311,312,331-Raw Mill Feed - 361,391,421,441,4D1-Raw Mill PDF

5000 TPD CMIC CEMENT PLANT PROJECT
IN CAMBODIA
331-RAW MILL FEED

361- RAW MEAL GRINDING
391- RAW MEAL TRANSPORT AND STORAGE
421-DEDUSTING OF KILN SYSTEM
441-PREHEATING
4D1-DUST TRANSPORT AND INSUFFLATION
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
5000TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA
目录
Catalog
第一章前言............................................................................................................................... 1
Chapter 1 Foreword...................................................................................................................... 1
第二章工艺流程及工艺设备介绍 ................................................................................................ 3
Chapter 2 Introduction for technical process and equipment ............................................................ 3
一、工艺流程简介 Instruction for process .............................................................................. 3
二、工艺设备简介 ................................................................................................................ 15
第三章启动前的准备工作 ......................................................................................................... 16
Chapter Three Preparation Before Starting ................................................................................. 16
第四章启动与停车操作 ............................................................................................................. 22
Chapter 4 Starting and Stopping Operation ................................................................................. 22
—、设备的启动操作顺序 The starting operation sequence of the equipment ............................. 22
二、二、系统运转中的检查与调整 Inspection and adjustment during the system operation
............................................................................................................................................... 36
三、系统的停车操作 Stopping operation of the system ...................................................... 41
第五章试生产及生产中的注意事项 ........................................................................................ 57
Chart 5 Pilot Production and Matters Need Attention in Production .............................................. 57
一、试生产的日程安排及其目的 Pilot Production Schedule and Aim................................. 57
二、试生产的准备 Pilot Production Preparation .................................................................. 58
三、试生产系统的开停顺序说明 Start up and shut down instructions for pilot production
system .................................................................................................................................... 58
四、生产中的注意事项 Matters need attention in production .............................................. 64
第一章前言
Chapter 1 Foreword
本调试操作说明书仅供 5000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

水泥厂项目的原料配料、原料粉磨及废气处理系统操作时使用。原料粉磨及废气处理系统是
指从原料储存库底开始至生料均化库顶为止的工艺生产线。本工段包括：原料配料、原料粉
磨、生料输送入库、废气处理等部分。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。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，请与我公司
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。
This commissioning specification is only applied for operations of raw mill & exhaust gas
treatment in 5000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA. The system for
raw material grinding and exhaust gas treatment refers to the process production line from the
bottom of raw material storage to the top of homo silo. This part includes: raw mill feed and
grinding, raw material transportation to silo and exhaust gas treatment. The commissioning
specification simply introduces main technical process and equipment in every system, on which
basis it proposes major operating items for normal operation and production according to the
requirements and features of each system. The operators must master the main points in the
specification, understand the performance, maintenance and operations of each device, be familiar
with operating methods and procedures in CCR; besides, they must know the operating ranges
indicated by each instrument measuring point, the alarm parameters, and the steps and actions taken
in the alarming condition, in order to promptly solve problems that may happen in the actual
production. See the single-unit operating instruction provided by relevant manufacturers for details
on methods and requirements for performance, maintenance and operation of each device. The
operating specification is formulated on the basis of the designing documents and experienced
obtained from the previous production and commissioning. If the actual condition in the production
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differs from that stated in this specification or you have any problem, please contact with the
technicians on site for solution, and modify it according to the actual site condition.
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第二章工艺流程及工艺设备介绍
Chapter 2 Introduction for technical process and equipment
本工程的原料粉磨系统采用 PFEIFFER 的 MVR 5000 R-4 辊式磨作为原料磨，并设有窑
尾高温风机、原料磨循环风机及窑尾袋收尘排风机组成的三风机系统。原料磨的操作除参考
本操作说明书外，还应参考磨机供应商提供的操作维护说明书及各种资料，并遵循磨机供应
商提出的要求。The raw material grinding system adopts MVR 5000 R-4 roller mill of PFEIFFER
as the raw mill, and the three-fan system, respectively the kiln tail high temperature fan, the raw
mill circulating fan and the exhaust fan of kiln tail bag-type dust collector. Besides this
specification, the operations for raw mill also refer to instructions on operation and maintenance
provided by suppliers and variable data, and follows the requirements proposed by suppliers.
一、工艺流程简介 Instruction for process
1.1 原料配料、原料粉磨及废气处理系统工艺流程见附图。
Process for this department refers to flowsheet.
1.2 原料配料系统
原料配料系统设有石灰石(HG/LS limestone)、石灰石&粘土混合料(pre mix mat.)、铝钒土
(bauxite)、铁矾土(laterite)库各一座，每个库下各设一台定量给料机,，按照化验室或质量控制
系统设定的配比，各种原料按比例配合，混合原料经胶带输送机（331-BC1,331-BC2）,气动
两路阀(361-MW1)、回转锁风喂料阀(361-RF3)送至原料磨(361-RM1)。在胶带输送机(331-BC2)
上设有除铁器(361-MS1)将来料中的金属除掉。当有个别金属未除去时，装在胶带输送机
（331-BC2）上的金属探测器（361-MT1）会报警，同时，控制气动两路阀（361-MW1）将
此部分物料外排，保护立磨。各原料的配比及总的喂料量均可由中央控制室自动调节。
The raw material batching system contains four bins for HG/LS limestone, pre mix mat,
bauxite and laterite, each of which is equipped with a constant feeder. According to the proportion
set by the laboratory, these materials are mixed proportionally, and then the mixed materials are
transported to the raw mill (361-RM1) by belt conveyor (331-BC1,331-BC2), two-way pneumatic
valve (361-MW1), and rotary air lock feeder valve (361-RF3). With a magnetic separator (361-MS1)
on the belt conveyor (331-BC2), metals in the feeding materials can be removed. If certain metal
cannot be removed, the metal detector (361-MT1) installed on the belt conveyor (331-BC2) will
alarm and force the two-way pneumatic control valve (361-MW1) to discharge it out, in this way to
protect the mill. The CCR can automatically control the proportions of the four parts and the total
quantity of feeding materials.
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1.3 原料粉磨系统 Raw material grinding system
本系统采用 MVR5000-4 辊式磨作为原料磨。磨机入口由回转锁风阀进行锁风。
This system adopts MVR5000-4 mill and the inlet of the mill uses the rotary air lock valve.
该立磨当 90%的入磨物料粒度 0~70mm，水份≤5%，出磨生料细度为 90µm 筛余≤15%，
200µm 筛余≤1.5%，水分 0.5%时，磨系统产量为 410t/h（干）。
When the particle size of feeding material is <50mm, the moisture <5% and the screen residue
of the discharging material fineness with 90µm <15%, and that of 200µm is 1.5% as well as the
moisture is 0.5%, the mill output is 440t / h (dry).
胶带输送机(331-BC2)送来的原料通过气动两路阀(361-MW1)、喂入原料磨(361-RM1)，
各种原料在磨机内被碾压粉碎、烘干并被选粉机分选，粗粉返回磨盘重新粉磨，合格成品随
出磨气流经旋风收尘器（391-CN1~391-CN4）收集。空气输送斜槽(391-AS1~391-AS3) 、斗
式提升机(391-BE1)、空气输送斜槽(391-AS4~391-AS10)送入生料库储存、均化。出立磨选粉
机的气体经原料磨循环风机(361-FN2)，一部分气体作为循环风入磨，其余气体进入窑尾袋收
尘器(421-BF1)过滤净化后由窑尾排风机(421-FN1)排入大气。当原料磨正常生产时，出预热器
的高温废气经管道增湿(421-CT1)降温后，经窑尾高温风机(441-FN1)，进入原料磨作为烘干热
源。
The materials transported by belt conveyor (331-BC2) via two-way pneumatic valve
(361-MW1) are fed to the raw mill (361-RM1). A variety of materials are crushed, ground and
dried inside the mill before classified by the separator; the coarse returns to the mill for another
crushing and grinding while the qualified is discharged along with the airflow from the mill and
collected by cyclone dust collector (391-CN1~391-CN4). The collected finish products are fed to
the homosilo through the air slide (391-AS1~391-AS3) for storage and homogenization. Some of
the air from the separator via the circulating fan (361-FN2) enters into the mill as the recirculating
air while the rest is discharged into the air by the fan (421-FN1) after purified by the bag filter
(421-BF1). When the mill is in normal operation, the exhaust gas from the preheater enters into the
mill as the drying source after it goes through the ID fan (J1F01).
当原料磨停磨而窑运转时，磨机进风管道上的闸阀(361-SD2)关闭，窑尾废气经高温风机
(441-FN1)沿旁路管道送入窑尾袋收尘器（421-BF1）净化，然后由窑尾排风机(421-FN1)经烟
囱排入大气。窑尾袋收尘器收下的粉尘经链式输送机(421-CV1~421-CV4)、电动三通分料阀
(421-MW1)，经斗式提升机(361-BE1)入生料均化库，或经冲板流量计(421-FM1)、斗式提升机
(431-BE1)送入窑尾预热器系统。
If the raw mill stops while the kiln works, the Shut off gate (361-SD2) is closed and the
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exhaust gas go into the bag filter (421-BF1) and then discharged into the air by the exhaust fan
(421-FN1). The collected dust by bag filter (421-BF1)is transported by the chain
conveyor(421-CV1~421-CV4)two-way gate (421-MW1) and bucket elevator (361-BE1) into the
homo silo; or it is transported to the preheater system by via flowmeter(421-FM1)& bucket elevator
(431-BE1).
为了节能，部分粗料通过立磨的排渣口卸出，经锁风翻板阀（361-FV2），再通过胶带输
送机（361-BC3）、斗式提升机(361-BE1) ，与入磨原料汇合后重新入磨。
In order to save energy, part of the coarse materials are re-fed to the mill by air lock discharge
gate（361-FV2）, belt conveyor (361-BC3), bucket elevator (361-BE1)
原料粉磨系统借用水泥粉磨系统的燃油热风炉(561-HG1)一套，作为原料粉磨系统首次运
行或单独运行时的烘干热源。
Use the hot gas generator(561-HG1) for the raw mill first operation before kiln work.
原料粉磨系统设有自动取样装置(391-SM1)，试样经过 X-荧光分析仪检测并由计算机自
动控制和调整（或由人工调整）各种原料的配合比例，保证出磨生料化学成分的合格与稳定。
The raw material grinding system is equipped with automatic sampling unit (R1XS01); the
samples are detected by the X-ray fluoroanalyzer, and the proportion is controlled and adjusted by
the computer (or the operator), in order to guarantee the quality and stability of the material
chemical property.
1.3.1 MVR5000-4 立磨系统简介 The brief introduction for the MVR5000-4 vertical mill
立磨的优点：允许入磨的水分大；入磨粒度大；流程简单，占地面积小，建筑空间小；
控制方便，物料在磨内停留时间短，成分、细度调整方便；噪音低，漏风少。
该立磨详细结构说明见立磨说明书。
The advantages of vertical mill: the moisture of the allowable feeding material is large; the
particle size is large; its operation process is simple and it covers much less area with small building
space; the control is convenient, the time for material staying in the mill is short, and the adjustment
for composition and fineness is easy; the noise is low and the air leakage is less.
1.4 废气处理系统 The exhaust gas treatment
高温风机(441-FN1)排出的窑尾废气分为三路。第一路去往原料粉磨系统，作为原料粉磨
系统的烘干热源；第二路经电收尘器(441-EP1)除尘后入煤磨，烘干磨内原煤水分；第三路经
旁路管道进入窑尾袋收尘器(421-BF1)，净化后经窑尾排风机(421-FN1)排入大气。
The exhaust gas from the preheater is divided into three ways: one is discharged into the raw
mill system as the drying source; another is discharged into the coal mill to dry the moisture of the
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coal after removed dust by the dust precipitator (441-EP1); the third is purified by the bag filter
(421-BF1) and then discharged into the air by the fan ((421-FN1).
窑尾废气、原料磨废气净化收集下来的窑灰及生料通过螺旋输送机、链式输送机、空气
输送斜槽、斗式提升机等设备送入生料均化库或入窑尾预热器。
exhaust gas and the kiln dust (collected by the raw mill waste gas purification) are transported
to the homo silo or the preheater via screw conveyor, chain conveyor, aerated trough conveyor and
bucket elevator.
1.5 生产过程控制回路 The control loop of production process
1.5.1 先根据原料的化学成分及配料所要求达到的率值选好设定值。生料磨运行后，每隔
一定时间从系统中自动连续取出试样送至化验室，用 X 射线荧光分析仪分析生料成份。根据
此生料成份分析值和原料成份，自动调节配料库下各台喂料皮带秤的配比。
Choose the set value in accordance with the material composition and the batching
requirements. After the raw mill is running, automatically and continuously take samples from the
system at intervals, prepare samples and then send them to the laboratory before analyzing the
composition of materials by X-ray fluoroanalyzer. According to the assay value and the material
composition, it automatically adjusts the proportion of belt weighers in the batching silo.
1.5.2 根据磨机进出口气体压差调节胶带输送机的输送量，从而控制入磨物料量，可稳定
磨机进出口压差。
Adjust the operational throughput of belt conveyor according to the differential pressure
between the inlet and the outlet, in order to control the quantity of feeding materials and stabilize
the differential pressure.
1.5.3 根据生料细度，由中控调节选粉机转子转速，从而控制出磨生料的细度。
CCR can adjust the rotor speed of separator according to the material fineness, in order to
control the particle size of materials discharged by the mill.
1.5.4 通过调节磨机进口冷风阀门（361-LD2）的开度，或循环风阀门(361-LD1 的开度来
调节入磨风温，稳定磨机出口气体温度。
Adjust the opening of the air-cooling valve (R1V29) at the inlet or the opening of the
recirculating air valve (R1V30, R1V31) to control the inlet air temperature, by which to keep the
outlet air temperature stable.
1.5.5 根据磨机出磨风温，自动调节磨机喷水阀门开度，调节喷水量。
According to the air temperature of the mill outlet, automatically adjust the water spray valve
opening to control the water quantity.
1.5.6 根据窑尾增湿管道出口气体温度，自动调节增湿喷水阀门开度，调节喷水量。
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According to the air temperature of the conditioning tower outlet, automatically adjust the
water spray valve opening of the conditioning tower to control the water quantity.
1.5.7 以窑尾排风机(421-FN1)入口阀门开度，调节窑尾袋收尘器入口负压。
Adjust the inlet valve opening of the exhaust fan (421-FN1) and the speed of the fan to control
the inlet negative pressure of bag filter.
1.5.8 以原料磨循环风机(361-FN2)电机电流，结合气体流量显示仪表的显示值，调节入
磨风量。
Adjust the motor current of raw mill recirculating fan to control the air volume into the mill.
1.5.9 金属探测仪(361-MT1)与气动分料阀(361-MW1)联锁。当探测到金属件时，金属探测
仪发出信号，气动分料阀阀板开至旁路，使金属件外排，以保护磨机；几秒后待这部分料流
通过后阀板复位，恢复主通道继续向磨内送料。
The metal detector(361-MT1)is interlocked with the pneumatic distribution
gate(361-MW1),The metal alarms when it detects metal pieces, and then the valve plate of
pneumatic distribution valve moves to the bypass to remove metal pieces, in which way to protect
mill; after this part of materials go through several seconds later, the valve plate returns to its
original position before continue feeding materials to the mill.
1.6 系统内设备分组 The device groups in the system
系统内设备按工艺流程和操作要求分成若干组，各组内设备之间、各组之间有连锁关系。
正常启动时操作员按组顺序分组启动。
According to the technical process and the operational requirements, the equipment in this
system can be divided into certain groups; there are interlock relationship among the equipment in
one group and among the groups. When start the equipment, the operator should follow the startup
sequence by group.
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表 1-1 原料配料、生料粉磨及废气处理系统内设备分组表
Table 1-1 the equipment groups in the system of the batching, grinding and waste gas
treatment
序号组名组内设备备注
No. Group Name Equipment in the group Remarks
1 生料均化库顶收尘组 1. 均化库顶收尘器（391-BF3）的下料
The dust collection 器（391-RF7）
group at the top of the The rotary feeder, (391-RF7) of the bag
raw meal homo silo filter(391-BF3) at the top of the homo silo
2. 均化库顶收尘器(391-BF3)清灰程序
控制器
The dust-removal programming controller
of the bag filter (391-BF3) at the top of the
homo silo
3. 均化库顶收尘器风机(391-FN3)
The fan(391-FN3) at the top of the homo
silo
2. 生料输送收尘组 The 1. 收尘器（ 391-BF2 ）的下料器
raw meal transport （391-RF6）
group The rotary feeder, (391-RF6) of the bag
filter(391-BF2)
2. 收尘器(391-BF2)清灰程序控制器
of the bag filter (391-BF3)
3. 收尘器风机(391-FN2)
The bag filter fan(391-FN2)
4. 收尘器（ 391-BF1 ）的下料器
（391-RF5）
The rotary feeder(391-RF5) of the bag
filter(391-BF1)
5. 收尘器(391-BF1)清灰程序控制器
of the bag filter (391-BF3)
6. 收尘器风机(391-FN1)
The bag filter fan(391-FN2)
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3 生料输送及入库组 1. 生料分配器斜槽风机(391-FA5)
The raw meal 1. the chute fan of raw meal distributor
transportation and (391-FA5)
feeding group 2. 均化库顶斜槽风机(391-FA4)
the air slide fan at the top of homo silo
(391-FA4)
3. 入库斗式提升机(391-BE1)
the bucket elevator(391-BE1)
4. 自动取样器(391-SM1)
automatic sampler(391-SM1)
5. 空气输送斜槽风机 (391-FA3A,
391-FA3B, 391-FA3C, 391-FA3D)
Air slide fan(391-FA3A, 391-FA3B,
391-FA3C, 391-FA3D)
6. 空气输送斜槽风机
(391-FA1A,391-FA2A,391-FA1B,39
1-FA2B)
Air slide fan
(391-FA1A,391-FA2A,391-FA1B,391-FA
2B)
7. 回转下料阀(391-RF1~391-RF4)
rotary feeder(391-RF1~391-RF4)
4 废气处理排风机组废气处理排风机(421-FN1) 风机启动时,
The waste gas the exhaust blower of waste gas 风机进口调
treatment exhaust treatment(421-FN1) 节阀
blower group
(421-LD3)关
闭
When start the
blower, close
the inlet
regulating
valve
(421-LD3) of
the blower
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5 废气处理窑尾袋收尘 1. 冲板流量计(421-FM1)
器回灰组 the plate flow meter(J1T01)
The waste gas 2. 电动分料阀(421-FM1)
treatment bag filter the electric distribution valve(421-FM1)
and returning ash 3. 气动闸板阀(421-SG1a)
group the shut off gate(421-SG1a)
4. 链式输送机(421-CV4)
the chain conveyor(421-CV4)
the chain conveyor(421-CV3)
6. 窑尾袋收尘器拉链机
(421-CV2,421-CV1)
the chain conveyor(421-CV2,421-CV1) of
main bag filter
7. 窑尾袋收尘器卸料器
(421-RF1~421-RF1)
the rotary feeder (421-RF1~421-RF1) of
main bag filter
8. 窑尾袋收尘器(421-BF1)
The main bag filter(421-BF1)
9. 当窑灰需要外排时，确认窑灰车准备
就绪，开启风机(4D1-FN1),开启袋收
尘器 (4D1-BF1) 下的回转下料阀
(4D1-RF1),开启袋收尘器(4D1-BF1)
清灰程序控制器,开启装车机
(4D1-LA1) ，开启电动闸阀
(4D1-SD1) ，关闭气动闸板阀
(421-SG1a) ，窑灰由链式输送机
(421-CV4)头部卸出
When the kiln dust need to cement
mill by bypass,confirm the bulk truck
at the position.then start the
fan(4D1-FN1) →rotary feeder
(4D1-RF1) →bag filter (4D1-BF1)
→bulk loader (4D1-LA1) and closed
the gate(421-SG1a)
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6 废气处理增湿回灰组 1. 螺旋输送机(421-SC1)
The waste gas the screw conveyor(421-SC1)
treatment conditioning 2. 锁风翻板阀(421-FV1)
tower and returning the air lock flap valve
ash group (421-FV1,421-FV2)
The chain conveyor(421-CV5)
当增湿湿灰需要外排时,关闭锁风翻板
阀(421-FV1),开启锁风翻板阀(421-FV2),
螺旋输送机(421-SC1)反转。
When the dust need go to the bypass,close
the air lock flap valve(421-FV1)and open
the air lock flap valve(421-FV2). Then
change direction of the screw
conveyor(421-SC1)
7 废气处理电收尘回灰 1.链式输送机(421-CV8) 当煤磨系统
组 The chain conveyor(421-CV8) 运行准备就
The waste gas 2. 窑尾袋收尘器拉链机绪后,为煤磨
treatment and (421-CV7,421-CV6) 提供烘干热
returning ash group of The chain conveyor(421-CV7,421-CV6)
源
EP 4. 煤磨前电收尘器(441-EP1)
When coal
EP(441-EP1)before coal mill mill need run
8 原料磨气流循环组 1.原料磨循环风机(361-FN2)
The raw mill air the recirculating fan (361-FN2) of raw
current circulation mill
group 2. 密封风机(361-FA1)
the sealing fan(361-FA1)
3.立磨选粉机(361-SR1)
the separator (361-SR1) of vertical mill
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7 原料磨液压、润滑装 1. 磨机 (361-RM1) 主减速机稀油站
置组 The raw mill (361-LQ1)
hydraulic & The main reducer oil lubrication station
lubricating device (361-LQ1)of the mill (361-RM1)
group 2.磨机(361-RM1)液压站(361-HS1)
the mill (361-RM1) hydraulic pressure
station (361-HS1)
3.磨机(361-RM1)磨辊润滑站(361-LQ4)
The grinding roller lubrication station
(361-LQ4) of the mill(361-RM1)
4.选粉机润滑站(361-LQ2，361-LQ3)
The lubrication station (361-LQ2 ，
361-LQ3) of the Separator (361-SR1)
8 磨机传动电机组 1. 磨机主电机 (361-RM1.M1) the main
The mill drive motor motor(361-RM1.M1)
group 2. 磨机辅助传动电机 (361-AD1.M1)
361-AD1.M1)
9 磨机喷水组 1. 喷水装置 (361-IJ1) the water spray
The mill water spray device(361-IJ1)
group 2. 喷水装置水泵 (361-WP1) the water
spray pump(361-WP1)
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10 喂料及输送组 1.各收尘组 dust collection group:
The feeding and 1.1 风机(361-FN3)→袋收尘器(361-BF2)
transportation group 卸灰阀(361-RF2)→袋收尘器(361-BF2)
清灰程序控制器
fan(361-FN3)→rotary feeder (361-BF2)→
bag filter (361-BF2)
1.2 风机(361-FN1)→袋收尘器(361-BF1)
卸灰阀(361-RF1)→袋收尘器(361-BF1)
1.3 风机(331-FN1)→袋收尘器(331-BF1)
清灰程序控制
1.4 风机(312-FN6)→袋收尘器(312-BF6)
fan(312-FN6)→rotary feeder (312-RF6)→
1.5 风机(312-FN5)→袋收尘器(312-BF5)
1.6 风机(312-FN4)→卸灰阀(312-RF4)→
袋收尘器(312-BF4) 清灰程序控制器
1.7 风机(311-FN4)→卸灰阀(311-RF4)
→袋收尘器(311-BF4) 清灰程序控制器
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10 喂料及输送组 2.回转喂料阀(361-RF3)
The rotary feeder(361-RF3)
3.气动两路阀(361-MW1)
the two-way gate(361-MW1)
4.金属探测仪(361-MT1)
the metal detector(361-MT1
5. 除铁器(361-MS1)
the magnetic separator(361-MS1)
6. 胶带输送机(331-BC2)
(此胶带输送机带通过式皮带秤
361-BW1)
the belt conveyor(331-BC2)
(The belt conveyor is equipped with belt
weigher (361-BW1))
331-BW1)
the belt conveyor(331-BC1)
(The belt conveyor is equipped with belt
weigher (331-BW1))
8. 石灰石定量给料机(331-WF2)
the weigh feeder(331-WF2)
9. 混合料定量给料机(331-WF1)
the weigh feeder (331-WF1)
10. 混合料板式喂料机(331-AF1)
The apron feeder(331-AF1)
11. 铝钒土定量给料机(331-WF4)
12. 铝钒土板式喂料机(331-AF3)
13. 铁矾土定量给料机(331-WF3)
14. 铁矾土板式喂料机(331-AF2)
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二、工艺设备简介 Instruction for equipment
本系统所有工艺设备主要技术参数见工艺设备表。
Equipment technical please see the equipment list.
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第三章启动前的准备工作
Chapter 3 Preparation Before Starting
原料配料、原料粉磨及废气处理系统的全部设备在每次启动前均应作认真的检查、调整
工作。
The careful inspection and adjustment shall be conducted to all the equipment of raw material
proportioning, grinding and waste gas treatment system before starting.
—、现场设备的检查
1. Inspection of on-site equipment
1.1 液压装置、润滑设备润滑油的检查及调整。
1.1 Inspection and adjustment of the lubricating oil for the hydraulic device and lubrication
device
设备润滑对保证设备的长期、稳定运转起着关键的作用。润滑油量要合适，既不能过多，
也不能过少，油量过多会引起设备发热，油量过少设备会因缺油而损坏。另一方面，要定期
检查更换润滑油。各润滑点润滑油的品种、标号不能有误，而且要保证油中不能有杂质和水。
The lubrication for the equipment plays a key role on its long-term and stable operation. The
amount of lubricating oil shall be appropriate, neither too much nor too little. Too much lubricating
oil will cause equipment heating, and too little oil will lead to equipment damage. Besides, the
lubricating oil shall be replaced regularly. The type and grade of the lubricating oil at each
lubricating point shall be correct. And it shall be ensured that there shall not be any impurities or
water in the oil.
主要检查确认如下项目：
Main items needed to be inspected and confirmed are as follows:
1.1.1 磨机主减速机的润滑油系统油量要合适，油位应在上下油标之间。油管路各连接处
应无漏油，仪表完好，管路和阀门畅通，油温合适。
1.1.1 The lubricating oil system of the main gearbox of the mill shall have proper amount of
oil. Its oil level shall be at the position between the upper and lower level marks. No oil leakage is
allowed at each connection place of the oil pipeline. The instruments shall be in good condition and
pipeline and valves shall be smooth. The oil temperature shall be appropriate.
1.1.2 磨辊液压系统油量要合适，油管应无漏油，管路和阀门畅通，开闭灵活，仪表完好。
1.1.2 The hydraulic system of the mill roller shall have proper amount of oil. No oil leakage is
allowed for the oil pipe. The pipeline and valves shall be smooth and their opening and closing shall
be flexible. The instruments shall be in good condition.
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1.1.3 磨辊循环润滑系统油量应合适，油路应畅通且无泄漏，阀门启闭灵活，仪表完好。
1.1.3 The circulating lubricating system of the mill roller shall have proper amount of oil. The
oil circuit shall be smooth, without leakage. The opening and closing of the valve shall be flexible.
The instrument shall be in good condition.
1.1.4 选粉机润滑系统油量合适，油路应畅通且无泄漏，阀门启闭灵活，仪表完好。
1.1.4 The lubricating system of the separator shall have proper amount of oil. The oil circuit
shall be smooth, without leakage. The opening and closing of the valve shall be flexible. The
instrument shall be in good condition.
1.1.5 所有运动部件、传动链条、联轴器加油情况。
1.1.5 The oiling condition of all moving parts, drive chains and couplings.
1.1.6 所有的电动机轴承加油情况。
1.1.6 The oiling condition of all the motor bearings.
1.1.7 所有的阀门及其执行器加油情况。
1.1.7 The oiling condition of all the valves and their actuators.
1.2 冷却水的检查
1.2 Inspection of cooling water
冷却水对设备保护至关重要，设备启动前要检查冷却水管路上的阀门是否打开，并控制
合适的流量，需冷却的设备有：
The cooling water is crucial to protecting the equipment. Check if the valve on the cooling
water pipeline is opened or not before starting the equipment. The flow shall be controlled
appropriately. The equipment needed to be cooled is as follow:
1.2.1 原料磨主减速机润滑装置。
1.2.1 The lubricating device of the main gearbox of the raw mill.
1.2.2 原料磨主辊润滑装置。
1.2.2 The lubricating device of the main roller of the raw mill.
1.2.3 原料磨选粉机减速器轴承。
1.2.3 The gearbox bearing of the raw mill separator.
1.2.4 原料磨循环风机轴承及稀油站
1.2.4 The circulating fan bearing and thin oil station of the raw mill.
1.2.5 窑尾排风机轴承及稀油站。
1.2.5 The exhaust fan bearing and thin oil station at kiln inlet.
1.2.6 窑尾高温风机轴承及稀油站。
1.2.6 The high temperature fan bearing and thin oil station at kiln inlet.
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1.3 原料磨喷水系统检查
1.3 Inspection of the water spraying system of raw mill
原料磨喷水系统启动之前要检查水管是否畅通，阀门的动作是否灵活，管路上的过滤器
要进行清洗，防止堵塞，装好后水压实验无渗漏。
Before starting the water spraying system of raw mill, check if the water pipe is smooth or not
and if the valve is flexible to open and close. Clean the filter on the pipeline to avoid blockage. And
no leakage is allowed in hydrostatic test after assembly.
1.4 压缩空气的检查
1.4 Inspection of compressed air
原料配料、原料粉磨及废气处理系统所需压缩空气由空气压缩机站供给，系统启动之前
须检查空压机站是否启动，各储气罐是否按规定进行排污，压力是否达到额定值，压缩空气
管道及阀门有无漏气现象，有问题及时处理，供气管道上的手动阀是否处于开启状态。
The compressed air required by the raw material proportioning, grinding and waste gas
treatment system is supplied by the air compressor station. Before starting the system, check if the
air compressor station is started, if the pollution is discharged form each air storage tank in
accordance with the provisions, if the pressure reaches rated value, if there is any air leakage of the
compressed air pipe and valve, and if the manual valve on the air supply pipe is open. Deal with the
problem if any.
需压缩空气的设备：
The equipment requiring compressed air:
1.4.1 脉冲袋式收尘器。
1.4.1 Pulse bag filter.
1.4.2 气动两路阀、气动闸板阀。
1.4.2 Pneumatic two-way valve, pneumatic gate valve.
1.5 原料储存库、返料仓、设备内部、人孔门、检修门的检查及密封
1.5 Inspection and seal of the raw material storage bin, return bin, equipment internal, manhole
door, and maintenance door.
原料储存调配库、返料仓加料之前应清除安装或检修时掉在库内部的杂物，防止仓口堵
塞或金属物体进入原料磨。
Before feeding to the raw material storage allocation bin and the return bin, the foreign matters
left in the bins during installation and maintenance shall be removed, in order to avoid blockage at
the bin opening and to prevent the metal matters from entering into the raw material mill.
在设备启动前要对设备内部进行全面检查，清除安装或检修时掉在设备内部的杂物，以
18
防止设备运行时卡死或打坏设备，造成不必要的损失。
Full inspection shall be conducted to the equipment internal before starting it. Remove the
foreign matters left in the equipment during installation and maintenance, in order to avoid jamming
or damage of the equipment during operation.
在设备内部检查完毕后，所有人孔门、检修门都要严格密封，防止生产时漏风、漏料、
漏油。
After inspecting the equipment internal, seal all the manhole doors and maintenance doors
strictly to avoid air leakage, material leakage and oil leakage during production.
1.6 阀门的检查和备妥
1.6 Inspection and readiness of the valve
1.6.1 各原料库下料阀，全部开到适当的位置，保证物料畅通。
1.6.1 Open all the unloading valves of the raw material bins to proper position to ensure the
smooth flow of materials.
1.6.2 所有的手动阀门，在设备启动前都应确认开关方向，并打到适当的位置。
1.6.2 Confirm the opening and closing direction of all the manual valves before starting
equipment, and open them to proper position.
1.6.3 所有电动、气动闸门，首先在现场确认其启闭是否灵活，阀轴与连杆有无松动。对
中控室遥控操作的阀门，要确认中控室与现场的开闭方向一致，开度与指示准确。带有上下
限位开关的阀门，需与中控室核对限位信号是否返回。
1.6.3 Confirm if the opening and closing of all the electric and pneumatic gates is flexible on
site, and if the valve shaft and connecting rod are loose or not. For the valves remote-controlled by
the central control room, confirm their opening and closing directions in central control room are
consistent with that on site, and confirm their opening and indication are correct. For the valves
with upper and lower limit switches, check with the central control room if the limit signals return
or not.
1.7 设备的紧固检查
1.7 Fastening inspection of the equipment
检查设备紧固件(如磨内选粉机的螺栓，所有设备的基础螺栓等)，不能有任何松动。对
设备的易松动部件、传动连杆等都要进行严格的检查。
Check the fasteners of the equipment (such as the bolts of the separator in the mill, the basic
bolts of all the equipment and so on). No looseness is allowed. The easy-to-loose parts and
transmission connecting rod of the device shall be checked strictly.
1.8 原料储存库内物料的检查
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1.8 Inspection of the materials in the raw material storage bin
确认原料储存库的物料储存量合适，料位计指示准确，库内物料位置与中控显示一致，
试生产初期，仓内物料不宜过满，一般石灰石为仓满的 60%~70%，石灰石和粘土的混合料、
砂岩和铁矾土为仓满的 30%左右。随着试生产的进行，对物料特性的认识进一步加强后，再
适当调整各种物料在库中的料位。
Confirm the storage amount of the materials in the bin is appropriate and the material level
meter indication is accurate. The position of the material level in the bin is consistent with the
display of central control. At the initial stage of trial production, the materials in the bin shall not be
too full. Generally, the amount of limestone shall be 60%~70% of the full storage amount. The
amount of the mixture of limestone and clay, the sandstone and the laterite shall be 30% of the full
storage amount respectively. With the development of trial production, adjust the material level of
each kind of material appropriately after further enhancing the understanding of the material
characteristics.
1.9 盖板的检查
1.9 Inspection of cover plate
凡需遮盖的部份均应盖好，如设备的安全罩，螺旋输送机盖板，地沟盖板等，均应逐—
检查。
The parts required cover shall be covered well, such as the safety cover of equipment, the
cover plate of spiral conveyor, the cover plate of trench and so on. Check them one by one.
2.0 原料磨及其附属设备的检查
2.0 Inspection of the raw mill and its accessory equipment
按照设备说明书的要求严格进行检查。
Strict inspection shall be carried out as the requirements of equipment instruction.
磨机在启动前必须检查机器的安装。所有管路的布管和电气安装都必须完成，包括调整
磨机和液压系统中所有电机的联轴器在内。检查每个辅助系统，确认工作可靠。检查所有的
连杆、缸、轴承、阀等部件，确认运转动作灵活，工作可靠。所有互锁必须可靠，而且电气
不允许跳线。磨辊和磨盘间的距离必须可以根据具体情况在机械上或电气上进行调整。液压
缸蓄能器必须预充氮气。磨机启动前磨盘上应铺满干料。料面与磨盘上物料挡圈的高度(或磨
辊中心线交点)等高。
The installation of the mill must be checked before starting it. All the piping and electrical
installation must be completed, including adjusting the couplings of all the motors in the mill and
hydraulic system.Check each auxiliary system to confirm it works reliably. Check all the
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connecting rods, cylinders, bearings and valves to confirm they operate flexibly and work reliably.
All the interlocking must be reliable and the jumper wire is not allowed for electric. The distance
between the mill roller and the mill disc must be able to be adjusted mechanically or electrically
based on specific circumstances. The hydraulic cylinder accumulator must be filled with nitrogen in
advance. The mill disc shall be paved with dry materials before starting the mill. The material level
shall be equal to the height of material retainer ring(or the intersection point of the centerline of the
mill roller).
二、电气设备及仪表的检查
2. Inspection of the electrical equipment and instruments
2.1 电气设备的检查
2.1 Inspection of the electrical equipment
2.1.1 检查电源是否已供上，电压是否正常，设备的备妥信号是否全部返回。
2.1.1 Check if the power has been supplied, if the voltage is normal, and if all the readiness
signals of the equipment return.
2.1.2 电气开关柜是否推到工作位置，电气保护整定值要合适。
2.1.2 Check if the electrical switch cabinet is pushed to the working position. The electrical
protection setting value shall be appropriate.
2.1.3 设备的现场开关是否按要求打到“集中”位置。
2.1.3 Check if the on-site switch of the equipment is at the position of “centralizing”.
2.1.4 确认高压电设备送电条件，并送电。
2.1.4 Confirm the power transmission condition of the high-voltage equipment, and transmit
power.
2.2 现场仪表的检查
2.2 Inspection of the on-site instruments
现场有许多仪表，可以帮助巡检人员及时了解生产及设备的运行情况，在开车前，都要
进行系统的检查，并确认电源已供上，是否有指示。送信号进入中控室指示的仪表，还要与
中控室人员配合，核实传输信号的准确性。
There are many instruments on site, which can help inspectors to know the operation condition
of the production and equipment in time. Before starting, systematical inspection shall be conducted.
Confirm the power has been supplied and check if there is a indication. Send signals to the
indicating instruments in the central control room and cooperate with the personnel in the central
control room to check the correctness of the transmission signals.
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第四章启动与停车操作
Chapter 4 Starting and Stopping Operation
本章所述内容是正常生产时启动与停车操作顺序，运行中的调整及故障停车操作。系统
中的各组设备已编好程序，由计算机控制，组与组之间一般按顺序连贯启动。
The content described in this chapter is the operation sequence of starting and stopping under
normal production, and the adjustment and failure stopping operation during running. Each unit of
equipment in this system has been programmed, controlled by the computer. Generally, the units
are started in sequence one by one and continuously.
—、设备的启动操作顺序 The starting operation sequence of the equipment
1.1 用备用燃油热风炉提供热源时，原料配料、原料粉磨及废气处理系统的启动操作顺序
见表 4-1
1.1 The starting operation sequence of the raw material proportioning, grinding and waste gas
treatment system when using the heat sources supplied by the stand-by fuel oil hot air furnace is
showed in Table 4-1.
表 4-1 备用燃油热风炉提供热源时，原料磨系统的启动操作顺序
Table 4-1 The starting operation sequence of the raw mill system when using the heat sources
supplied by the stand-by fuel oil hot air furnace
序操作步骤检查与调整
号 Operating steps Inspection and adjustment
No.
1 确认开车范围做好启动前系统内设备的检查工作
1. Confirm the starting range. Inspect the equipment in the system before
2.确认原料配料系统、原料粉磨系统、 starting.
废气处理系统运转前的准备工作已完
成。
2. Confirm the preparation works before
the operation of the raw material
proportioning, grinding and waste gas
treatment system have been completed.
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2 确认原料储存及调配库内的物料储量通知相关系统配合操作
合适，并且原料供应部分输送设备可以 Notify the relevant system to cooperate.
保证随时供料。
1. Confirm the amount of the materials
stored in the raw material storage and
allocation bin is appropriate, and the
conveying equipment for raw material
supplying can ensure the supplying at
any time.
2.确认生料均化库允许进料。
2. Confirm the raw meal homogenizing
silo allows feeding.
3 确认各阀门的位置 1. 进磨热风阀门(361-SD2,421-LD4)关闭
Confirm the position of each valve. The feeding hot air valves
(361-SD2,421-LD4)are close.
2. 进磨冷风阀门(361-LD2)全开;进窑尾袋收
尘器的风管上冷风阀(421-BV1)全开
The feeding cool air valve(361-LD2) is
full-open.
The cool air valve (421-BV1) at the inlet air duct
of the bag filter is full-open.
3. 热风炉出口阀门
(361-SD3,361-LD5,361-SD4,361-LD6)关闭
The outlet valves
(361-SD3,361-LD5,361-SD4,361-LD6)of HGG
are close.
4. 循环风机进口阀门(361-LD3)关闭
The inlet valve(361-LD3)of circulating fan is
close.
5. 出循环风机阀门
(361-LD1,361-LD4,361-SD1)开
The outlet valves(361-LD1,361-LD4,361-SD1)of
circulating fan are open.
6. 废气处理系统排风机进口阀门(421-LD3)关
闭
The inlet valve (421-LD3) of the fan of the waste
gas treatment system is close.
7. 旁路风管上阀门(421-LD1)关闭
The valves(421-LD1) on the bypass air duct are
close.
8. 去煤磨前电收尘的风管上阀门(441-SD2)关
闭
The valves (441-SD2) on the air duct of the
electrostatic precipitator in front of the coal mill
are close.
23
4 均化库顶收尘器组启动
Start the dust filter unit on the top of the
homogenizing silo.
1.均化库顶收尘器风机(391-FN3) 启动
Start the fan(391-FN3)
2.均化库顶收尘器（391-BF3）的下料
器（391-RF7）启动
Start the rotary feeder（391-RF7）
3.均化库顶收尘器(391-BF3)清灰程序
控制器启动
Start the dust filter(391-BF3)
5 生料输送及入库组启动注意斗式提升机 (391-BE1) 启动电流 Pay
Start the raw meal conveying and attention to the starting current of the bucket
entering into silo unit. elevator(391-BE1).
1.生料分配器斜槽风机(391-FA5)启动
Start the slide fan(391-FA5)of raw meal
distributor
2.均化库顶斜槽风机(391-FA4) 启动
Start the slide fan(391-FA4)
3.入库斗式提升机(391-BE1) 启动
Start the enter-into-silo bucket elevator
(391-BE1)
自动取样器(391-SM1) 启动
Start the automatic sampler (391-SM1)
空气输送斜槽风机 (391-FA3A,
391-FA3B, 391-FA3C, 391-FA3D) 启
动
Start the slide fan(391-FA3A,
391-FA3B, 391-FA3C, 391-FA3D)
6. 空气输送斜槽风机
(391-FA1A,391-FA2A,391-FA1B,391-F
A2B)
Start the slide fan
(391-FA1A,391-FA2A,391-FA1B,391-F
A2B)
7.回转下料阀(391-RF1~391-RF4) 启动
Start the rotary
feeder(391-RF1~391-RF4)
6 Start the air flow circulating unit 风机启动时,风机进口调节阀(361-LD3)关闭
原料磨循环风机（361-FN2）启动设定合适的选粉机启动转速
1. Start the circulating fan (361-FN2) of Close the inlet adjusting valve (361-LD3) when
raw mill. start the fan.
2. 立磨密封风机(361-FA1)启动 Set an appropriate starting rotate speed for the
2. Start the seal fan (361-FA1) of vertical separator.
mill.
3. 立磨选粉机(361-SR1)启动
3. Start the separator(361-SR1) of
vertical mill.
24
7 原料磨液压、润滑装置组启动准备 1. 检查所选油泵管路是否打开
Prepare for the starting of the hydraulic 1. Check if the pipeline of the chosen oil pump is
and lubricating devices of raw mill. open or not.
1.与现场联系，确认油泵选择 2. 检查油箱的油温
1. Contact with the site and confirm the 2. Check the temperature of the oil in the oil
choice of the oil pump. tank.
2.如油温低，稀油站油箱要加热 3. 检查冷却水阀门开度是否合适
2. Heat the oil tank of the thin oil station 3. Check if the opening of the cooling water
if the oil temperature is low. valve is proper or not.
8 原料磨液压、润滑装置组启动注意供油状况注意供油状况
Start the hydraulic and lubricating Pay attention to the oil supply condition.
devices of raw mill.
1.磨机(361-RM1)主减速机稀油站启动
1. Start the thin oil station of the main
gearbox of the mill (361-RM1).
2.磨机(361-RM1)主辊液压站启动
Start the hydraulic station of the main
roller of the mill361-RM1
3.磨辊润滑装置启动
Start the lubricating device of the mill
roller
磨机(361-SR1)选粉机油站启动
Start the oil station of the
Separator(361-SR1)
9 废气处理排风机组启动风机启动时,风机进口调节阀(421-LD3)关闭
Start the exhaust fan unit of the waste The inlet adjusting valve(421-LD3)of the fan is
gas treatment. close when starting the fan.
1. 风机冷却水系统启动
Start the cooling water system of the fan.
排风机(421-FN1) 主电机启动
Start the main motor of the exhaust fan
(421-FN1).
10 废气处理袋收尘器(421-BF1)回灰组启
动
Start the dust return unit of the waste gas
treating dust filter(421-BF1).
1.电动分料阀(421-FM1) 阀板开至入
库侧的位置
The valve plate of the electric material
distributing valve (421-FM1) shall be
opened to the position of enter-into- silo
side.
2.气动闸板阀(421-SG1a) 启动
Start the slide gate(421-SG1a)
链式输送机(421-CV4) 启动
Start the chain conveyor(421-CV4)
链式输送机(421-CV3) 启动
25
10 Start the chain conveyor(421-CV3)
窑尾袋收尘器拉链机
(421-CV2,421-CV1) 启动
Start the chain
conveyor(421-CV2,421-CV1)
窑尾袋收尘器卸料器
(421-RF1~421-RF1) 启动
2.Start the rotary
feeder(421-RF1~421-RF1) 窑尾袋收尘
器(421-BF1) 清灰程序控制器启动.
Start the dust removal procedure
controller of the bag filter (421-BF1).
3.当窑灰需要外排时，确认窑灰车准备
就绪，开启风机(4D1-FN1),开启袋收尘
器 (4D1-BF1) 下的回转下料阀
(4D1-RF1),开启袋收尘器(4D1-BF1)清
灰程序控制器,开启装车机(4D1-LA1)，
开启电动闸阀(4D1-SD1)，关闭气动闸
板阀(421-SG1a)，窑灰由链式输送机
(421-CV4)头部卸出
When the kiln dust need to cement mill
by bypass,confirm the bulk truck at the
position.then start the fan(4D1-FN1)
→rotary feeder (4D1-RF1) →bag filter
(4D1-BF1) →bulk loader (4D1-LA1)
and closed the gate(421-SG1a)
11 通知现场点燃备用燃油热风炉
燃油热风炉点火初期，注意磨机系统风
机进口阀门开度不能太大，防止将燃油
热风炉拉灭；随着燃油热风炉燃油量的
增加，慢慢地增加系统风量
At the beginning of its ignition, pay
attention that the opening of the inlet
valve of the fan of the mill system shall
not be too large, in order to prevent
putting out the furnace. With the
increasing of the oil quantity of the
furnace, slowly increase the air volume
of the system.
26
12 系统风量调整，预热立磨内部系统的最低拉风量，不低于系统正常生产
时系统风量的 80%（备用燃油热风炉提供的热
Adjust the air volume of the system and
风一般只能满足系统正常产量的 70%左右，系
preheat the mill interior. 统拉风和加料时应注意这一点
1. 逐渐打开磨机进口阀门 The minimum pulling air volume of the system
shall be not less than 80% of the air volume used
(361-SD2,421-LD4) 和热风炉出口阀 under normal production.(Generally, the hot air
provided by the standby oil hot air furnace can
门(361-SD3,361-LD5)，热风全速进入 only satisfy around 70% of the normal
系统 production of the system, which shall be noted
when the system is pulling air and the materials
Gradually open the inlet valve are being fed.)
(361-SD2,421-LD4) of the mill and the
outlet valve (361-SD3,361-LD5) of the
hot air furnace. The hot air enters into
the system at full speed and the air
volume is sufficient.
1.逐渐打开排风机进口阀门(421-LD3)
及循环风机进口阀门(361-LD3)，控制
系统风量接近要求值
Gradually open the inlet valve
(421-LD3) of exhaust fan and the inlet
valve (361-LD3) of the circulating fan to
control the air volume to be close to the
required value.
2.调整冷风阀门(361-LD2)开度，控制出
磨气体温度逐渐提高至 90℃左右;调整
进窑尾袋收尘器的风管上冷风阀
(421-BV1) 开度，保证袋收尘器在许可
温度及流量条件下安全运行
Adjust the opening of cool air valve
(361-LD2) to control the temperature of
the air out of the mill to be increased to
about 90 ℃ gradually. Adjust the
opening of the cool air
27
12 valve(421-BV1)on the air duct into the
bag filter at kiln inlet to ensure the safe
operation of the bag filter under the
permissive temperature and flow
condition.
3.调整循环风阀门(361-LD3)开度,控制
入磨气体温度
Adjust the opening of the circulating air
valve (361-LD3) to control the air
temperature into the mill.
13 1.检查确认磨辊是否已抬起此时磨辊在抬起状态
The mill roller has been lifted.
1. Check to confirm if the mill roller has
been lifted.
2.磨机减速机运转是否正常
2. Check if the gearbox of the mill is
normal or not.
28
14 原料喂料组启动，磨机预铺料 1) 确认金属探测仪未显示有金属信号。当金
Start the raw material feeding unit. The 属探测仪报警时，三通阀通向旁路。
materials shall be spread in advance in 1) Confirm the metal detector doesn’t show
the mill. metal signal. If the metal detector alarms, the
1.下列各组收尘组启动： three-way valve shall lead to by-pass.
1.1 风机(361-FN3)启动→袋收尘器 2) 检查胶带输送机、皮带秤是否备妥。
(361-BF2)卸灰阀(361-RF2)启动→袋收 2) Check if the belt conveyor and the belt scale
are ready.
尘器(361-BF2) 清灰程序控制器启动 3)根据化验室的要求设定物料配比,并以此控
→逐渐开启风机(361-FN3)进口阀门制各皮带喂料秤的喂料速度。
(361-BV8)阀板 3) Set the material proportioning ratio according
Start the fan (361-FN3)→Start the rotary to the requirements of the laboratory, so as to
feeder(361-RF2) →Start the bag filter control the feeding speed of the feeding scale of
(361-BF2)→Gradually start the valve each belt conveyor.
(361-BV8) 4）现场确认回转下料器无故障。
1.2 风机(361-FN1)启动→袋收尘器 4) Confirm the rotary unloader is free of failure.

5）确认立磨磨盘上已经预铺了厚约 70~90mm
(361-BF1)卸灰阀(361-RF1)启动→袋收
的原料（以立磨说明书中数值为准）。
尘器(361-BF1) 清灰程序控制器启动
5) Confirm there is 70~90mm thick raw
→逐渐开启风机(361-FN1)进口阀门 materials spread on the mill disc of the vertical
(361-BV7)阀板 mill in advance.(subject to the value in the
vertical mill instruction)
Start the fan (361-FN1)→Start the rotary 预铺料完成后，
331-WF1,331-WF2,331-WF3,331-WF4 四台定
feeder(361-RF1) →Start the bag filter
量给料机喂料量给定值设定为 0。
(361-BF1)→Gradually start the valve After finishing spreading materials in advance,
set the set value of the feeding quantity of four
(361-BV7)
constant weight feeders
1.3 风机(312-FN6)启动→袋收尘器 331-WF1,331-WF2,331-WF3,331-WF4 to be
zero.
→逐渐开启风机(312-FN6)进口阀门
(312-BV20)阀板
Start the fan (312-FN6)→Start the rotary
29
14 (312-BF6)→Gradually start the valve
(312-BV20)
1.4 风机(312-FN5)启动→袋收尘器
(312-BV17)阀板
(312-BF5)→Gradually start the valve
(312-BV17)
(312-BV14)阀板
(312-BV14)
(311-BV11)阀板
(311-BV11)
2.回转喂料阀(361-RF3) 启动
Start the rotary feeder(361-RF3)
30
14
3.气动两路阀(361-MW1) 阀板开至入
磨
Open the valve plate of the pneumatic
two-way valve(361-MW1) to the
position of entering into the mill.
4.金属探测仪(361-MT1) 启动
Start the metal detector(361-MT1)
5.除铁器(361-MS1) 启动
Start the iron separator(361-MS1)
6. 胶带输送机(331-BC2) 启动
(361-BW1)
Start the belt conveyor(331-BC2)
(The belt conveyor is equipped with
belt weigher (361-BW1))
331-BW1)
Start the belt conveyor(331-BC1)
(The belt conveyor is equipped with
belt weigher (331-BW1))
8.石灰石定量给料机(331-WF2)
Start the weigh feeder(331-WF2)
9.混合料定量给料机(331-WF1)
Start the weigh feeder (331-WF1)
10.混合料板式喂料机(331-AF1)
Start the apron feeder(331-AF1)
11.铝钒土定量给料机(331-WF4)
Start the weigh feeder (331-WF4)
12.铝钒土板式喂料机(331-AF3)
Start the apron feeder(331-AF3)
31
15 13.铁矾土定量给料机(331-WF3) 注意磨机主电机启动电流
Pay attention to the starting current of the main
Start the weigh feeder (331-WF3) motor of the mill.
14.铁矾土板式喂料机(331-AF2) 确认磨喷水装置给排水管线手动阀门已打开。
Confirm the manual valve of the water supply
Start the apron feeder(331-AF2) and drainage pipeline of the water spraying
15.立磨外循环系统启动 device has been opened.
确认拉紧装置液压系统运行正常。
Start raw mill external circulation system Confirm the hydraulic system of the tensioning
磨主传动组启动: device operates normally.
同时确认：
Start the main transmission unit of the At the same time, confirm:
mill: 原料输送系统正常。
The raw material conveying system is normal.
1.启动预告信号（15S）压缩空气供给正常。
1. Start the anticipating signal (15S) The supply of compressed air is normal.
循环风机启动。
2.启动立磨喷水装置 The circulating fan is started.
2. Start the water spraying device of 废气排风机启动。
The waste gas exhaust fan is started.
vertical mill. 生料均化库的料位合适。
3.启动拉紧装置液压系统 The material level of the raw meal homogenizing
silo is appropriate.
3. Start the hydraulic system of the 出磨废气温度＞设定值。
tensioning device. The temperature of the waste gas out of the mill
＞ set value.
4.启动立磨辅助传动装置
减速机输入轴振动速度＜5mm/sec。
4. Start the auxiliary driving device of The vibrating speed of the input shaft of the
the vertical mill. gearbox ＜5mm/sec
减速机机壳振动速度＜5mm/sec。
5.延时 3min, 启动立磨主传动电机,辅 The vibrating speed of the gearbox shell ＜
助传动装置停止。 5mm/sec
喷水装置正常。
5. With a delay of 3min, start the main The water spraying device is normal.
driving motor of the vertical mill and 确认立磨磨盘上已经预铺了厚 70~90mm 的原
料。
stop the auxiliary driving device. Confirm there is 70~90mm thick raw materials
spread on the mill disc of the vertical mill in
advance.
32
16 原料磨系统运转时的调节: 1.维持生料磨进出口压差，从而维持磨
The adjustment during the operation of raw 内物料量在一个恒定的水平。
mill system: 1. Keep the differential pressure between
1.根据原料磨进出口压差，调节喂料皮带输 the inlet and outlet of the raw mill to
送机和各定量给料机的喂料速度，以控制入 maintain a constant quantity of materials
磨物料量。 in the mill.
1. Adjust the feeding speed of the feeding belt

conveyor and each constant weight feeder to 2.当入磨气体温度过高时，截断入磨热
control the material quantity into the mill 源。

according to the differential pressure between 2. Cut off the heat resource into the mill
the inlet and outlet of the raw mill. when the temperature of the gas into the
2.根据磨机出口温度，调节喷水装置喷水量， mill is too high.
以控制出磨气体温度。
2. Adjust the water spraying quantity of the
water spraying device to control the
temperature of the gas out of the mill
according to the outlet temperature of the mill.
3.根据旋风收尘器(391-CN1~391-CN4)出口
流量大小，调节（361-LD5,361-LD2,361-LD1）
阀门的开度，以控制入磨气体流量。
3. Adjust the opening of the valves
(391-CN1~391-CN4) to control the gas flow
volume into the mill according to the outlet
flow volume of the cyclone dust collector
（361-LD5,361-LD2,361-LD1）.
4. 调节废气风机（ 421-FN1 ）入口阀门
(421-LD3)开度以控制原料磨入口负压。
4. Adjust the valve (421-LD3)to control the
negative pressure of raw mill inlet.
5.调节分离器(361-SR1)转速，以调节生料成
品细度。
5. Adjust the rotate speed of the separator

(361-SR1)to adjust the product fineness of the
raw meal.
33
17 使用备用热风炉时, 自动回路不投入 The
automatic circuit is not put into use when using
the standby hot air furnace.
1.2 熟料烧成系统运行正常时，系统的启动操作顺序
1.2 The starting operation sequence under normal operation of clinker burning system
利用熟料烧成系统窑尾废气时，原料粉磨系统的启动操作顺序与使用备用燃油热风炉提
供热源时，原料粉磨系统的启动操作顺序基本一致，但需注意以下几点（表 4-2）。
The starting operation sequence of the raw material grinding system using the waste gas from
kiln inlet of the clinker burning system is basically the same with using the heat sources supplied by
the stand-by fuel oil hot air furnace. However, attention shall be paid to the following main points:
表 4-2 利用窑尾废气时原料粉磨系统启动顺序要点
Table 4-2 Main points of the starting sequence of the raw material grinding system using the
waste gas from kiln inlet.
序号操作步骤检查与调整
No. Operating steps Inspection and adjustment
1 1.确认原料粉磨系统运转前的准备工 1.确认开车范围，做好启动前系统内设备的检
作已完成查工作
1. Confirm the preparation work is 1. Confirm the start-up range and inspect the
finished before the operation of the equipment in the system before starting.
raw material grinding system.
2.确认均化库顶收尘器组已运行
2. Confirm the dust filter unit at the top
of the homogenizing silo has been
operated.
3.生料输送及入均化库组已运行
3. Raw meal conveying and entering
homogenizing silo units has been
operated.
4.废气处理系统已正常运行
4. The waste gas treatment system has
been operated normally.
5.确认熟料烧成系统正常运行
5. Confirm the clinker burning system
is operated normally.
34
2 1.确认原料储存库内的物料储量合通知相关系统配合操作
适，并且原料供应部分输送设备 Notify the relevant system to cooperate.
可以保证随时供料
1. Confirm the amount of the materials
stored in the raw material storage is
appropriate, and the conveying
equipment for raw material supplying
can ensure the supplying at any time.
2.确认生料均化库允许进料
2. Confirm the raw meal homogenizing
silo allows material feeding.
3 确认各阀门位置 1.进磨热风阀门(361-SD2,421-LD4)关闭
The valves (361-SD2,421-LD4) are close.
Confirm the position of each valve.
2.进磨冷风阀门(361-LD2)全开
The valve(361-LD2) is full-open.
3.热风炉出口阀门
(361-SD3,361-LD5,361-SD4,361-LD6)关闭
The valves
(361-SD3,361-LD5,361-SD4,361-LD6)are
close.
4.出循环风机阀门
(361-LD1,361-LD4,361-SD1)开
The valve(361-LD1,361-LD4,361-SD1) are
open.
5.废气处理系统排风机进口阀门(421-LD3)关
闭
The valves(421-LD3)is close.
6.循环风机进口阀门(361-LD3) 关闭
The valves(361-LD3)is close.
7.袋收尘进口风管上冷风阀(421-BV1)开
The valve(421-BV1)is open.
8.煤磨前电收尘器进风阀门(441-SD2)关闭
The valve(441-SD2)is close.
9.窑尾高温风机进口阀门(441-LD1)关闭
The valve (441-LD1)is close.
4 系统喂料至满负荷且稳定运转时,投自动调节回路投入后,注意系统运转情况
入有关自动调节回路 Pay attention to the operation of the system
The relevant automatic adjusting after the automatic adjusting circuit being put
circuit shall be put into use when the into use.
system is fed to full load and is
operating stably.
35
二、系统运转中的检查与调整 Inspection and adjustment during the system operation
下面所讲的内容是系统正常运转之后，为保证各设备顺利工作，必须进行必要的检查及
调整。设备运行时，应经常观察各参数（电流、电压、温度、风量、喷水量等）的数值及变
化趋势，判断运行情况，并采取适当的措施进行调整处理，使系统正常而稳定地运行。系统
运转中的检查与调整项目见表 4-3。
The necessary inspection and adjustment must be conducted to ensure the smooth operation of
each equipment during normal operation of the system. When equipment is running, the value and
its change trend of each parameter(current, voltage, temperature, air volume, water spraying volume
and so on) shall be frequently observed to judge the operation condition and take measures to adjust
it if needed, in order to make sure the stable and normal operation of the system. See Table 4-3 for
the inspection and adjustment items during system operation.
表 4-3 系统运转中的检查与调整
Table 4-3 The inspection and adjustment items during system operation
序号检查项目检测判断方法调整处理方法
No. Inspection item Detection and judgment Adjustment and treatment
1 磨机（R1M01）主减速机仪表显示 1. 检查供油压力、温度
轴承温度高 Display on the 1. Check the pressure and
The temperature of the instrument temperature of oil supply.
main gearbox bearing of 2.检查油质
the mill (R1M01) is high. 2. Check the oil quality.
3.检查冷却水系统
3. Check the cooling water
system.
2 磨辊润滑油油温高仪表显示 2. 检查供油压力、温度
The temperature of the Display on the 1. Check the pressure and
lubricating oil of the mill instrument. temperature of oil supply.
roll is high. 2.检查油质
2. Check the oil quality.
3.检查冷却水系统
3. Check the cooling water
system.
36
3 系统内各点气体压力不系统内阀门位置不合调整系统内阀门开度
正常适 Adjust the opening of the valves.
The gas pressure at each The positions of the
point in the system is valves in the system is
abnormal. not suitable.
4 原料磨生产能力低 1.喂料速率低 1.增加喂料速率
The production capacity of 1. Feeding speed is low. 1. Increase the feeding speed.
the raw mill is low. 2.粉磨压力低 2.增加粉磨压力
2. Grinding pressure is 2. Increase the grinding pressure.
low. 3.降低选粉机转速
3.产品细度太细 3. Reduce the rotate speed of
3. Fineness of the separator.
products is too small. 4.调整系统风量
4.系统风量低 4. Adjust the air volume of
4. Air volume of the system.
system is low.
37
5 原料磨振动太大 1.喂料不均匀 1.均匀喂料
The vibration of raw mill 1. Feeding is not 1. Make the feeding uniform
is too heavy. uniform. 2.增加喂料速度或降低粉磨压
2.磨盘料层过薄力
2. The material layer of 2.Increase the feeding speed or
mill disc is too thin. reduce the grinding pressure.
3.入磨物料过干 3.增加磨内喷水
3. The feeding material 3. Increase the water spraying in
is too dry. the mill.
4.内循环量过大 4.适当降低选粉机转速(但要保
4. The inner circulating 证产品细度)
quantity is too large. 4. Reduce the rotate speed of
5.金属件进入磨机 separator (but the product
5. There are metals fed fineness shall be ensured).
into the mill. 5.检查金属探测器,磁铁分离器
6.喂料突然变细工作是否正常
6. Feed materials turn to 5. Check if the metal detector
be fine suddenly. and magnetic separator work
normally or not.
6.稳定入磨物料粒度
6. Stabilize the feeding particle
size.
6 磨机进出口压差过大 1.粉磨压力低 1.增加粉磨压力
The differential pressure 1. The grinding pressure 1. Increase the grinding pressure.
between the inlet and is low. 2.降低喂料速率
outlet of the mill is too 2.喂料量高 2. Reduce the feeding speed.
large. 2. The feeding volume 3.降低选粉机转速
is high. 3. Reduce the rotate speed of the
3.产品太细 separator.
3. The products are too 4.增加系统风量
fine. 4. Increase the air volume of the
4.系统风量偏低 system.
4. The air volume of the
system is small.
38
7 产品太细 1.选粉机转速过高 1.降低选粉机转速
The products are too fine. 1. The rotate speed of 1. Reduce the rotate speed of the
the separator is too separator.
high. 2.增加系统风量
2.系统风量过低 2. Increase the air volume of the
2.The air volume of the system.
system is too small.
8 产品太粗 1.选粉机转速过低 1.提高选粉机转速
The products are too 1. The rotate speed of 1. Increase the rotate speed of
coarse. the separator is too low. the separator.
2.系统风量过大 2.减少系统风量
2. The air volume of the 2. Reduce the air volume of the
system is too large. system.
9 生料水分偏高 6. 出磨气体温度低 1.提高出磨气体温度(允许范围
The moisture content of 1. The temperature of 内)
the raw meal is high. the gas out from the 1. Increase the temperature of
mill is low. the gas out from the mill (in the
2.磨内喷水过量 allowed range).
2. The water spraying in 2.减少磨内喷水
the mill is too much. 2. Reduce the water spraying in
3.喂料量偏高 the mill.
3. The feeding quantity 3.降低喂料量(允许范围内)
is large. 3. Reduce the feeding quantity
(within the allowed range).
10 磨系统风量不合适系统排风机阀门开度调整阀门开度或风机转速
The air volume of the mill 或风机转速不合适 Adjust the valve opening or the
system is inappropriate. The valve opening of rotate speed of the fan.
the exhaust fan or the
rotate speed of the fan is
improper.
39
11 磨机吐渣 1.磨辊压力不足 1.增加磨辊压力
Slag rejection of mill 1.The pressure of mill 1. Increase the pressure of mill
roller is not enough. roller.
2.入磨物料量过大 2.减少入磨物料量
2. The feeding quantity 2. Reduce the feeding quantity.
is too large. 3.增加入磨风量
3.入磨风量小 3. Increase the feeding air
3. The feeding air volume.
volume is small. 4.调整风环风面积
4.风环风速低 4. Adjust the air area of the air
4. The air speed of the ring.
air ring is low. 5.调整系统有关阀门,增加入磨
5.入磨气体负压过低气体负压
5. The negative pressure 5. Adjust the relevant valve of
of the feeding air is too the system to increase the
low. negative pressure of the feeding
6.挡料圈的高度不合适 air.
6. The height of the tail 6.适当调整挡料圈的高度
ring is not suitable. 6. Adjust the height of the tail
ring appropriately.
12 生料化学成分不合格各种原料配合比不合调整各计量秤给料比例
The chemical composition 适 Adjust the feeding ratio of each
of the raw meal is The proportioning of measuring scale.
unqualified. various raw materials is
improper.
13 废气处理系统排风机仪表显示温度过高检查润滑油量是否充足
(J1F02)固定轴承和活动 The temperature Check if the lubricating oil is
轴承温度过高 displayed on the enough or not.
The temperature of the instrument is too high.
fixed bearing and live

bearing of the exhaust
fan(J1F02) of waste gas
treatment system is too
high.
40
三、系统的停车操作 Stopping operation of the system
下面分别介绍正常情况下的停车、故障联锁停车及紧急停车等几种情况下的操作要领。
This section describes the essential points of the stopping operation under normal condition,
the failure interlocking stopping and the emergency stopping.
3.1 熟料烧成系统正常运转情况下的原料配料、原料粉磨系统停车操作
3.1 The stopping operation of the raw material proportioning and grinding system under the
condition of normal running of clinker burning system
熟料烧成系统正常运转情况下的原料存储与输送、原料粉磨系统停车操作见表 4-4。熟料
烧成系统正常运行时，废气处理系统不能停车。
See Table 4-4 for the stopping operation of the raw material storing, conveying and grinding
system under the condition of normal running of clinker burning system
表 4-4 烧成系统正常运转时原料配料、原料粉磨系统的停车操作
Table 4-4 The stopping operation of the raw material proportioning and grinding system under
normal running of clinker burning system
1 1.确认停车范围通知有关部门，做好系统停车过程的配
1. Confirm the stopping range. 合准备
2.将自动控制转为手动控制 Notify the relevant department to prepare
2. Change the automatic control to the for the cooperation with the system
manual control. stopping.
2 将原料喂料总量设定值降至原料磨允许 1.通知相关系统配合操作
的最低负荷 1. Notify the relevant system to cooperate.
Reduce the setting value of the total feeding 2.降低系统风量至允许值
quantity of the raw material to be the 2. Reduce the air volume of the system to
minimum load allowed by raw mill. the allowed value.
3 喂料及输送组停车 1.停车后，将定量喂料机设定为零
Stop the feeding and conveying unit 1. After stopping, set the constant weight
组内各设备的停车顺序和启动时的顺序 feeder to be zero.
相反 2.操作时速度不要太快，要保证磨内物料
The stopping sequence of the equipment of 可以被烘干

this unit is opposite to the starting sequence. 2. The operation shall not be too quick so
that the materials in the mill shall be
ensured to be dried.
41
4 磨机喷水组停车注意磨机出口气体温度，出磨风温不应
The stopping of the mill water spraying unit 过低，以保证产品水份合格
1.喷水装置电磁阀关闭 Pay attention to the gas temperature at mill
1. Close the magnetic valve of the water outlet. It shall not be too low so that the
spraying device moisture content of the product can be
2.喷水装置水泵变频控制箱停车 ensured to be qualified.
2. Stop the water pump frequency
conversion control box of the water
spraying device.
5 磨机主电机组停车 1.待磨内料空,磨辊抬起(自动),磨机主电
Stop the main motor unit of the mill 机组停车
1. Stop the main motor unit of the mill
after the mill is empty and the mill roller is
lifted (automatically).
2.防止断料后磨机振动
2. Avoid the mill vibration after stopping
feeding.
6 原料磨液压、润滑装置组停车待磨机主电机停车后磨辊落下(自动),再
Stop the hydraulic and lubricating devices 进行停车操作
of raw mill Stop the devices after the main motor of
the mill stops and the mill roller drops
(automatically).
7 立磨选粉机组停车选粉机转速设定为零
Stop the separator unit of the vertical mill Set the rotate speed of the separator to be
立磨选粉机停车 zero.
Stop the separator of the vertical mill
8 调整各阀门开闭状况注意废气处理系统的操作,保持废气处理
Adjust each valve. 系统为负压运行
原料磨进出风管道上阀门关闭 Pay attention to the operation of the waste
Close the valves at the inlet air duct and gas treatment system, and keep the
outlet air duct of the raw mill negative pressure operation.
废气处理系统中增湿塔进风阀门及出风
至袋收尘器的阀门开启
Open the inlet air valve of the conditioning
tower in the waste gas treatment system and
its outlet air valve to the bag filter
42
9 此时系统进入窑开，磨停状态，由于烧成进行系统检查,为下次开车做好准备工作
系统依然工作，当烧成系统的窑灰选择进 Inspect the system to prepare for next
入生料库时，生料均化库顶收尘器组和生 starting.
料输送入库组继续运行；当选择将窑灰直
接送入烧成系统时，生料均化库顶收尘器
组和生料输送入库组关闭
At this moment, the kiln is running and the
mill is stopped. The burning system is still
working. If the kiln dust from the burning
system enters into the raw meal silo, the
dust filter unit on the silo top and the raw
meal conveying and enter-into-silo unit will
continue running. If the kiln dust is sent to
the burning system directly, stop the dust
filter unit and the raw meal conveying and
enter-into-silo unit mentioned above.
3.2 使用热风炉情况下的原料配料、原料粉磨系统停车操作
3.2 The stopping operation of the raw material proportioning and grinding system under the
condition of using hot air furnace
使用热风炉情况下的系统停车操作与熟料烧成系统正常运转情况下的系统停车操作基本
一致，但要注意以下几点，见表 4-5。
The stopping operation under the condition of using hot air furnace is basically consistent with
that under the normal running of the clinker burning system. However, attention shall be paid to the
following main points. See Table 4-5.
表 4-5 使用热风炉时原料配料、原料粉磨系统的停车操作
Table 4-5 The stopping operation of the raw material proportioning and grinding system
under the condition of using hot air furnace
1 确认停车范围通知有关部门，做好系统停车过程的配合
Confirm the stopping range. 准备
Notify the relevant department to prepare
for the cooperation with the system
stopping.
43
2 通知现场停止热风炉供油，相应设备停注意停车后的检查
车 Pay attention to the inspection after
Notify the site to stop supplying oil for the stopping.
hot air furnace and the relevant equipment
shall be stopped.
3 喂料及输送组停车停车后，将定量喂料机设定为零
Stop the feeding and conveying unit Set the constant weight feeder to be zero
after stopping.
4 磨机喷水组停车注意磨机出口气体温度，出磨风温不应过
Stop the mill water spraying unit 低，以保证产品水份合格
1.喷水装置电磁阀关闭 Pay attention to the gas temperature at mill
1. Close the magnetic valve of the water outlet. It shall not be too low so that the
spraying device. moisture content of the product can be
2.喷水装置水泵变频控制箱停车 ensured to be qualified.
2. Stop the water pump frequency
conversion control box of the water
spraying device.
5 废气处理收尘器回灰组停车注意系统内的物料要输送干净
Stop the dust return unit of the dust filter Pay attention that the material in the system
of the waste gas treatment shall be totally conveyed.
6 废气处理排风机组
The exhaust fan unit of the waste gas
treatment
排风机主电机停车
Stop the main motor of the exhaust fan
7 均化库顶收尘组和生料输送及入库组停确认废气处理系统的输送设备停车后再
车停车
Stop the dust collecting unit on the silo top Stop them after confirming that the
and the raw meal conveying and conveying equipment of the waste gas
enter-into- silo unit treatment system is stopped.
8 进行系统检查，为下次开车做好准备工
作
Inspect the system to prepare for next
starting.
3.3 设备故障停车及紧急停车的处理
3.3 The equipment failure stopping and the emergency stopping
44
在设备运行过程中，由于设备突然发生故障或电机过载跳闸、保护跳闸及现场停车按钮
按下时，系统的部分设备会联锁停车。另外在某种紧急情况下，为了保证人身及设备安全，
也会使用紧急停车按钮，使系统内设备紧急停车，为了保证能顺利地再次启动，必须进行处
理操作。
During the operation of equipment, parts of the equipment in this system will be stopped in
interlocking due to the sudden failure of the equipment, the overload trip or protection trip of the
motor, and the push of stop button. Besides, in certain emergencies, the emergency stop button will
be pushed to stop the equipment to ensure the safety of person and equipment. Therefore, in order
to ensure that next starting is smooth, the treatment must be conducted.
当设备突然停机时，基本的处理程序是：
The basic handling procedure is as follow when the equipment is stopped suddenly:
(a)马上停止与之有关的部分设备。
(a)Immediately stop the relevant equipment.
(b)查清事故原因，判断能否在短时间内(30 分钟以内)处理完毕，以决定再次启动时间，
并进行相应的操作。
(b) Find out the failure reason and judge if it can be treated in short time (within 30 minutes).
Then determine the time of re-starting and carry out the corresponding operation.
(c)原料磨系统内部分设备突然停车，可能会导致系统内温度升高，超过设备允许的界限，
应及时调整系统内（包括废气处理部分）的阀门开度，降低风温，保护设备，同时尽量不要
影响窑系统的操作。
(c) The sudden stop of some equipment in the raw material grinding system may lead to the
temperature raising in the system, which may exceed the permissible limit of the equipment. Thus,
the opening of the valves in the system (including the waste gas treatment) shall be adjusted in time
to reduce the air temperature and protect the equipment, and at the same time, try not to affect the
operation of the kiln system.
系统内设备几种常见故障的处理方法见表 4-6。
See Table 4-6 for the treatment of several common failures of the equipment in the system
45
表 4-6 系统内设备几种常见故障的处理方法
Table 4-6 The treatment of several common failures of the equipment in the system
序号设备名称故障产生原因处理方法

No. Equipment Failure Reason Treatment
name
1 液压系统不能正常 1.加热器损坏 1.更换加热器
工作 1. The heater is damaged. 1. Replace the heater.
The hydraulic 2.冷却水管道堵塞 2.清理管道或更换过滤
system cannot work 2. The cooling water pipe is
normally. blocked 器
2. Clean the pipe or
replace the filter.
2 减速机振动大 1.入磨物料粒度太大或太小 1.调整物料粒度
1. The particle size of the 1. Adjust the particle
The gearbox
feeding material is too large or size.
vibrates heavily. too small. 2.更换衬板
2.衬板磨损 2. Replace the liner.
2. The liner wears. 3.检查、调整喷水量
3.喷水系统水量不够 3. Inspect and adjust the
3. The water quantity of the quantity of water
water spraying system is not spraying.
enough. 4.补充氮气
4.氮气压力不够 4. Supplement nitrogen.
4. The nitrogen pressure is not
立磨 enough.
3 磨辊无法升起 1.油泵损坏 1.更换油泵
Vertical
1. The oil pump is damaged. 1. Replace the oil pump
Mill The mill roller
2.油泵反转 2.调整油泵运转方向
cannot be lifted. 2. The oil pump runs in 2. Adjust the running
opposite direction. direction of the oil pump.
4 选粉机振动大 1. 导风叶片磨损 1.补焊或更换
1. The air guide blade wears. 1. Repair welding or
The separator exchanging
2.轮子磨损
vibrates heavily. 2. The wheel wears. 2.补焊或更换
3.电动机故障 2. Repair welding or
3. Motor fails. exchanging
3.检查转子、联轴器、主
4.轴轴承,发现故障进行
排除
3. Check the rotor, the
coupling, and the main
shaft bearing. If any fault
is found, remove it in
time.
46
5 喷水管破损磨内风量太大在喷水管外部增加耐磨
The water spraying The air volume in the mill is 护套并定期更换
pipe is broken. too large. Add wear resistant sleeve
to the external surface of
the pipe and replace it
regularly.
6 磨辊衬板产生裂纹安装不当,衬板底面与磨辊面正确安装新衬板
The liner of the mill 不均匀接触,导致衬板振动 Install a new liner
roller cracks. The improper installation and correctly.
the non-uniform contact
between the bottom surface of
the liner and the surface of the
mill roller lead to the liner
vibration.
7 液压缸故障装配或安装精度差及时检修、调整,更换不
The assembly or installation
The hydraulic
accuracy is poor. 良元件和密封圈
cylinder fails. 活塞密封圈损坏 Maintain and adjust it in
The seal ring of piston is
damaged. time, and replace the
间隙密封的活塞缸壁磨损大、 defective elements and
内漏多
seal rings.
Piston cylinder wall with
clearance gap seal wears
seriously and there is much
inner leakage.
缸盖处密封圈摩擦力过大
The friction force of the seal
ring at the cylinder cover is too
large.
活塞杆处密封圈磨损严重或
损坏,运动爬行
The seal ring at the piston rod
wears heavily or is damaged,
crawling movement.
8 液压元件生锈,磨油液中混入水分,变成乳白色将油静置 30min，从油箱
损快液体底部放出部分油水混合
The hydraulic Water is mixed into the oil. 物；严重时更换新油
elements rust and And the oil turns to be Leave the oil to stand for
wear quickly. milk-white liquid. 30min and then drain the
mixture liquid from the
bottom of the tank.
Exchange it with new oil
if the mixture is serious.
47
9 泵、阀等元件中的油液中混入了切屑、砂土、灰 1. 在灌油前清洗油箱
活动件卡死，小孔渣等杂质 1. Clean the oil tank
缝隙堵塞 Some foreign matters, such as before pouring.
The moving parts in chips, sand and ash, are mixed 2.加油时需加上过滤网
the pump and valve into oil. 2. Use the filtering screen
jam. The small hole when oiling.
clearance is 3.定期更换新油，及时清
blocked. 洗过滤器
3. Exchange it with new
oil regularly and clean
the filter in time.
10 磨辊液压缸连杆断连杆长期受突变应力的冲击, 更换连杆
裂在连杆螺纹处应力最集中,产 Replace the connecting
The connecting rod 生疲劳断裂 rod.
of the mill roller The connecting rod is affected
hydraulic cylinder by the impact of discontinuity
is broken. stress for long time. Most of
the stress is concentrated on
the thread of connecting rod.
Then the rod is broken because
of fatigue.
11 磨辊液压缸的活塞连杆长期受突变应力的冲击, 更换活塞杆
杆头部连接螺纹处在连杆螺纹处应力最集中,产 Replace the connecting
断裂生疲劳断裂 rod.
The connecting The connecting rod is affected
thread at the head by the impact of discontinuity
of the piston rod of stress for long time. Most of
the mill roller the stress is concentrated on
hydraulic cylinder the thread of connecting rod.
is broken Then the rod is broken because
of fatigue.
12 磨辊液压缸连杆与润滑不良引起轴承损坏将轴销割断,取出轴承,
穿心轴销轴承损坏 Poor lubrication lead to the 更换新轴承和新轴销
The connecting rod damage of bearing. Cut off the shaft pin to
of the mill roller take out the bearing.
hydraulic cylinder Replace them with new
and the cross-core bearing and shaft pin.
shaft pin bearing
are broken
13 磨辊液压缸盖与活油封被磨损更换油封,一般 2~3 年更
塞杆处漏油 Oil seal wears. 换一次
Oil leaks at the Replace the oil seal, once
cover and piston every 2-3 years generally.
rod of mill roller
hydraulic cylinder
48
14 风机振动大工作介质含尘大,磨损大 1. 在停磨时,对风叶进
The fan vibrates The dustiness of the working 行动平衡实验
heavily. media is high, and the wearing 1. Carry out dynamic
is severe. balance test for the fan
blade when the mill is
stopped.
2.用补焊的方法,解决平
衡问题
2. Use repair welding to
solve the balance
problem.
3.磨损严重时,应更换风
机叶轮
3. Replace the fan
impeller if the wearing is
severe.
15 风叶无载端轴承损 1. 风机经常开停,风机叶轮更换轴承
坏轴不断因冷热而胀缩 Exchange the bearing.
No-load end 1. The fan is started and
bearing of the fan stopped frequently so that the
blade is damaged. impeller shaft constantly
expands and contracts because
of heat and cold.
2.工作介质和环境含尘大
2. The dustiness of the working
media and the environment is
high.
16 主减速机齿轮传动 1.在输出端和止推轴承罩之 1.在检修时,拆卸齿轮传
装置润滑油泄漏间有少量泄漏动装置,更换密封毡
Th lubricating oil 1. There is a small amount of 1. Disassemble the gear
leakage of the gear leakage between the output end transmission device and
transmission device and the thrust bearing housing. replace the seal felt
of the main gearbox 2.在输入端有少量泄漏 during maintenance.
2. There is a small amount of 2.在检修时,拆卸齿轮传
leakage at the input end. 动装置,更换密封毡
3.紧固件没有充分拧紧 2. Disassemble the gear
3. Fastenings are not tightened transmission device and
enough. replace the seal felt
during maintenance
3.按规定拧紧紧固件
3. Tighten the fastenings
as required.
49
17 低压油泵系统供油 1.低压油系统泄漏 1.检查低压供油系统,修
压力不足而引起的 1. The low-pressure oil system 理泄漏的管道;泄漏严重
报警或磨机停车 leaks. 时应停磨处理
The alarm or mill 2.低压油泵系统吸气管阻塞 1. Check the
stopping caused by 2. The air intake duct of the low-pressure oil supply
the inadequate oil low-pressure oil system is system. Repair the
supply pressure of blocked. leaking pipe. Stop the
the low-pressure oil 3.油过滤器阻塞 mill to handle it if the
pump system 3. The oil filter is blocked. leakage is serious.
4.油泵损坏 2.清理阻塞的吸气管
4. The oil pump is damaged. 2. Clean the blocked air
intake duct.
3.清理油过滤器
3. Clean the oil filter.
4.更换油泵
4. Replace the oil pump
18 高压润滑油系统的 1.高压润滑油系统泄漏 1.检查高压润滑系统,修
压力不足而引起的 1. The high-pressure 理泄漏的管道;泄漏严重
报警或磨机停车 lubricating oil system leaks. 时应停磨处理
The alarm or mill 2.高压泵系统的吸气管阻塞 1. Check the
stopping caused by 2. The air intake duct of the high-pressure lubricating
the inadequate high-pressure pump system is system. Repair the
pressure of the blocked. leaking pipe. Stop the
high-pressure 3.润滑油过滤器阻塞 mill to handle it if the
lubricating oil 3. The lubricating oil filter is leakage is serious.
system blocked. 2.清理阻塞的吸气管
4.油泵损坏 2. Clean the blocked air
4. The oil pump is damaged. intake duct.
3.清理油过滤器
3. Clean the oil filter.
4.更换油泵
4. Replace the oil pump.
19 磨机隆响振动 1.起动前磨床上铺料不足。 1.立即停机，待加厚磨床
The mill makes a 1. The material spread on the 上物料量后重新起动。
noise loudly and grinder is insufficient before 2.结合磨机工况下的其
vibrates. starting. 它参数、及时采取相应
2.进磨物料粒度过粗；磨机供的操作措施，但情况严
料不足或过多；选粉机调整的重时需考虑停磨。
细度过细。 3.停机检修
2.The particle size of the 1. Stop it immediately to
feeding material is too coarse. increase the material
The material supply is quantity on the grinder
insufficient or too much. The and then restart it.
set fineness of the separator is 2. Take corresponding
too small. measures in combination
3.窑尾高温风机故障而中断 with other parameters
供风；磨机风机故障而无法满 under the mill working
足磨内通风与选粉出料的要 condition. Stopping shall
求。 be considered if the
The air supply breaks off situation is serious.
because of the failure of the 3. Stop to repair it.
high-temperature fan at kiln
inlet. The requirements of
ventilation within mill and
powder separating and
discharging cannot be satisfied
because of the failure of mill
fan.
50
20 磨辊张紧压力下降管路渗漏；压力安全溢流阀失对于完好设备，可起动
The tension 灵；油泵工作中断；压力开关油泵重新开始工作，关
pressure of mill 失常。泵后仍能保压。否则停
roller decreases. Pipe leakage; failure of the 磨。
pressure safety-relief valve; If the equipment is in
interruption of the oil pump; good condition, start the
failure of the pressure switch. oil pump to run again and
the pressure can still be
kept after stop the pump.
If not, stop the mill.
21 磨辊密封风压下降管道漏风；密封风机故障；阀检查设备，若风压略有
The seal air 门调节不当降低后仍能恒定，可不
pressure of mill Air leakage of the pipe; failure 停机，但如果其恒定值
roller decreases. of the seal fan; improper 已超过最低要求。磨机
adjustment of the valve. 将自动连锁停机。
Check the equipment. If
the air pressure can still
be constant after slight
reduction, the mill may
not be stopped. If the
constant value is less than
the minimum limit value,
the mill will be stopped
automatically in
interlocking.
22 排风机窑尾袋收尘排风机 1.叶轮变形，磨损；轴承箱剧 1.停机检修。相应地也停
停车烈振动窑、磨。
Exhaust
The exhaust fan of 1. The impeller becomes 1. Stop to repair it. Stop
fan (J1F02) the bag filter at kiln deformed and wears. The the kiln and the mill
inlet is stopped. bearing box vibrates heavily. accordingly.
2.轴承温度超限 2.清扫灰尘、疏通管路、
2. The bearing temperature 修复渗漏、补加润滑油、
exceeds the limit value. 保证冷却水通畅。若此
3.系统流量压力超过规定值，后仍不能恢复正常，则
造成电机超负荷应考虑停机。
3.The flow pressure of the 2. Clean the dust. Dredge
system exceeds the specified the pipeline. Repair the
value, leading to overload of leakage. And add
the motor. lubricating oil. Make sure
the cooling water flows
smoothly. If it still cannot
be back to normal after
taking the above
measures, stopping shall
be considered.
3.首先查明原因，然后根
据对工艺操作与设备安
全的影响程度决定是否
系统停车。
3. Find out the cause
firstly and then determine
if the system shall be
stopped based on the
degree of the influence
on the process operation
and equipment safety.
51
23 原料定量定量给料机计量显 9. 计量元件或显示仪表故 1.首先密切监控磨机工
示物料流量变化很障，计量皮带跑偏。况、加强仓底现场巡视，
给料机 1. Failure of the measuring 并视影响程度决定是否
大
Constant The measuring of elements or the indicating 停磨。故障处理必须马
the constant weight instrument; Deviation of the 上进行，尽快恢复。
weight measuring belt. 1. Closely monitor the
feeder shows that
feeder for the material flow 2.料仓内结拱堵料或塌料。 working condition of the
changes largely. 2. Material blockage or mill firstly and
raw collapse inside the material Strengthen the site
bin. inspection on the bin
material
3.料仓内储量不足，料位过 bottom. Then determine
低。 if the mill needs to be
3. Materials stored in the bin stopped based on the
are insufficient and the influence degree. The
material level is too low. troubles shall be handled
4.皮带秤设定参数可能不合 immediately.
适。 2.必须马上到现场捅料
4. The set parameter of the belt 清堵，如果清堵时间超
scale may not be appropriate. 过 4 个小时，应考虑停
磨，否则出磨生料质量
难于均化调整。
2. Blockage removal
must be carried out
immediately. If the
removal needs over 4
hours, the mill shall be
stopped. Or the raw meal
out from the mill will be
difficult to be
homogenized or adjusted.
3.必须马上向物料储仓
送料。
3. Materials must be
conveyed to the storage
bin right away.
4.请制造厂改变给定参
数
4. Ask the manufacturer
to change the parameter.
24 均化库顶生料均化库顶分配 1.生料水分过大而堵塞充气 1.加强原料磨生产操作
系统布料不均，输层。参数控制。控制出磨物
生料分配
送不畅。 1. The moisture content of the 料水分。
系统 Uneven material raw meal is too large so that 1. Strengthen the control
spreading and the aerating layer is blocked. of the production
Raw meal obstructed 2.生料中混有杂物沉积在充 operation of the raw
distributing conveying of the 气层上造成堵料；分配器安装 material mill. Control the
distributing system 倾斜；充气层破裂；风机故障 moisture content of the
system on on the top of materials out from the
供风不足。
the top of homogenizing silo. 2. The foreign matters mixed in mill.
the raw meal deposit on the 2.加强检查清理，若情况
homogeniz
aerating layer and cause 严重应考虑停磨。
-ing silo blockage. The distributor is 2. Strengthen the
installed slantingly. The inspection and cleaning.
aerating layer breaks. Air Consider to stop the mill
supply is not enough because if the situation is serious.
of the fan failure.
52
25 袋收尘器收尘系统冒灰 4）收尘风管阀门调节不当；尽快查明原因，采用相
Bag filter The dust collecting 袋收尘器内部滤袋糊袋；应措施。必要时应单机
system gives off 1. The adjustment of the valve 停车检修和更换。
ash. of the dust collecting air duct is Find out the causes and
improper. The dust sticks to the take corresponding
filtering bag in the bag filter, measures. Stop the single
causing blockage. equipment to repair and
2.滤袋破损、拉裂、卡箍脱落。 replace it if necessary.
2. The filtering bag breaks or
cracks. The clamp falls off.
26 胶带输送皮带跑偏 1.头、尾滚筒不平行 1.调整头尾轮
Deviation of the 1. The head and tail pulley is 1. Adjust the head and
机
belt not parallel. tail wheel.
Belt 皮带打滑 2.进料口物料卡死 2.清除进料口的物料
conveyor Slipping of the belt 2. The materials at the feed 2. Remove the material
inlet block. blockage at feed inlet.
3.皮带未张紧 3.调正皮带张紧力
3. The belt is not tensioned. 3. Adjust the tensioning
of the belt.
皮带撕裂或折断 1.有钢件卡在皮带上 1.更换新皮带
The belt tears or 1. There is steel piece sticking 1. Replace it with a new
breaks off. on the belt. belt.
2.皮带张得过紧，或胶接不好 2.用皮带扣连接
2. The tensioning of the belt is 2. Use belt fasteners to
too tight, or the joint is poor. connect them.
油冷式电动滚筒烧 1.缺油更换油冷式滚筒电机
坏 1. Oil starvation Replace the oil cooling
Oil cooling electric 2.进料口物料堆积而过载 pulley motor.
drive pulley burns 2. The materials at feed inlet
out. stack, which leads to overload.
27 斗式提升提升机电流过大 1.给料太多 1.减少给料量
机 The current of the 1. Materials are fed too much. 1. Reduce the feeding
elevator is too 2.斗子刮底，刮壳 quantity.
Bucket
large. 2. The bucket rubs on the 2.清除提升机底部杂物，
elevator bottom and the shell. 调整垂直度、轴轮平行
3.出料口堵塞及水平度
3. The discharge port is 2. Remove the sundries at
blocked. the bottom of the
elevator. Adjust the
perpendicularity and the
parallelism and levelness
of the arbor wheel.
3.疏通出料口
3. Remove the blockage.
53
有擦壳的声音 1.斗子严重变形 1.整修或更换
There is a sound of 1. The bucket becomes 1. Repair or replace it.
scrape on the shell. deformed seriously. 2.调整顶丝
2.轴轮歪斜 2. Adjust the top thread.
2. The arbor wheel is inclined. 3.停机检修
3.锥销脱落 3. Stop to repair it.
3. The taper pin falls off
提升机不能起动 1.电机故障 1.通知电工检查
The elevator cannot 1. Failure of the motor. 1. Notify the electrician
be started. 2.链轮落架 to check it.
2. The chain wheel falls down 2.调整好顶丝、配重、滑
from the frame. 轨
2. Adjust the top thread,
the balance weight and
the slide rail.
上下链轮的滚子轴 1.缺少润滑脂或润滑脂污染 1.加润滑脂或更换新润
承发热 1. Lack the lubricating grease 滑脂
The roller bearings or the grease is polluted. 1. Add lubricating grease
of the upper and 2.轴承安装不良 or replace it with new
lower chain wheels 2.The installation of the lubricating grease.
generate heat. bearing is poor. 2.调整
2. Adjust it.
下部跑灰严重密封橡胶破裂或磨损更换
The ash leakage at The sealing rubber breaks or Replace it
the bottom is wears.
serious.
28 链式输送链式输送机电流过 1.给料过多，机内料量过多 1.减少给料量，
机大 1. Materials are fed too much. 1. Reduce the feeding
The current of The materials in the conveyor quantity.
Chain
chain conveyor is are too much. 2.疏通出料口
conveyor too large. 2.出料口堵塞 2. Remove the blockage.
2. The discharge port is 3.调整链条与壳体间隙
blocked. 3. Adjust the clearance
3.链条等刮壳 between the chain and the
3. The chain rubs on the shell. shell.
有擦壳声音链条与下壳体摩擦尾轮张紧螺栓拧紧
There is a sound of The chain rubs on the lower The tensioning bolt of the
scrape on the shell. shell. tail pulley shall be
tightened.
链式输送机不能启 1.电机故障 1.通知电工检修
动 1. The motor fails. 1. Notify the electrician
The chain conveyor 2.链传动脱落 to repair it.
cannot be started. 2. The chain drive falls off. 2.重新装配，并加润滑油
2. Re-assemble it and add
lubricating oil.
54
链轮轴承发热 1.缺少润滑油脂或润滑油脂 1.加足润滑油脂或更换
The bearing of the 变质；新润滑油脂
chain wheel 1. Lack lubricating oil and 1. Add enough
generates heat. grease or the lubricating oil lubricating oil and grease
and grease is bad. or replace it with new
2.轴承安装不良 lubricating oil and grease.
2. The installation of the 2.安装调整
bearing is poor. 2. Adjust the installation.
29 空气输送斜槽堵死 1.透气层糊死或破损 1.清理并更换透气层
The slide is blocked 1. The air layer is blocked 1. Clean and replace the
斜槽
seriously.
seriously or broken. air layer.
Air slide
2.鼓风机开启前即开始下料 2.清理斜槽，按先开斜槽
2. Feeding starts before starting 风机后开前后进料设备
the air blower. 2. Clean the slide. Start
3.风机压力不足或漏风 the slide fan firstly and
3. The pressure of the fan is then start the front and
insufficient or the air leaks.
back feeding equipment.
3.方式操作见 30 风机
3. See 30 fan for the
operation methods.
30 风机风机振动过大 1.地脚螺栓松动 1.拧紧
Fan The fan vibrates too 1. The anchor bolt is loose. 1. Screw it firmly.
heavily. 2.叶轮积灰 2.清除积灰
2.Dust gathers on the impeller 2. Remove dust.
3.风机叶片磨损严重 3.更换
3. The blade of the fan wears 3. Replace it.
seriously. 4.更换
4.轴承座轴承损坏 4. Replace it.
4. Bearing seat bearing is 5.更换
damaged. 5. Replace it.
5.风机轴变形
5. The shaft of the fan deforms.
轴承发热 1.轴承磨损严重、损坏 1.更换
The bearing 1. The bearing wears heavily, 1. Replace it.
generates heat. or is damaged. 2.加注润滑油
2.轴承缺油 2. Add lubricating oil.
2. The bearing lacks oil. 3.加大冷却水量或提高
3.轴承缺冷却水或水压不足水压
3. The bearing lacks cooling 3. Increase the volume of
water or the water pressure is cooling water or increase
insufficient. the water pressure.
55
出风口无风 1.电机反转 1.对换电机接线头
There is no air at 1. The motor runs inversely. 1. Exchange the wiring
the outlet. 2.进、出口阀门未打开 terminals of the motor.
2. The inlet and outlet valves 2.打开阀门
are not opened. 2. Open the valve.
3.传动皮带松驰 3.张紧传动带
3. The driving belt is loose. 3. Tighten the driving
belt.
值得一提的是：一些常见故障往往是由于系统相关环节的众多因素综合作用而造成的，
所以出现问题后应首先进行细致的检查核实，及时查找出真正原因所在，然后才采取适当灵
活的处理措施，从而避免误判断、误操作而使事故故障扩大化、严重化。
It’s worth noting that some common failures are often caused by the comprehensive effects of
so many factors of the relevant links in this system. Therefore, the careful inspection shall be
carried out firstly after troubles occur to find out the real reasons in time. Then take proper and
flexible measures to handle them. Only in this way can mis-judgment and mis-operation be avoid so
that the accidents and failures won’t be expanded or more serious.
56
第五章试生产及生产中的注意事项
Chart 5 Pilot Production and Matters Need Attention in Production
一、试生产的日程安排及其目的 Pilot Production Schedule and Aim
1、日程安排 Schedule
当所有设备安装完毕，同时经过单机试车和联动无负荷试车，各设备经过全面检查，确
认没有隐患之后，就必须进行各系统的试生产阶段的试车，如在试车期间中有的设备出现故
障，则必须把用于检查维修的时间剔除出。If all the equipment is installed and the single-unit test
run and interlock no load test run is completed, make a comprehensive inspection for all equipment
and confirm no hidden danger, the pilot production test run can be commenced, if any equipment
failures, deduct the maintenance time.
2、目的 Aim
为了使轴承，齿轮等设备的运转部件适应运转的需要，进行无负荷试车是必要的，同时
为了避免投料试车中的以下几点出现故障，必须给予充分的检查：各设备的润滑油供应情况、
运动部件与固定部件之间有无不正常接触、组装时的精度等。In order to enable the bearing, gear
and other running parts adapt to operation requirements, it is indispensable to carry out no load test,
and highlight the following inspections to avoid failures in load test: lubrication conditions of each
equipment, abnormal contacts between the moving parts and the fixed parts, and the assembly
precision,etc.
为了检查各设备的运转情况，为满负荷试车作好准备。必须进行 30%、60%负荷的试车，
经过这一阶段的试车，能使各轴承，齿轮更好的跑合，增加齿轮表面的硬度。同时经过这一
阶段的试车，可以看出各计量仪表的工作性能，以及让操作人员学会如何实际地去操作，去
调整，为满负荷试车做好准备。With the aim of checking the operation conditions of each
equipment and prepare for full-load test, conduct a 30%、60% of the rated load test and run for a
period of time to enable a better running of the each bearing and gear, and the improvement of gear
surface rigidity. Meanwhile, through the test run, the work performance of each instrument is
perceivable which will provide an opportunity for operators to learn to actually operate and adjust
the equipment, so as to prepare for full-load test.
90%、100%负荷试车，主要是为了根据控制各个参数来选择最佳的设定值，从而找到最
好的运行条件和效果。As for 90%、100% of the rated load test, the main aim is to select the
optimized setting values in accordance with each parameter control , so as to find out the best
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operation conditions and effects.
二、试生产的准备 Pilot Production Preparation
在充分细致地检查完立磨及其它所有设备之后，必须进行下述试运转的准备。After a
comprehensive inspection for vertical mill and other equipment, make the following test run
preparations :
1、润滑油的注入 Lubricant filling
在加入润滑油之前，要对润滑装置进行仔细地清洗及内部检查，然后，按各设备的说明
书要求，加入合适的润滑油，达到油位计标准线为止。确保各加油点，润滑点均不补遗漏。
注意使用相应的正确油号的润滑油，润滑油路畅通，油压符合说明书要求。Before filling the
lubricant, carefully clean and check the lubrication device, then fill appropriate lubricant to the
normal line of oil level gauge in accordance with the equipment instruction requirements.
2、主机设备的检查 Inspection of Main Equipment
原料磨的开机检查按设备制造商 PFEIFFER 的说明和要求进行。入库的斗式提升机设备
的开机检查及安装按照设备制造商提供的说明和要求进行。其他单机设备更为详细的开机前
检验要求参见相应设备的产品说明书。According to the equipment manufacturer PFEIFFER
instruction and requirements, implement the raw mill starting inspection. The starting inspection
and installation of bucket elevator that connected with the homo silo, shall be in line with the
instruction and requirements provided by equipment manufacturer. In terms of other single-unit
equipment, refer corresponding equipment instruction for detailed starting inspections.
三、试生产系统的开停顺序说明 Start up and shut down instructions for pilot production
system
3.1 单机试车确认事项 Confirm matters for single-unit test run

(1)本系统每台设备逐个进行单机试运转、应严格按照相应设备的说明书及验收标准进
行。 Carry out single-unit test run for each equipment in the system in strict conformance with
corresponding equipment instructions and the conduct acceptance shall be in line with relevant
standards.
(2)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，故障报警保护有
效，设备性能达到铭牌或生产要求。After test run, confirm the main monitoring parameters
(vibration and bearing temperature and so on) are normal and the alarm protections are effective, as
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well as the equipment can meet the requirements of the nameplate or production requirements.
(3)确认传动机构、设备旋转运行方向正确无误。Confirm the rotation direction of driving
part and the equipment is correct.
(4)确认各种阀门、闸板等动作灵活，操作位置与状态显示正确对应。Confirm each kind of
valves and gates moves flexibly, the operation location is consistent with the displayed state.
(5)确认设备能够正常运行，无刮壳、卡堵等异常现象。各种水、气、油的管路没有堵塞
和渗漏。 Confirm the equipment operates normally, without looseness, blockage and other
abnormalities. The water pipeline, air pipeline and lubricant pipeline are no blockage and leakage.
(6)对定量给料机的荷重元件作静态校正和加码标定，确认计量误差满足精度要求。
Implement static calibration and markup calibration for load components of constant weight feeder
and confirm the measurement tolerance meet the precision requirements.
(7)确认所有现场的电气、自控元件与仪表等完好可靠，反应灵敏、显示准确。Confirm all
electrical and automatic control components, and instrument are in good conditions, rapid-response
and precise-displayed.
(8)对试车中可能发现的部件损坏，设备异常、水气供应不畅、润滑加油不当等情况，必
须及时进行修理，并确认完全可以随即投入正常进行。As for damaged component, abnormal
equipment, obstructed water, air pipelines and improper lubricant filling, repair them timely and
confirm that can be put into normal operation immediately.
3.2 联动空载试车 Interlock load test
联动空载试车可结合单机试车前的检查、试车后的确认情况，以及试车中可能的设备异
常故障性质等，有计划、有步骤地和单机试车交叉进行。在联动空载试车后，除了对上述小
节确认事项中的某些内容仍需认可外，还应至少确认以下内容。Combined with the inspection
before single-unit test run and the confirmation after the test run, the interlock load test can be
carried out crossover with the single-unit test run in a planned and orderly manner. Apart form the
above confirmation matters, the following items shall be confirmed after the interlock test run:
(1)确认系统每一分组中的设备开停顺序符合工艺联动要求，其联锁、模拟各种故障停车、
报警保护等检验均有效可靠。Confirm the equipment start up and shut down sequence in each
group conforms to the process interlock requirements, the interlock, simulated failure shut down,
alarm protection and other tests are reliable and effective.
(2)确认中央控制和机旁控制均可进行正常的开停操作，并对模拟各种故障均能快速、有
效、灵活地处理。Confirm the normal start up and shut down operation of central control and local
can be executed, and can handle variously simulated failure rapidly, effectively and flexibly.
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(3)确认系统在多种运行方式下，气体管路上调节风门的操作阀位正确有效，物料输送流
向符合要求。Confirm the operation valve location on the air duct is correct and effective and
material transport flow direction shall meet the requirements.
(4)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，
供以后判断物料输送情况时参考。Each Roots Blower shall carry out at least 8 hours continuous
operation and utilize the pipeline gates to adjust the outlet pressure to design pressure. Observe the
bearing temperature of Roots Blower, air temperature in outlet pipeline, motor current, etc, so as to
judge and confirm whether the Roots Blower can operate reliable in the long-run. Furthermore,
record the outlet static pressure of each Roots Blower in normal work conditions, so as to take a
reference to judge the material transportation in the future.
3.3 投料试生产 Material Feeding Test Run
由于本系统和熟料烧成、生料均化库有非常密切的联系，主要因为熟料烧成需要生料、
原料粉磨烘干需要热源、废气都利用窑尾收尘器净化排空——这三者互为牵涉所致，因此系
统运行方式就有以下二种：Due to this system has a close relation with clinker firing, homo silo,
the clinker firing requires the raw material grinding, and utilizing kiln inlet exhaust discharged from
the dust collector to provide heat source to dry the material——these three factors are involved,
therefore, there are two operation manners:
(1)窑磨同时运行 Kiln an raw mill runs simultaneously
这种工况是工厂进行正常平衡连续生产最为基本的一种方式。一般在原料磨尚未起动前，
窑已经正常运转，窑尾收尘器也已稳定工作，此时只需顺序起动原料磨系统和物料输送、并
根据磨机起动要求调节入磨热风量，就可使原料磨逐步投入运行。这种情况下，管道上的调
节阀门工作状态如下：This working conditions is the most basic manner for normal balanced
continuous production of the plant. Normally before start the raw mill, the kiln has been already in
operation, and the dust collector at kiln inlet has operate reliably, only needs to start the raw mill
system and material transportation system by sequence. Besides, enable the raw mill to gradually
operate by adjusting the hot air volume that enters into the mill in accordance with mill starting
requirements. In this case, the work states of adjusting valve in the pipeline are as follows:
——窑尾高温风机至窑尾袋收尘器的旁路风管上阀门(421-LD1)全关。
The valves(421-LD1) shall be closed.
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——窑尾高温风机至煤磨前电收尘器的风管上阀门(441-SD2)根据煤磨的运行状态决定
启闭。
Open or close the valves(441-SD2) on the air ducts to EP in front of the coal mill in
accordance with the operation conditions of coal mill.
——窑尾高温风机至原料磨的风管上阀门(421-LD4,361-SD2,361-LD2)，出磨循环风机后
的管道上阀门(361-SD1,361-LD1,361-LD4)均处于开启、调节状态。
All valves (421-LD4,361-SD2,361-LD2)on the air ducts from ID fan to raw mill, as well as the
valves (361-SD1,361-LD1,361-LD4)on the pipeline behind the circulating fan connected with the
mill shall be in open and adjustable state.
(2)停磨开窑运行 Shut down the mill and start the kiln
这种工况一般发生在需停磨大修或生料均化库需清库修理、以及原料磨系统事故故障停
车而无法短时修复时，此时窑尾废气进入增湿塔增湿降温后进入窑尾收尘器净化排空，相应
地管道上调节风门工作状态如下：This working conditions applies to shut down the mill to
maintain or clean and repair the homo silo, as well as the raw material system can not be repaired in
a short period of time due to failure shut down, at this moment the kiln inlet exhaust enters into
conditioning tower to be humidified and the temperature is lowered, then enters into dust collector
at kiln inlet to be purified, correspondingly the working state of control dampers should be as
follows:
——进磨热风管道上阀门(421-LD4,361-SD2,361-LD2)全关；
Valves(421-LD4,361-SD2,361-LD2))on hot air ducts connected with mill shall be closed;
——高温风机至窑尾袋收尘器旁路风管上阀门(421-LD1) 开启、调节；
Valves (421-LD4,361-SD2,361-LD2)on the air ducts from ID fan to main bag filter shall be in
open and adjustable state.
——出磨循环风机后的管道上阀门(361-SD1,361-LD1,361-LD4)全关。
All dampers(361-SD1,361-LD1,361-LD4)on circulating air ducts shall be closed.
由上述系统运行方式可以看出：原料磨系统的投料试生产、包括以后的正常生产，只要
在废气处理、物料输送已投入稳定运行后，就可以按照磨机的调试、投料、供风等操作步骤
与要求逐步投入。原料磨调试、试生产的开机操作详细说明请参见设备制造商的产品说明书
和操作维护手册。
It can be observed from the operation manner of the above system: as long as the exhaust
treatment, material transportation runs stably, the commissioning test run of raw material grinding
system, including the normal production process in the future, can be gradually put into operation in
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accordance with the operation steps and requirements of mill commissioning, material feeding and
air supply. Refer equipment instruction and operation and maintenance manual provided by the
equipment manufacturer for detailed start up instruction of pilot production.
3.4 系统的开停顺序说明 System start up and shut down sequence instruction
本系统各分组设备的开停顺序操作基本原则如下：
(1)库顶及斗式提升机的收尘总是先于生料与回灰输送开机，并在生料与回灰输送的有关
设备完全停机后才允许停收尘设备。Normally, first start the dust collector at top of the silo and
bucket elevator before the start of raw material and ash returning conveyor and it is permitted to
shut down the dust collector after completely shut down the relevant equipment of raw material and
ash returning conveyor.
(2)根据实际生产时系统运行方式，正确选择气体流向与物料流向的相应阀门的开关。
According to the actual production operation manner, select appropriate gate switches consistent
with air flow direction and material flow direction.
(3)斗式提升机只有在库顶输送设备正常起动后才能进料；若库顶输送设备发生故障，由
此而造成或其它可能原因引起的斗式提升机料位超限自动报警，同时还将联锁紧停进料输送
机。After normal start of the transportation device at top of the silo, the bucket elevator can be fed
material; if the transportation device at top of the silo fails, it may leads to the material level of the
bucket elevator exceeds the limit and it will automatically send alarms, as well as interlocked
emergently stop feeding material to the transportation device.
(4)只有在窑尾收尘器排风机起动运行后才能起动窑尾高温风机，管路上阀门开关应根据
实际操作时系统运行方式而决定。After the start and operation of exhaust fan of dust collector at
kiln inlet, the high temperature fan at kiln inlet can be started, the actual system operation manner
determines the pipeline valve switches.
(5)磨机起动总是在密封风机、选粉机、主减速机润滑系统均起动显示正常运行，且所有
水、气、油、料等外部条件全部备妥后才能进行，当正常运行中某一个条件不满足或超限时，
均能自动联锁停机。张紧液压系统在磨机起动运行后投入。Generally, provided that the start and
normal operation of the lubrication systems of the seal fan, air separator, main reducer, and the
water, air, lubricant, material and other external factors are ready, the mill can be started. If one or
more factors do not meet the requirements or exceeds the limit, the mill shall interlocked shut down.
The hydraulic tension system is in operation after the start of the mill.
(6)磨机起动后才允许原料配料系统的定量给料机开车喂料并输送入磨。电磁除铁装置和
金属探测仪应与喂料皮带机同步起动运行，当进磨前金属探测仪检测出配合原料中混有合金
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属杂物，磨前气动两路阀将联锁转到旁路状态排出金属杂物，几秒钟后又马上恢复主通道继
续向磨内送料。当磨机故障停车时将自动联锁胶带输送机或定量给料机停止喂料。只有当原
料输送系统停车后，原料磨才允许停机。After the start of the mill, it is allowed to start the
constant weight feeder of the raw material batching system and feed material and transport to the
mill. The electromagnetic iron remover and metal detector shall be started and operated
simultaneously with the feeding blet conveyor. If the metal detector found the batching material
mixed with metal sundries before the material is transported to the mill, two pneumatic valves in
front of the mill shall interlocked convert to bypass state to discharge the metal sundries, several
seconds later resume to main route to go on transporting the material. If the mill failure shut down
occurs, the blet conveyor and constant weight feeder shall interlocked stop feeding material. Only
by shutting down the material transportation system, the mill can be shut down.
3.5 正常生产操作 Normal production operation
结合前述本系统的运行前检查准备和投料试生产，正常生产操作方法基本上与此类同，
不再赘述。但必须注意以下几点事项：Combined with the above stated inspection before operation
and commissioning test run, the normal production operation methods are basically similar, no need
to repeat again. Pay attention to the following items:
(1)密切监控磨机进出风口压差变化和原料的稳定供给，尽可能避免配料库内结拱堵料或
塌料而造成原料磨供料不足或喂料过量，严防“空磨”或“过饱磨”。Closely monitor the pressure
difference variation between the inlet and outlet of the mill and the stable supply of the raw material,
try to avoid wet material or blockage in the raw mill feed or inadequate material supply or excessive
material supply caused by material collapse.
(2)密切监控磨机进出口风的温度变化，防止烧成系统生产异常时出预热器废气温度骤变
而使进磨热风温度与风量发生过大变化，进而可能引起磨机工况波动剧烈和综合连锁反应，
导致事故紧急停车。Closely monitor the temperature variation between the inlet and outlet of the
mill, avoid significant variation of hot air temperature and air volume that enters in to the mill,
caused by the sudden temperature change of preheater exhaust when the firing system is abnormal,
which will lead to the working conditions of the mill fluctuates sharply and comprehensive chain
reaction, and result in accident emergent shut down.
(3)对正常运行中可能出现的密封风压不足、主减速机轴承温度过高、磨振过大、张紧压
力无法保压等重大故障之一时，都必须停磨。平时必须密切监控磨机主轴承、磨辊的轴承、
主减速机轴承、主电机轴承和大风机(窑尾高温风机、窑尾收尘器排风机)的轴承温度。If found
insufficient seal air pressure, high temperature of main reducer bearing, excessive grinding
vibration, non-pressure maintaining of tension device and other major failures in normal operation
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process, the mill must be shut down. Always closely monitor the temperature of mill main bearing,
grinding roller bearing, main reducer bearing, main motor bearing and large-scale fan (high
temperature fan at kiln inlet, exhaust fan of dust collector at kiln inlet).
(4)不管发生哪一种故障，首先要对故障原因，对工艺生产与设备安全保护的影响程度，
以及排除故障预计所需时间能够及时作出准确判断，然后根据轻重主次，以先单机停车、其
次分组停车、最终迫不得已才系统停车的原则来实施故障处理，尽可能快地恢复正常生产。
No matter what failures, first make an accurate judgment of failure reasons, the impact on process
production and equipment safety protection, as well as the estimated time to eliminate the failure,
then according the order of priority, insist on the principle of first execute single-unit shut down,
second execute equipment group shut down and finally execute system shut down to carry out
failure handling, so as to resume production as soon as possible.
(5)必须强调：本系统应选择有较好技术和责任的操作人员，建立车间日常的维护保养制度，
每班必须对磨机、大风机、收尘器等进行检查，通过勤监视、勤检查、勤联系，以便及时发
现问题，尽快采取正确的应变措施，使系统工作状态能时时稳定在最佳的操作控制范围内。
Emphasis: select responsible operator with better technology for the system, establish workshop
daily maintenance system, each shift must check the mill, fan, dust collector etc. Find out the
problems in a timely manner by frequent surveillance, inspection, and coordination, to take proper
emergency measures as soon as possible, so as to maintain an optical working state .
四、生产中的注意事项 Matters need attention in production
4.1 注意系统的联锁关系 Pay attention to system interlock relationship

立磨是原料粉磨系统中集原料烘干、原料粉磨、物料选粉于一身的关键设备，影响设备
正常运转的因素较多。因此，在调试过程中除了注意设备之间的联锁关系外，还要注意温度、
压力、振动等模拟量的准确度及其与主电机联锁关系的可靠性，确保设备的安全。The vertical
mill is a key equipment, integrating with raw material drying, raw material grinding and material
separating, and a large number of factors affect the normal operation of the equipment. Therefore,
apart from the interlock relationship between the equipment, pay attention to the temperature,
pressure, vibration and the precision of other analog quantity, as well as the reliability of the
interlock relationship with the main motor, so as to guarantee the safety of the equipment.
4.2 注意原料喂料计量设备的准确度 Pay attention to the precision of the raw material
feeding equipment
立磨原料粉磨系统对喂料量要求较高，喂料过多、过少都会导致立磨振动停车，这是立
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磨原料粉磨系统调试过程中出现问题较多的环节，因此对原料喂料计量设备除了静态标定外，
还必须进行实物标定，确保原料喂料计量设备的准确度。 The raw material grinding system of
the vertical mill has higher requirements on the feeding amount, feeding too much, or feeding too
little will lead to vibration shut down, in which a lot of problems occur in the commissioning
process. Therefore, besides the static calibration, the material actual calibration should also be
carried out to ensure the precision of the raw material feeding measurement equipment.
4.3 注意相关系统的操作及风量的平衡 Pay attention to operation of relevant system and air
volume balance
原料粉磨、废气处理和烧成系统的操作密切相关，运行过程中各系统要注意协调并及时
调整系统内各阀门的开度，使窑尾高温风机出口压力保持在－200~－300Pa The operation of
raw material grinding, exhaust treatment and firing system closely related with each other, beware
that all systems shall coordinate and timely adjust the openness of the valves in the system in
operation process, maintain the outlet pressure of the high temperature fan at kiln inlet in the rage of
－200~－300Pa.
4.4 磨机通风量 Mill air volume
通过调节系统排风机入口阀门开度和循环风管阀门开度，使磨内通风量恒定，有利于烘
干、粉磨和成品细度的稳定。 By adjusting the inlet valve openness of exhaust fan, enable the
constant air volume in the mill, which facilitates the drying, grinding and the stable fineness of the
finished products.
4.5 料层的稳定 Stability of bed of material
立磨在运行过程中只有在磨盘与磨辊之间形成一个稳定的料层时才会平稳持续地运行，
在这种状态下，振动量最小，最终产品产量提高，电耗接近最低。因此，为使立磨能稳定运
行，在磨盘上建立一个稳定的物料层是相当重要的，它的获得可以通过以下措施来实现。The
vertical mill can operate smoothly only by formulating a stable bed of material between the
grinding table and the grinding roller in the operating process. In this state, the vibration is at least,
the output of the final products is increased and the power consumption is almost minimum.
Therefore, in order to ensure the stable operation of the vertical mill, it is vital to form a stable bed
of material on the grinding table through the following measures:
(1)调整合适的磨盘筒边的挡料圈高度，一般为磨盘直径的 3%。Adjust appropriate height of
the material retaining ring at the edge of the grinding table, normally 3% of the diameter of the
grinding table.
(2)对磨盘上的物料喷水，可以改善硬质原料成分在磨系统中和在磨盘上出现聚集而导致
65
的不稳定的粉磨料层，可以使干而细的物料流动性得到降低，使粉磨料层的稳定性得到改善，
对于大多数含有通常水分的混合料来说，喷水还可以用来控制磨机的出口温度。Spray water to
the material on the grinding table to improve the accumulation of the hard material on the grinding
system and on the grinding table, which lead to unstable grinding bed of material, so as to reduce
the fluidity of the dry and fine material and increase the stability of the grinding bed of material. As
for the mixed material with moisture, spray water can also control the outlet temperature of the mill.
(3) 确保喂料系统的连续运行，保证喂料的均匀与稳定。Guarantee the continuously
operation of the feeding system and the uniform and stable material feeding.
(4)根据实际情况，合理调整研磨压力，当料层增加时，稍增大研磨压力，反之减小压力。
According to the actual situations, properly adjust the grinding pressure. If the bed of material
increase, enlarge the grinding pressure, otherwise reduce the pressure.
4.6 适合的挡料圈高度 Appropriate height of material retaining ring
对于立磨来说，合适的磨盘周边的挡料圈高度是至关重要的。磨盘的挡料圈高度太低，
高离心力使得中粒到细粒的物料不能留在磨盘上形成稳定的料层，其直接结果是在磨盘周围
和磨盘上方产生高循环荷载，从而影响粉磨效率，降低产量；若挡料圈太高，形成的料层过
厚，磨辊将在料层上产生滑动，将物料犁开，而不能从物料上面碾压过去以产生粉磨作用，
加在磨辊上的高的液压力不能有效地传递给料层，降低了粉磨效率，影响产量，增加电耗。
For the vertical mill, appropriate height of material retaining ring around the grinding table is
of vital importance. In case of low height of material retaining ring, high centrifugal force makes
the medium size particles and fine particles material not stay on the grinding table to form a stable
bed of material, with a direct result of high cycle loading occurs above the grinding table and
around the grinding table, thus affect the grinding efficiency and reduce the output; in case of high
height of material retaining ring, the bed of material will be too thick, grinding roller would slide on
the bed of material and plow off material, and can not roll on the material and produce grinding
effect, and high fluid pressure exert on the grinding roller can not be effectively transferred to the
bed of material, which reduces the grinding efficiency, affects the output and increases power
consumption.
4.7 合理的入磨物料粒度及其级配 Rational material granularity into the mill and its
granular composition
对于立磨的入磨物料粒度要求来说并非象对于球磨机那样越细越好，而粗的范围也是有
限的，这是因为：As for the granularity of material into the vertical mill, it is not similar to ball mill,
the finer the better, the roughness is very limited, the reasons are as follows:
立磨内当物料颗粒太细时，料层变得极易流动，不能支持磨辊，因此，磨辊在磨盘上开
66
始滑动，将物料犁开，而不是在物料上面碾压过去以产生粉磨作用。此时磨辊的运动是波浪
式的，从而产生强烈的振动，这就是对立磨来说所谓的“波浪效应”。If the material granularity
is too small in the mill, the bed of material is likely to flow and can not support the grinding roller,
thus the grinding roller slides on the grinding table and plow off the material, rather than roll on the
material and generate grinding effect. At this moment, the movement of the grinding roller is wavy
type, and generate strong vibration, this is so-called wavy effect of the mill.
立磨运转过程中当产生“波浪效应”时，细粒物料不能从磨盘上被带走，为了避免这种
情况，必须降低喂料量或往磨盘上喷水使料层变湿成团，以使料层获得“刚性”。同样，当
入磨物料粒度过粗时，也可能对立磨的附属设备（如喂料系统等）造成卡死或堵塞。因此，
入磨物料粒度要符合要求。If wavy effect occurs in the operation process of vertical mill, the fine
material can not be taken away from the grinding table. In order to avoid such situation, reduce
feeding quantity or spay water to grinding table to make the bed of material become wet and form
pellet, so that the bed of material becomes rigid. Similarly, if the material granularity is too large
into the mill, the auxiliary equipment (feeding system) of the vertical mill may get stuck or blocked.
Therefore, the material granularity into the mill shall meet the requirements.
4.8 防止铁块进入磨机 Avoid iron entering into the mill
铁块混入物料进入磨机不仅引起磨机振动量大而跳停，而且还会严重损伤立磨衬板，因
此，在输送物料的皮带机上设置的除铁器和金属探测仪必须能够正常有效工作，避免由于铁
块混入物料进入磨机，而导致磨机振动跳停或损伤磨机。
Iron mixes into the materials and enters into the mill not only lead to vibration of the mill and
trip, but also seriously damage of the vertical mill liner. Therefore, the iron remover and metal
detector installed on the material conveyor shall work effectively to prevent the iron from mixing
into the material and entering into the mill, which result in vibration and trip of the mill or
damage the mill
4.9 合理的工艺操作参数 Rational process operation parameters
(1)保持风量与物料量的平衡。 Maintain a balance between air volume and material quantity
入料量大，风量小，易造成吐渣； In case of large feeding quantity, small air volume, it may
give rise to slag rejection;
入料量小，风量大，料层难以形成，易引起振动 In case of small feeding quantity, large air
volume, it is difficult to form the bed of material and lead to vibration
(2)保持入料量与磨辊压力的平衡。Maintain a balance between the feeding quantity and the
pressure of grinding roller.
67
当入料量一定时，压力大，则料层薄，易引起振动；In case of constant feeding quantity, large
pressure, the bed of material becomes thin and is likely to vibrate.
压力小，则料层厚，易造成吐渣。 In case of small pressure, thick bed of material, it gives rise
to slag rejection.
(3)料层厚度与入磨气体负压。Negative pressure between the thickness of the bed of material
and air into the mill
入磨气体负压的大小，反映了气体入磨的压力高低，当入磨气体负压值偏大时，料层慢
慢变薄，主要原因是在风环处的功能增大，部分物料被悬浮起来，不能有效地落入磨盘上最
终导致料层变薄。The negative pressure of air into the mill reflects the air pressure enters into the
mill. If the negative pressure of air into the mill is too large, the bed of material becomes thin, and
the main reason is that the function of the air ring becomes large and part of the material is
suspended and can not effectively falls on the grinding table and eventually leads to thin bed of
material.
(4)物料细度控制。Material granularity control
选粉机的转速高，成品细度细；选粉机的转速低，成品细度粗。选粉机的转速不同程度
影响磨内循环。转速高，有利于稳定料层，但转速过高，影响产量。
The rotation speed of the air separator is high, the granularity of the finished products is small;
the rotation speed of the air separator is low, the granularity of the finished products is large. The
rotation speed of the air separator affects the internal circulation of the mill. The high rotation speed
facilitates stable bed of material. However, excessive high rotation speed influences the output.
原料配料、原料粉磨和废气处理系统的正常连续运转与每台设备的正常维护管理密切相
关，而且预防性维护比故障性维修更为重要。正常的维护管理既是设备本身安全保护与延长
工作寿命的要求，又是保证系统长期稳定运行和消除事故隐患的必要手段。本节仅从工艺生
产角度阐述主机设备的主要维护工作，更为详细的要求请参阅有关设备的说明书。The normal
and continuous operation of raw material is closely related with normal maintenance of each
equipment, and the preventative maintenance is more important than failure maintenance. The
normal maintenance management is not only the requirements of equipment safety protection and
the prolonged service life, but also the necessary measures to guarantee long-term stable operation
and elimination of potential dangers and accidents. This section merely expound in main routine
maintenance of main equipment, and refer instructions of relevant equipment for detailed
requirements.
5.1 原料配料 Raw material batching
68
(1)每班清扫一次中型板式喂料机、定量给料机的称重传感器和传动电机上的积灰，清除
滚筒粘料。Each shift shall clean the medium-scale apron feeder, weighing sensor of constant
weight feeder and accumulated dust on drive motor and the sticky material on the cylinder for one
time.
(2)每日清扫一次皮带机的漏料，清除电磁除铁器的铁块杂物。Clear the spilled material of
the belt conveyor, and the iron sundries of the electromagnetic iron remover once a day.
(3)对混有铁质异物的物料排放后，应及时清走。Discharge the material mixed with iron and
clear it in time.
(4)定期检查袋收尘器滤袋、清灰装置、提升阀、电磁阀等工作情况。Regularly check the
work conditions of the filter bag of dust collector, ash-removal device, lift valve and the
electromagnetic valve
(5)定时补充添加润滑油，定期检查清洗润滑点并更换新的润滑油。Regularly supplement
lubricant and regularly check and clean the lubricant points and replace with new lubricant.
(6)配料库的各料仓内物料积存时间应不宜过长，长期停车前应尽可能卸空物料。The
material accumulated in each bin of the batch silo shall be not stored for a long period of time,
discharge all material as far as possible before long- term shut down.
5.2 原料粉磨及废气处理 Raw material grinding and exhaust treatment
(1)磨机的日常维护与保养的详细内容请参见设备制造商提供的有关说明书。Refer the
corresponding instructions provided by the equipment manufacturer for detailed mill routine
maintenance.
(2)每日观察检查风机振动、噪声、电机电流是否异常等情况。停车一日以上，需清除风
机内部积灰。Observe the fan vibration, noise and motor current every day. Clear the internal
accumulated ash for the fan, if shut down more than one day.
(3) 每日观察各润滑点的润滑情况，定时、定期添加或清洗更换润滑油。Observe the
lubrication conditions for each point, regularly supplement or clear or replace with new lubricant.
(4)磨内喷水系统的工作情况，停车检修时一定要清洗喷嘴、清除其水管和设备冷却供水
管路中的污垢。Observe the water spraying conditions in the mill, before shut down and
maintenance, must clean the nozzle, clear the dirts on the water pipeline or cooling water pipeline.
(5)每日清扫一次各管道上调节风门执行机构的积灰，观察其动作是否灵活、可靠。Clear
the accumulated ash on the actuating element of the adjusting damper on the pipeline once a day
and observe whether they move flexibly and reliably.
(6)清除窑尾收尘器灰斗内的积灰和粘结物料，检查叶片、链条、刮板等磨损情况，并及
69
时更换。Clear the accumulated ash and sticky material in the ash hopper of the kiln inlet dust
collector and check the abrasion of the blade, chain and scrapper and replace in time.
(7)定期对管道膨胀节、保温等使用情况进行检查。 Regularly check the expansion joints of
the pipeline, as well as the insulation material.
5.3 生料与回灰输送 Raw material and ash-return transportation
(1)拉链机、回转锁风阀等传动装置、清除机壳内壁粘结的物料，并根据检查情况决定是
否更换磨损的叶片。Check the drive device of chain conveyor, rotary air lock valve, clear the
sticky material on the inner wall of shell and replace the abrasive blade based on inspection
conditions.
(2)停机维修均应放空空气输送斜槽、生料均化库顶分配系统内的生料，清扫干净，仔细
检查充气层的情况和密封是否良好，若充气层粘堵、破损必须马上更换。Discharge and clean all
raw material on air slide and the distribution system on top of homo silo. Carefully check the
conditions and sealing of the inflation layer, if it becomes sticky and get stuck or damaged, replace
immediately.
(3)库顶分配系统的生料是否均分配，布料输送是否顺畅。Check whether the material
distribution system at top of the homo silo distributes evenly and whether the distributed material is
transported smoothly.
(4)收尘器各部件工作情况。如发现已有损坏或预计继续使用可能在较短一段时间内就会破
损，必须及时检修更换。Check the working conditions of each component of the dust collector. If
found damage, or may damage in an estimated short period of time, must maintain and replace it in
time.
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5000 TPD CMIC CEMENT PLANT PROJECT

331-RAW MILL FEED

CITIC HIC Engineering&Technology Co.,Ltd

本调试操作说明书仅供 5000 TPD CMIC CEMENT PLANT PROJECT IN CAMBODIA

一、工艺流程简介 Instruction for process

—、设备的启动操作顺序 The starting operation sequence of the equipment

(361-BF2)→Gradually start the valve each belt conveyor.

1.2 风机(361-FN1)启动→袋收尘器 4) Confirm the rotary unloader is free of failure.

磨物料量。 in the mill.

1. Adjust the feeding speed of the feeding belt

control the material quantity into the mill 源。

5. Adjust the rotate speed of the separator

轴承温度过高 displayed on the enough or not.

The temperature of the instrument is too high.

fixed bearing and live

The stopping sequence of the equipment of 可以被烘干

序号 设备名称 故 障 产生原因 处理方法

一、试生产的日程安排及其目的 Pilot Production Schedule and Aim

二、试生产的准备 Pilot Production Preparation

三、试生产系统的开停顺序说明 Start up and shut down instructions for pilot production

3.1 单机试车确认事项 Confirm matters for single-unit test run

四、生产中的注意事项 Matters need attention in production

4.1 注意系统的联锁关系 Pay attention to system interlock relationship

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序号设备名称故障产生原因处理方法