、冷却用水的管路上仪表显示是否正常，设备轴承温度是否超限。
5.1.4 Observe compressed air, instrument on cooling water pipe displying and whether bearing
temperature of equipment is over limit or not.
5.1.5 计量仓上进出料口软接头是否正常伸缩，有无冒灰。计量仓底充气管路是否有漏气
和堵塞现象。
5.1.5 Flexible joint for inlet and outlet of measuring bin is normal or not, haing ahs or not.
Whether inflatable pipeline in measuring bin is leaking and blocking or not.
5.1.6 检查库底气动卸料阀和计量仓侧卸料装置动作是否灵活有效，卸料是否通畅。
5.1.6 Check to see whether silo bottom pneumatic discharge valve and discharge device on
measuring bin side is flexible and effective or not, and whether discharging is smooth or not.
5.1.7 观察袋收尘器的运行情况和各收尘点有否扬尘，并根据风机出口排风情况来判断滤
袋是否破损和脱落。
5.1.7 Observe bag type dust collector operating situation and to see whether there is raising
dust or not. And judge whether filter bag is broken and dropped or not according to air exhause
condition of fan air outlet.
5.1.8 若上述情况出现异常，应马上通知中控室和生产调度，以便能及时处理。
5.1.8 If above situaiton is abnormal , should immediately inform the control room and
production scheduling, so that the treatment will be at time.

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

5.2 常见故障及处理 Common fault and treatment

5.2.1 库内物料下落不均或塌陷
5.2.1 Material in silo is uneven falling down or collapsing
有时均化库充气设备运转正常，出磨生料成分符合控制要求，且库内也储有一定量
的生料，但均化效果却明显下降，不能满足入窑生料要求。出现这种情况多数是由于库使用
期间，由于生料入库水分控制不好(例如增湿塔湿灰进入库内) ，使库内充气箱透气性能减弱，
从而可能造成仅有一个或二个卸料口卸料，或库内出现大漏斗，入库生料通过漏斗快速卸出，
使均化库重力混合作用明显减弱。库内生料停用一段时间再使用也易发生上述情况。显然，
解决这一问题的办法仍然是限制入库水分，并同时将库内生料用至接近放空，使库内原有流
动性不好的生料放出后，再加入干燥的生料，从而使库的操作恢复正常。严重时需清库，停
窑后处理。
Sometimes inflatable equipment of homo silo is operating properly, raw material composition
from mill meets to control requirements, and there are a certain amount of raw material in the silo.
But homogenizing effect is decreased can not meet to kiln feed requirements. This situatioin occurs
mostly due to silo use period. Moisture in raw material enters into silo controls not so good(for
example, wet ash in conditioning tower enters into silo), so inflatable tank breathability in silo is
reduced, which may result in only or two discharge port to discharge material, or there is a funnel in
the silo. So raw material enters into silo will be unloaded quickly through the funnel. So that homo
silo gravity mixing significantly reduced. Raw material in silo stopped use for a certain time to use
again is also easy appear the above situation. Obviously, the way to solve this problem is to limit
moisture of raw material enters into silo, meawhile, raw material in silo shall be used closed to
empty to let the illiquid original raw material in the silo out of the silo, and add in dry material. So
that the operation for the silo will be return to normal. If seriously, the silo needs to be cleared and
receive treatment after kiln stopped.
5.2.2 充气箱充气材料的损坏
5.2.2 Inflatable mateiral of air inflating tank is damaged
均化库内充气材料有时易损坏，很多时候充气材料由于异物落入，或在库内清料时，
被工具刮刺而造成的。如果不能及时发现，生料就会充满充气箱，充气箱失去作用，有时甚
至倒灌到充气管道和气动阀中。充气箱或库内管道漏气也会出现上述情况。
Inflatable material in homo silo is easy to be damaged. Inflatable material is often damged
because of falling down foreign matters, or damaged by tools when silo cleaning. If you can not
discover in time, inflatable tank will be filled with raw material, so inflatable tank will be out of

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
action, and sometimes raw material will be into inflatable pipeline and pneumatic valve. Inflatable
tank or pipeline in silo would appear the above situation.
处理措施一般当只有一、二个充气箱充气层损坏时，可先关闭该分路管道上的阀门，然
后根据继续运行后的实际情况来决定是否马上清库停窑后更换；若损坏数量较多或生料倒灌
情况严重，已无法正常运行和／或出库生料质量已无法控制时，应马上停磨放空库内生料后，
进入库内更换新的充气材料。更换时，可先开罗茨风机将管道内和充气箱内的积灰吹空，然
后涂刷密封胶，再装上充气层，并检查是否漏气，其更换过程应遵循产品说明书中的维修要
求。
If only one or two inflatable layers for inflatable tank damaged, you can shut off the valve on
the bypass pipeline, then decide whether to clear silo and replace inflatable layer immediately after
kiln stopped according to continued actual running situaiton. If inflatable layers damage are too
many or raw material instrusion is seriously, can not properly operation and/ or discharged material
quality is out of control, should immediately stop the mill and empty raw material in silo. And then
enter silo to replace inflatable material. When replacing, roots fan can be turned on at first to blow
off accumulated ash in pipeline and inflatable tank, then to blush sealant, and then to install
inflatable layers. And check to see whether it is leaking air or not. Replacement process should
follow maintenance requirements in product manual.
5.2.3 当库底卸料装置和输送设备都运行正常，而计量仓内料重明显减小；或其它设备运
行正常而计量仓内料重逐渐增大、流量计显示的料量却又不变，上述情况若有一条发生，且
伴随仓底罗茨风机供气压力的降低，有可能是充气管道漏气或仓底充气层破损，造成不能完
全流态化出料，影响了流量阀的调节性能，此时应及时检查和补漏或根据实际情况采取其它
相应措施。
5.2.3 When unloading device in bottom of silo and conveyor are running properly, but material
weight in measuring bin is reduced significantly, or other equipments are operting properly and
material weight in measuring bin is increased gradually but flow gauge for material weight displays
not change. If one of the above situaitons happened, meanwhile, gas supply pressure for roots fan is
reduced, there may be pneumatic pipeline leak or pneumatic layer in bottom of bin is damaged,
resulted in the discharge can not be fully fluidized. Affected adjusting performance of flow valve.
At this time, you should check in time and repair leaking or take other appropriate measures
according to the actual situaiton.
5.2.4 若气动阀动作迟缓或不到位，应检查压缩空气管路是否漏气和堵塞、气压是否满足
工作要求、阀门气动元件是否扭弯和卡死等。若罗茨风机出口压力降低，除上述原因外，还
应检查其风机的轴承温度是否超限、润滑是否良好、冷却水供给是否断路，水压是否满足工

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

作要求等。
5.2.4 If the pneumatic valve operation is slow or not in place, you should check pipeline to see
whether it is leaking and clogged, whether gas pressure meets to working requirements, valve
pneumatic components twisted and stuck. If Rootes blowrer outlet pressure is reduced, in addition
to the above reasons, you should check whether bearing temperature of fan is over limit or not,
lubrication is good or not, cooling water supply is breaked, water pressure meets to working
requirements or not.

5.3 日常维护 Daily maintenance

为了保证均化库及 H1L03 储料仓正常运转，必须加强对设备的维护，除一些通用设备如：

风机、输送设备、卸料设备、收尘器及电气设备、仪表按各自的单机使用说明要求维护外，
尚有如下若干项目需按期执行检查和维护。
In order to ensure homo silo and H1L03 storage silo can be running in normal, equipment
maintenance must be strongened. In addition to some general equipment, such as: fan, conveyor
equipment, unloading equipment, dust collector and electrical equipment and instruments. These
equipment shall be maintenance according to each stand-alone use instruction. There are also a
number of items need to perform inspection and maintenance at fixed period.

检查、维护周期

项目 内容 Inspection, maintenance cycle

Item Content 每班 每月 每半年至一

Per shift Every 年

month Every half to

one year

1 库顶阀门 锈死、卡死 1

1. Valve for top of silo Rusted, stuck

2 库内充气装置 破损、位移 1

2. Air filling device Damaged,

inside silo displacement

3 库底管路系统 泄漏 1

3. Piping system in Leakage

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5,000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

bottom of silo

4 清库、检查积料 积料、渗水、漏灰 1

4. Cleaning silo and Accumulatioin

inspection material, water leaking

accumulation material and ash leaking

5 H1L03 储料仓底定 为防止仓底物料长期 2~4

期充气 不卸料板结，需要定

5.Air filling for bottom 期充气，活化物料。

of H1L03 storage silo Air filling and material

can be done at fixed activating shall be

period. performed at fixed

period to prevent

long-term

undischarged

accumultion material

from handened.
关于清库检查周期可以这样安排：
Silo cleaning and inspection cycle can be perfomred in the following way:
5.3.1 首次装料，使用 4～6 周后，需将料放空清库后，做一次全面的检查，以便及时解
决暴露的问题，保证今后长期正常使用。
5.3.1 The first charge, after 4 to 6 weeks using, need to empty mateiral and clean silo to do a
comprehensive inspection for the silo. In this way, exposed problems can be solved in time to
ensure the long-term use in the future.
5.3.2 以后可每隔半年至一年清库检查维护一次，若情况无异常，使用效果好，还可以适
当延长维护周期。
Silo cleaning, inspection and maintenance can be performed every six months to one year
afterward. If there is no abnormal situation, and using condition is very good, maintenance cycle
can be appropriate extended.

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