Hot-blast stove User Manual

User Manual

NCII CEMENT FACTORY，LUANDA,ANGOLA

Submitted by

SINOMA INTERNATIONAL ENGINEERING CO.,LTD.

December 2015

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 Contents

1. General...................................................................................................- 2 -

2. Operating principles..............................................................................- 2 -

3. Specifications and technical parameters............................................- 2 -

4. Installation, commissioning and operation regulations....................- 2 -

5. Maintenance, service and elimination of common faults..................- 5 -

6. Safety precautions................................................................................- 8 -

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1. General

YR-series hot-blast oil stove is a kind of high-efficiency energy-saving oil heating

equipment developed by the Company based on many-year experience. Its heating
capacity is 1×4.18×106kJ/h~30×4.18×106kJ/h. The hot-blast stove is basically composed of
fuel supply device, air supply device, burner, combustion chamber, mixing chamber and
thermal control system.
The product is featured by simple structure, small volume, safe operation, easy
maintenance, long service life, wide heating range and free setting of temperature. It is
widely used to provide heat for drying and roasting equipment in the cement, chemical,
metallurgy and other industries.

2. Operating principles

Operating principle of hot-blast stove: the fuel is transferred by the supply device to the
burner, mixed with the air sent by the air supply device, and fully burnt in the combustion
chamber; the high-temperature gas produced is mixed with the cool air in the mixing
chamber to produce the hot flue gas in conformity with the technological requirements.

3. Specifications and technical parameters

(I) Product model

YR-nD (Z, G) n=1~30, n=1 indicating the 1×4.18×106kJ/h heating capacity
G: high temperature type, heating temperature: 600~1200℃
Z: medium temperature type, heating temperature: 300~600℃
D: low temperature type, heating temperature: 100~300℃
Hot-blast stove

4. Installation, commissioning and operation regulations

(I) Installation
Installation of stove:
The stove shall be installed on the firm foundation, and the asbestos cord seal shall be
added between connecting flanges. See the installation drawing of hot-blast stove for
details.
Installation of burner:
1. The flame nozzle of burner shall be inserted into the hearth flame port, and the insertion
depth shall depend on the thickness of stove wall, and not exceed 150mm. The inner
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diameter of flame port on the stove wall shall be 15mm wider than the outer barrel in the
front of burner. The flame port shall have a 45°~50° taper angle. In this way, coking on the
conical surface of flame port can be avoided when the heavy oil is burnt.
2. After the insertion depth and inclination angle are determined properly, the movable
flange outside the burner shall be welded onto the outer barrel. In case of positive
pressure inside the hearth, the asbestos board shall be added between the flange and the
stove wall panel to prevent the flame inside the hearth from outward ejection. In this way,
the burn-through of enclosure can be avoided, and the energy can be saved. If the positive
pressure inside the stove is above 10 mm wc, the user shall install the induced draft fan at
the tail end of to exhaust the tail gas or increase the height of chimney.
3. For the burner, use 3~6 pressing plate clamp screws or the pressing plate to fasten the
flange welded onto the outer barrel in the front of burner securely onto the stove wall panel
or the support bracket.
4. Open the wire cover on the fan motor, connect the input power source and check if the
motor direction is correct.
5. To install the oil transfer pump, it is necessary to check if the motor direction is the same
as the direction shown on the nameplate. The oil pipeline shall be filled with filter and
provided with the oil return device. The oil pipe coupling and pressure gauge shall be
arranged in front of burner, and the adjustable needle valve shall be installed outside the
gauge. Those devices shall be connected with flexible hoses.
6. For the user using the heavy oil, the input oil line shall be provided with the steam heat
insulation and sweeping devices. Before ignition, the steam sweeping and preheating oil
line and oil nozzle shall be prepared. The temperature of heavy oil before the stove shall
not be lower than 120℃~130℃. Otherwise the oil cannot be pulverized well and it is easy
to form coking inside the flame barrel.
(II) Operation
1. Inspection before initial firing up:
Check the installation of burner and accessories, and check if the oil line, electric circuit
and air channel are safe and smooth.
Switch on the power source, and check if the operating directions of fan and oil pump are
correct by hand. In case of reverse rotation, switch off the power source and exchange the
wiring of any phase of oil pump or fan that rotates reversely to change the rotation
direction. Check if the solenoid valves and regulating valves of oil line and air channel
operate, then screw off the oil transfer hose from the oil nozzle, and open the oil valve to
discharge the oil to a barrel for 15 minutes in order to remove the sundries in the oil line. If
no abnormality is found, the manual firing up and commissioning can be performed. If the
manual firing up and commissioning are normal, the stove can operate automatically or
under the control of console.
Preparation before firing up every time:
① Remove the deposits and sundries inside the hearth, and turn on the fan to blow the
hearth for 3-5 minutes.
② In case of heavy oil, first open the steam valve heating the heavy oil for about 3
minutes, and close this valve after the accumulated water is completely discharged and
the steam is emitted; then open the steam sweeping valve and the hand wheel valve on
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the oil nozzle so that the steam is injected into the burner and hearth by the oil nozzle
through the uninsulated oil line to heat the oil line and oil nozzle; about 10 min later, close
the steam valve when the oil nozzle surface becomes hot.
2. Commissioning
Open the gantry gate of flue, close the fan damper, and start the fan. At this moment, there
is negative pressure inside the hearth. Open the damper to blow the hearth and then close
the damper. Adjust the regulating valve on the oil return pipeline, start the oil pump, and
increase the oil pressure to 1.0MPa. If the black smoke is emitted after firing up, the oil
pressure may be higher. In such case, increase the oil return valve by hand and observe
the flame till no black smoke is produced. If the stove temperature or material temperature
is not enough, the oil supply pressure may be too low. In such case, close the oil return
regulating valve slowly to increase the oil pressure, enhance the flame, and also adjust the
damper by hand till the combustion becomes stable and the required temperature is
reached. If it is impossible to reach the required temperature, check the reason or check if
the model is excessively low; in case of low model, the burner of higher model shall be
used.
3. Normal and safe operation regulations
① Check if the motor and electrical equipment are normal and the oil line and air channel
are smooth, and remove the oil deposit or coking on the nozzle.
② Before firing up, open the pipeline regulating valve. The air valve shall be closed tightly
before starting the blower. After the equipment operate normally, open the air valve to blow
the hearth for 3-5 minutes, and then close the air regulating valve.
③At the moment of firing up, there shall be negative pressure inside the stove, and the
pressure shall be kept at -100~-150Pa. If the negative pressure affects the firing up
greatly, adjust the pipeline valve and ensure the slight negative pressure inside the hearth.
④ Normally, the temperature shall be kept below 800 ℃. The flue gas temperature shall be
adjusted slightly through the pipeline regulating valve and the fireproof plate of hearth in
order to meet the technological requirements (normally kept at 100~300 ℃, and may vary
with the object).
⑤ Adjust the oil pressure according to the requirement of tail gas temperature, and adjust
the air valve according to the combustion flame. Under the oil pressure, adjust the air
regulating valve to ensure the sufficient combustion of oil; the flame shall not be very long.
To increase the temperature, it is necessary to increase the oil pressure and the opening
of damper; to decrease the pressure, it is necessary to decrease the opening of damper.
⑥ In case of cold stove, the temperature shall not rise fast, and it is necessary to use the
small flame to warm it up for 10 minutes before using the big flame.
⑦ To stop the stove, it is necessary to close the oil inlet solenoid valve of burner first and
then turn off the oil pump, and 3min later, stop the air supply and close the pipeline
regulating valve.
⑧ In case of automatic operation, the system, after being started, will operate
automatically according to the program, and adjust the regulating valve automatically to
achieve the balanced heating according to the change of tail gas temperature.
3. Precautions:

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①In case of firing failure, it is required to close the oil valve and increase the air flow to
blow the stove immediately, and 3min later, fire up the stove again according to the
program in order to avoid explosion because of excessive accumulation and vaporization
of oil mist in the hearth.
② To fire up the stove, the operator shall stand beside the firing hole and take care to
avoid the accident caused by tempering.
③ If the flame is easy to blow off and the combination is unstable, it is necessary to reduce
the opening of air valve to keep the flame in the burner, and then increase the opening of
air valve properly.
④ If the combination flame is too short or the flame deforms obviously, the oil gun may be
blocked, resulting in poor atomization of oil. In such case, it is necessary to dismantle the
nozzle in the front of oil gun, clean the atomizing plate and rotational flow sleeve, and then
reassembly them in sequence (notice to screw down those parts).
⑤ The operating pressure of oil pump is at 0.5~1.5MPa, and can be adjusted according to
the stove temperature. However, it is forbidden to deform the stove body because the
hearth is burned red.

5. Maintenance, service and elimination of common faults

(I) Maintenance and service

① The strainer shall be dismantled can cleaned timely to remove the sundries and repair
the damaged part.
② The flame barrel shall be cleaned periodically to keep the barrel surface clean the air
channel unblocked. Especially when the oil quality is bad, the oil temperature is low and
the air is not clean, the flame barrel shall be cleaned more frequently.
③ The oil gun shall be dismantled and cleaned regularly to keep the channel unblocked
and in accordance with the procedure and provision to avoid damage.
④ The accuracy of oil temperature, oil pressure and air pressure gauges shall be checked
regularly.
⑤ The tightness of various valves shall be checked regularly.
⑥ No sundries are allowed on the conical surface of flame port brick which shall be
cleaned timely to avoid tempering and damage to burner.
⑦ The tightness of air channel and oil line shall be checked regularly.
⑧ During operation, ensure that the steam can flow in the heat insulating sleeve of heavy
oil line.
⑨ The atomizing plate of oil nozzle, if worn, shall be replaced timely for fear of affecting
the atomizing effect.
⑩ The flame barrel, if damaged, shall be repaired timely because the damage of flame
barrel will change the air flow area and affect the combustion effect.
(II) Elimination of common faults (see the following table)

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Fault Cause Solution

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 1. Atomization fails. Increase the oil temperature to the stipulated value.

Check if the gap between firing poles is too large, or

2. The electric firing gun
remove the dirt on the pole and replace the firing
fails to ignite.
transformer.

Check if the oil solenoid valve is opened or replace the

Firing
3. No fuel. oil solenoid valve and check if the oil gun is clocked and
failure
clean the oil gun.

4. The damper is opened

Close the damper.
too much.

Check if the firing solenoid valve and oil pump deliver the
5. No firing source.
oil.

1. The oil pressure is too

Increase the oil pressure.
low.

2. The oil injection quantity

Adjust the oil pressure or replace the atomizing plate.
is too high to too low.
Smoking
during
3. The oil temperature is too
normal Increase the oil temperature.
low.
combustio
n
4. The opening of damper is
Adjust the air inlet damper.
too large or small.

5. The flame barrel is Remove the coking in the barrel, or replace the flame
damaged or cocked. barrel assembly.

1. The oil supply pump is

Replace the oil pump.
damaged.

2. The oil gun is blocked. Clean the oil gun.

Flameout
during 3. The oil supply solenoid
Check if the solenoid valve or light sensor is damaged.
normal valve is not opened.
combustio
n 4. The oil supply pipe is
Clean the pipeline or filter.
blocked.

5. The damper is opened

Reduce the opening of damper.
too much.

Serious 1. The air pressure is too 1. Increase the air pressure.

coking low.
2. Clean the air intake channel of flame barrel.
inside the

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 In accordance with the atomizing improvement
2. The oil mist is too coarse.
measures.

flame
Make and install a 1~3-high upward intake barrel at the
barrel 3. There is dust in the air.
air inlet on the combustion side.

4. The oil quality is bad. Replace the steam atomizing gun (g type).

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 1. The oil supply pressure is Adjust the oil supply pressure to make it
unstable. stable.

2. The oil gun is blocked. Clean the oil gun.

The temperature of
hearth or material is 3. The hole diameter of
too high or too low. atomizing plate is too large or too Replace the atomizing plate.
small.

4. The type of burner is not

Replace the burner.
suitable.

1. The oil supply solenoid valve Repair or replace the oil supply solenoid
or gate valve leaks. valve or gate valve.

2. The atomizing angle is too

Replace the atomizing plate.
small.
The flame port of
burner drops oil.
3. The atomizing plate is worn. Replace the atomizing plate.

4. No flame is produced after

Open the damper to remove the residual
several firing operations, and
oil in the flame barrel.
there is residual oil in the barrel.

According to the installation requirements,

1. The flame port is too small. the minimum diameter of flame port shall
be 10~15mm larger than the flame barrel.

2. The taper angle of flame port Refer to the dimension table of flame port,
Coking or
is too small. and make its taper angle more than 40℃.
tempering at the
flame port
3. The flame barrel and the flame Align the flame barrel and the flame port to
port are not concentric. make them concentric.

4. There are barriers in the flame

Remove the barriers.
port.

6. Safety precautions

1. At moment of firing, the workers shall not stand in front of the stove for fear of personal
injury due to explosion.
2. If the flame goes out or the firing fails, it is necessary to stop firing immediately, and
close the oil supply valve and air valve and eliminate the residual oil gas in the stove
before re-firing. In case of heavy oil, it is also needed to connect the steam to sweep the

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oil supply pipeline to eliminate the residual oil gas before re-firing.

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