KSF3300 石灰石分解炉系统

KSF3300 Limestone Calciner System

安装、使用说明书
Erection & Application Specification

KLP3300-SM
审定 Approved by：

审核 Reviewed by：

编制 Drafted by：

成都卡森科技有限公司
Chengdu Calciner Technology Co., Ltd

地址：成都市人民南路四段27号商鼎国际16楼

ADDRESS：No.27 Section Four，South Renmin Road，

Sun Dynasty 16 F，Chengdu，P. R. China

安装、使用、维修前必须仔细阅读此说明书
Thoroughly familiar with this specification before carry out associated mounting,
application and maintenance

目 录
Catalog
第一章：安全要求------------------------------------------------------------------------2

Chapter 1: Safety Instruction ------------------------------------------------------------2

第二章：技术参数-----------------------------------------------------------------------2

Chapter 2：Technical Data--------------------------------------------------------------2

第三章：工作/操作流程 ---------------------------------------------------------------5

Chapter 3：Working/Operation flow --------------------------------------------------5

第四章：安装说明-----------------------------------------------------------------------6

Chapter 4: Erection Specification------------------------------------------------------ 6

第五章：试运行--------------------------------------------------------------------------11

Chapter 5: Commissioning --------------------------------------------------------------11

第六章：维护/保养----------------------------------------------------------------------12

Chapter6: Maintenance-------------------------------------------------------------------12

第七章：故障及排除--------------------------------------------------------------------12

Chapter 7: Failure and Trouble Shooting----------------------------------------------12

第八章：备品备件----------------------------------------------------------------------12

Chapter 8: Spare Parts-------------------------------------------------------------------12

第九章：报废----------------------------------------------------------------------------13

Chapter9: Rejection ---------------------------------------------------------------------13

第一章安全要求
Chapter 1: Safety Instruction

安全注意事项 Safety instruction and notes：

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 1．工作人员必须穿高温防护服、佩戴安全帽。
The personnel must wear heat-resistant protective-clothing and safety cap.
2．工作人员必须注意安全，小心碰伤、烫伤或跌落等。
The personnel must be alert, and avoid bruise, burn or falloff.
3．设备生产过程中，严禁打开检查门、人孔门等设备。
Access doors and manholes etc. are forbidden to open during the production.

第二章 技术参数
Chapter 2 Technical Data
一. 主要参数：
Key Technical Data
1. 预热器 preheater：
1.1.C1：
内径 inside diameter：Φ5400mm
数量 Qty.：2 nos. 个
1.2.C2：
内径 inside diameter：Φ7400mm
数量 Qty.：1 nos. 个
1.3.C3：
内径 inside diameter：Φ7400mm
数量 Qty.：1 nos. 个
1.4.C4：
内径 inside diameter：Φ7900mm
数量 Qty.：1 nos. 个
1.5.C5：
内径 inside diameter：Φ7900mm
数量 Qty.：1 nos. 个
2. 气体管道 Air pipe line：
2.1.C2~C1 air duct 风管：
内径 inside diameter：Φ3770mm
数量 Qty.：1 nos. 个

2.2.C3~C2 air duct 风管：

内径 inside diameter：Φ4300mm
数量 Qty.：1 nos. 个
2.3.C4~C3 air duct 风管：

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 内径 inside diameter：Φ4410mm
数量 Qty.：1 nos. 个
2.4.C5~C4 air duct 风管 ：
内径 inside diameter：Φ4700mm
数量 Qty.：1 nos. 个
2.5.分解炉~C5 风管 calciner~C5 air duct：
内径 inside diameter：Φ4900mm
数量 Qty.：1 nos. 个
3. 物料下料管 Feeding downpipe：
3.1.C1Feeding downpipe 下料管：
内径 inside diameter：Φ800mm
数量 Qty.：2 nos. 个
3.2.C2Feeding downpipe 下料管：
内径 inside diameter：Φ1000mm
数量 Qty.：1 nos. 个
3.3.C3Feeding downpipe 下料管：
内径 inside diameter：Φ1000mm
数量 Qty.：1 nos. 个
3.4.C4Feeding downpipe 下料管：
内径 inside diameter：Φ1000mm
数量 Qty.：1 nos. 个
3.5.C5Feeding downpipe 下料管：
内径 inside diameter：Φ1000mm
数量 Qty.：1 nos. 个
4. 分解炉 Calciner：
规格 size：内径 inside diameter Φ6400mm
数量 Qty.：1 nos. 个
5. 下料锥体 feeding cone：
数量 Qty.：1 nos. 个
6. 翻板阀 flap damper：
6.1 Φ800 single flap damper 单板阀 数量 Qty.：4 nos. 个
6.2 Φ1000single flap damper 单板阀 数量 Qty.：3 nos. 个
6.3 Φ1000 double flap damper 双翻板阀： 数量 Qty.：1 nos. 个
7. 撒料盒 distribution box：
7.1 Φ800 distribution box 撒料盒（直 straight 60°） 数量 Qty.：2 nos. 个

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 7.2 Φ1000distribution box 撒料盒（直 straight 60°）数量 Qty.：5 nos. 个
8. 膨胀节 expansion joint：
8.1. Φ4900expansion joint 膨胀节：
长度 length：400mm
数量 Qty.：1 nos. 个
8.2. Φ2350expansion joint 膨胀节：
长度 length：400mm
数量 Qty.：1 nos. 个
8.3. Φ1000expansion joint 膨胀节：
长度 length：400mm
数量 Qty.：5 nos. 个
8.4. Φ800expansion joint 膨胀节：
长度 length：400mm
数量 Qty.：2 nos. 个
9. 分解炉喷煤装置 pulverized coal burner of calciner：
数量 Qty.：2 nos. 个。
二. 技术说明 technical specification：
（一）标记示例： Example of earmark

K SF 3300

产量 3300T/D Capacity
型号 Type
公司名称代号 Company Designation Code

（二）KSF3300 石灰石分解炉系统：
KSF3300 limestone calciner system
1. 炉型：KSF 型分解炉。
Type：KSF calciner。
2. 所配窑型：Φ4.6×62 米。
Fitted kiln type：Φ4.6×62m

3. 技术参数 Technical data

3.1 喂入生料粒度：80μ 筛筛余 12%
Fed raw meal granularity：0.08 mm residue12%
水分 moisture：＜1%

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 用量 consumption：220t/h
3.2 燃料：煤 fuel: coal
3.3 生料/熟料比 raw meal: clinker：1.6
3.4 热耗 thermal loss：
总热耗 total thermal loss： 750 Kcal/kg.Cl
煤的低位热值 lower calorific value of coal： 22900 KJ/kg
煤的挥发份 fugitive constituent of coal: ≥20%
分解炉用燃料百分率 rate of fuel consumed by calciner： 60 %
3.5 C1 outlet 出口：
风量 air volume： 525000 m3 /h
温度 temperature： 330 ℃
压力 pressure： -500 mmH2O
含尘量 dust concentration： 100 g/Nm3
3.6 进分解炉三次风 tertiary air into calciner：
风量 air volume： ~300000 m3/h
温度 temperature： ~850 ℃

第三章 工作/操作流程
Chapter 3 Working/Operation Flow
一、设备的用途：Equipment usage
在预分解窑系统中，石灰石分解炉系统是关键设备之一。回转窑废气进入
窑尾石灰石分解炉系统将原料预热，原料在分解炉中快速分解，最大限度地
减少了回转窑内的生料分解度，大大地提高了回转窑的单机生产能力。
The limestone pre-calcining system is one of the key equipment on the
precalciner kiln system. Waste gas from rotary kiln enters the pre-heater and pre-
calciner systems to pre-heat the raw material, which can be quickly dissolved in
the calciner, and in this way can uttermostly have the resolution of raw meal
lessened in the rotary kiln and remarkably productivity of rotary kiln alone
enhanced.
生料从 C2～C1 旋风筒风管加入，与热气流混合后，随上升气流进入 C1
旋风筒，物料在 C1 旋风筒内预热分离后，经 C1 旋风筒下料管进入 C3～C2
旋风筒风管，然后随上升气流进入 C2 旋风筒，在 C2 旋风筒中再次被预热后，
经 C2 旋风筒下料管进入 C4～C3 旋风筒风管，然后再随气流进入 C3 旋风筒，
物料在 C3 旋风筒中再次被预热后，经 C3 旋风筒下料管进入 C5～C4 旋风筒
风管，然后再次随气流进入 C4 旋风筒，物料在 C4 旋风筒中再次被预热、分
解后经 C4 下料管进入分解炉和上升烟道内，进入上升烟道内的那部分物料，
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被上升烟道内的气流带入分解炉涡壳，与三次风混合后，再与直接进入分解
炉内的那部分物料混合，两部分原料在分解炉内快速预热和分解后，经 C5～
分解炉风管进入 C5 旋风筒，由 C5 旋风筒分离后，经下料锥体进入回转窑中。

To be fed into the air duct of cyclone C2~C1, raw meal, after mixed with hot
currents, enters cyclone C1 with the upward air. After pre-heatedly separated in C1
and via feeding pipe of C1, material enters the air duct of C3~C2, and in upward
air into cyclone C2, where it is going to be pre-heated again. After that it enters the
air duct of cyclone C3~C4, through the feeding pipe of C2, then into C3, where it
is to be preheated again. And via feeding pipe of C3, the material enters air duct of
C5~C4, from where with air current go into cyclone C4 and heated and calcined
there. And then part of the material enters the calciner and uptake flue and into the
scroll of calciner, after mixed with tertiary air, then blended with material that
directly entered the calciner before then. All the raw material then are to be pre-
heated and calcined quickly there, and after that the material enter the air duct of
cyclone C5 via air duct of C5-calciner. After separated by C5, it via discharging
cone inters the rotary kiln.
本设备用于 3300t/d 水泥生产线。
This equipment works for 3300t/d cement production line.

第四章 安装说明
Chapter 4: Erection Specification
安装前施工人员应熟悉图纸及有关技术文件：了解设备结构及安装技术
要求，根据具体条件确定安装顺序及方法准备必要的安装工具与设备，编制
施工组织设计和安装计划，进行精心施工，优质快速地完成安装任务。
Before the erection, builders shall be familiar with the drawings and relevant
technique documents： Should comprehend equipment structures and installation
technique, make certain installation sequences and methods, as well as necessary
installation tools and equipments according to specific conditions, workout
construction organization and installation plan for accurate and careful
construction with high quality and speediness.

1. 安装前注意事项: Erection Precautions

安装前，所有的零、部件应存放在能避免受恶劣气候影响的地方。
因为，尽管这些设备在发运前已充分包装，但包装材料的使用期限
有限，在恶劣气候条件下，如延长存放期，势必影响包装箱内的设
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 备的性能，所以在安装前做好设备零、部件的管理工作，要求将设备
的零部件存放在干燥的室温环境中。安装过程中必需的吊车、焊机等
必须根据设备的具体情况来选用。工作人员必须穿防护服、戴安全帽
或专用防护罩等。
Before installation, all parts shall be kept from bad weather, the
reason is that, packing materials are limited in service life and under such
a bad condition, equipment performances would possibly be affected in
packing box by delayed storage, even if these equipments are packed
sufficiently before delivery. Therefore, keeping equipment parts under
good management and proper conditions are necessary. The equipment
parts nee d keeping in indoor dry place. The necessary crane and welding
machine for the mounting should be chosen to fit the actual situation. And
the personnel must wear protective clothing, safety cap or special shield
etc.

2. 零件的标识 Identification of Parts：

需要在现场组装焊接的预热器是分件包装发运的，所有相连接的零、
部件应在连接处便于识别的地方打上对接标记符号或者注明其零、部件图
号，以便现场识别及焊接。如果条件允许的话，可将预热器的零、部件根
据它们在预热器上的相应位置或按预先规定的安装顺序进行分类。

The preheater to be assembled and welded in field was transported in

disassembly, all joint parts and components should be identified with marks at
the interfaces or marked with part and component drawing No., so as to
identify and weld up in field. If conditions allow, might classify parts and
components of preheater according to their positions in preheater or the trial
assembly order.

3. 预热器的定位 Positioning of Preheater

安装预热器前应完成其基础施工，预热器各部件的安装位置是以回
转窑的冷态工作点为基准来定位的，这一点十分重要。安装时必须确定正
确的标高，以避免过多使用垫铁而造成各部件与支架发生干涉。

Should finish the foundation construction before erects the preheater, and
preheater parts and components assembly positions are positioned in datum
on the cold state work point of rotary kiln, this should be paid good attention.
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 Should confirm the accurate elevation, lest overusing wedge plates to cause
interferes between parts and supporting.

4. 安装顺序 Assembly Order：

预热器的安装顺序为：从下往上、先大后小、逐层安装，即先将
下料锥体就位后，再将分解炉或预热器安装就位，然后在进行两级
预热器间或分解炉和预热器间风管的安装；最后再进行各级预热器
下料管的安装。
Preheater assembly order: From underpart to upperpart, larger part
before smaller part, follows in layer, namely, setting the feeding cone in
position first, and setting the calciner and preheater in their positions, then
setting air ducts between two preheater stages or the calciner and
preheater; last, setting the feeding pipes of preheater stages.

5. 设备交货状态 Equipment Delivery

由于设备为薄壁大壳体结构,考虑到运输和吊装能力的限制,设备根据实
际情况进行分段制造并交付。具体分段方案应根据运输和吊装能力的具
体情况，由制造厂、安装公司和业主共同商定。设备最重件外形尺寸为：
10.5m×5.5m×4.5m，重约 15 吨，所有零部件起吊点均已焊接在包装或设
备零部件上。
The equipment has to be delivered in sectionals due to its huge and thin
housing structure and the limited transportation and hoisting capacity. The
final dividing proposal of equipment should be something agreed by the
manufacturer, installer and the owner according to the capability in
transportation and hoisting. The outline dimensions of the heaviest par of the
equipment are 10.5m×5.5m×4.5m, grossly 15t. The hoisting points for all part
are already welded on the package or on the parts of equipment.

6． 安装前预组装 Trial Assembly Before the Erection:

预热器各零部件在安装前都应进行一次预组装，以便验证能否装
配在一起；在组装过程中，相连接的零部件应作相应标记，以便现
场识别。
Should perform the trial assembly before erecting the preheater with
all parts, in order to proof if all parts and components in meshing; For
identification in field, all joint parts and components should be marked
during the trial assembly.

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7． 安装注意事项 Erection Precautions：
7.1 在进行预热器安装时，建议安装公司根据自己起重设备的能力和
预热器的安装情况，在地面上建一个小型钢制或混凝土制成的水
平平台，以用作安装预热器零部件的组装平台。
Suggestions: During the preheater erection, the erection company
according to the capacity of own hoisting apparatus and installation
conditions, should establish a miniature steel or concrete installation
platform for the prehearter erection and parts assembly.
7.2 预热器安装时必须同时安装支承架，不然会引起预热器零部件的
变形，从而引起预热器零部件尺寸的改变。
Should install supporting frame, meanwhile, erecting the preheater,
otherwise might cause deformations of preheater parts.
7.3 预热器各主要部件在安装时的位置和方向必须准确无误，以便各级
预热器间的风管、风管和各级预热器下料管的连接。安装时应注意各桶
料孔及人孔门位置，如果发现有不便于操作及使用之处，应及时向设
计单位提出以便妥善处理。
The position and direction of each main part of the preheater should be in
inerrability during the installation, so that to joint air ducts between
preheater stages, air ducts and feeding pipes of preheater stages. Should
notice positions of the poking hole and manhole, as soon as found the
discommodity for the operation, should present to the designer for
appropriate settlement.
7.4 各级预热器、分解炉、各级预热器间风管、分解炉至预热器间风管
等安装就位后，不允许将其底座与楼面焊接在一起。
The installed air ducts between preheater stages and calciners, preheater
stages, calciner and prehearter etc., should not weld up their seats with the
floor.
7.5 分解炉上安装喷煤装置的位置有两个，正常使用时两个位置都要
使用。
There are two positions on the calciner for setting the pulverized coal
burner, generally, the two positions should be token in operation.
7.6 预热器系统不论采用螺栓连接或是采用焊接连接，在其连接处均
必须保证其气密性。
No matter the preheater system adopts the joint of bolt or weld, should
warrant their tightness.

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 7.7 各级预热器下料管安装时，先将下料管、翻板阀、膨胀节和闸板阀
用法兰连接起来，并将其点焊就位或用螺栓定位，检查无误后，拆下
下料管、翻板阀、膨胀节，待浇注料施工好后，再按图纸进行法兰连接
和焊接。
Should joint feeding pipes, flap dampers, expansion joints and gate valves
with flange first when installing feeding pipes at each preheater stage,
then spot welding up or bolting in position, after checked the inerrability,
then disassembly feeding pipes, flap dampers and expansion joints, and
applying the castable, after all, jointing them again with flanges and weld
according to drawings.
7.8 翻板阀安装，阀板要求能够灵活地转动。
The flap damper installation requires the flap could flap in ease.
7.9 膨胀节安装时，不能拆除定位螺栓，更不允许用调节膨胀节长度
的方法来调整下料管的安装尺寸。在预热器系统安装完毕后（点火烘
窑前），拆除所有膨胀节运转定位螺栓，使之能够进行工作状况下的
热膨胀补偿位移。
The expansion joint installation does not allow disassembly positioning
bolts, neither controlling installing dimensions of the feeding pipe by
adjusting the length of the expansion joint. After the preheater installation
was completed (before warming up the kiln), removing all operation
positioning bolts of expansion joints, enables it to make up displacement
in operation.
7.10 所有测温、测压、吹堵管、捅料管等的内伸部分必须在耐火材料施
工前安装。
All inward protruding parts of temperature measurement, manometric
measurement, blockage blowing and lance pipes etc. should finish the
installment before refractory construction work.

8 . 涂漆防锈要求 Anti-rust Painting Requirements

石灰石分解炉系统外表面应涂上两遍耐热防锈漆，耐热钢件不应涂漆。
Surface of preheater should be paint with heat and corrosion resistant
paint twice, and complying with related stipulations in JC/T402;
refractory steel parts should not be painted.
第五章 试运行
Chapter 5: Commissioning

1. 运转前的检查 Inspection Before Commissioning：

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 所有安装工作完成后，在预热器投入使用前应进行下列各项检查：
After all installation work completed, should carry out the followed
inspection items before the preheater commissioning:
1.1. 是否拆除预热器安装过程中以及耐火材料砌筑过程中，所使用的
安装工具、模具和各种垫板。Confirming that implements, dies and pad
plates etc. have be removed, which were used during preheater
installation work and refractory masonry.
1.2. 应确保预热器系统内部和周围无异物，尤其是应避免可燃物 。
Should ensure preheater inner system and surrounding without extraneous
substances, especially avoiding the combustible material.
1.3. 检查翻板阀等所有设备是否能正常动作或运行。Inspecting the flap
damper etc. all equipment acting and operating in good condition.
1.4. 翻板阀安装好后，当阀体处于关闭状态时，配重臂应处于平衡位
置，并确保翻板阀轴上的紧定螺栓锁紧。预热器系统投料后，必须重
新对重锤进行调整并定位，以达到预期的锁风效果。
After the flap damper installation work was completed, the counterweight
boom should being in equilibrium position when the damper is closed,
and ensures the fastening bolt on the flap vale shaft be locked. After the
preheater was fed with material, should readjust and position the heavy
hammer, so as to attain the expecting air locking effect.
1.5. 待耐火材料干燥后，关闭所有检查门、人孔门和捅料孔，并检查
其密闭性。(耐火材料的砌筑施工及烘考参见图纸及相关技术文件)
After refractory work dried up, closes up all inspection doors, manhole
doors and poking holes, and checks their tightness. (Refractory masonry
and bake-out refers the drawings and related technical documents)
1.6. 检查需要用压缩空气的地方，是否已保证供给。
Should inspect the place that uses compressed air, to confirm its supply.
1.7. 检查所有的循环吹堵管道以及所有压力、温度等测点接口是否有
异物堵塞。
Checking all circulation blockage blow-off ducts and all butts of
manometric and temperature measurement points, to confirm that they are
without extraneous plugging.
1.8. 检查所有膨胀节的运输固定螺栓是否已经拆除或解除约束。所有膨
胀节应无阻碍物，能够进行位移补偿。
Inspecting that fixing bolts of expansion joints for transportation have been

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 removed or unbound. All expansion joints without hindrance and enable to
make up the displacement.
2．试运行 Commissioning：
所有零部件必须试运行约一个月，待一切正常运行后，方可投料生产。
All the parts must stand the commissioning for one month, before it can go
into real production with everything working well.

第六章 维护/保养
Chapter 6: Maintenance
设备运行过程中，必须定期（一个月/次）检查易损件及耐火材料的
磨损情况，磨损严重的部位必须及时修补或更换。
Must periodically (monthly) check the wear parts and refractory and in
time repair and replace the severely damaged parts with new.

第七章 故障及排除
Chapter 7: Failure & Trouble-shooting
因翻板阀、撒料盒等零部件的异常运行而引起设备堵料时必须用专用
工具捅料，排除故障。
When the equipment is blocked up due to abnormal operation of parts of
flap damper, distribution box etc. must use special tool to poke the
material, and shoot the trouble.

第八章 备品备件
Chapter 8: Spare Parts

以下备品备件供用户选型时参考。
The following is the reference for spare parts selection.

1．翻板阀阀板 flap damper plate

2．撒料盒撒料板 plate of distribution plate

3．各级旋风筒内筒 center tubes of each cyclone

注 ： 当 需 要 更 换 上 述 备 品 备 件 时 ， 请 联 系 我 们 ， 联 系 电 话 ： 028-
86026646。严禁购买其他厂家备品备件，否则后果自负。

Note: when there is a need for spares changing, please contact us at 028-
8626646. Any risks resulting from using spares made by other manufacturers
shall lie entirely with the user.
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 第九章 报废
Chapter 9: Rejection

设备的报废应按照当地的法律法规执行。
Equipment rejection should be carried out according to the local laws.

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