1、本文件以英文版为准，中文版仅供参考Project : Tangshan Iron i.e. 1 l of water has to be injected per 1 Nm3 of gas. In the case of misalignment between the cone and the venturi the L/G ratio will be lower than 1 at locations with higher gap width and higher than 1 at locations with lower gap width and the performance o
2、f the gas cleaning plant would get worseThe dust-laden water is collected in the annular gap zone sump and flows to the demister sump. From there it is recycled to the spray nozzles at the top of the scrubber via recirculation pumps. The clean gas that Water film GasAnular mist flow Outer coneMovabl
3、e iner coneMechanism of drplet formation iside th anular gp( deil I)gasgasgasgasgas1 2 3 4 5Nozledetail IWaterGasOperation Mode f th PW Anular Gp ScruberGs图 1: PW 环缝洗涤塔工作模式如果由于灰尘的堵塞而导致煤气流的中断，那么很明显环缝元件锥芯上的水雾不会很均匀地分布在周围。因此煤气的分布不均匀，从而环缝元件锥芯的磨损将不可避免。这将导致在环缝圆周方向上的液气比 L/G（水的质量流量与煤气的质量流量之比）的变化。最佳净化效率的液气比为
4、1，也就是说 1 标准立方米的煤气中要注入 1 升水。如果环缝元件锥芯与文丘里管没有准对中，那么在环缝宽度较大的地方液气比就会小于 1，而在环缝宽度较小的地方液气比就会大于 1，从而煤气净化系统的性能就会变差。带有灰尘的水收集在环缝洗涤段的排水锥内，然后流到脱水器下部集水池内。水通过循环泵从那里回到洗涤塔顶部的喷嘴。仍可能含有机械水的净化煤气从洗涤器流到脱水器。本文件以英文版为准，中文版仅供参考Project : Tangshan Iron & Steel Co. Operation & Maintenance Manual 项目 ： 唐钢 GCS 操作维护手册Project No : 280
5、1956 项目号 ： 2801956Prepared : ECN 作者 ： ECNE:wenkufile2018-122740dc4515-89fe-4f0e-b97c-d0d8b214d0704b70066cf7339e74c1700fa4bb4450dd.pdf Page: 7 of 56may still contain free water droplets leaves the scrubber in direction of the demister. 2.2 The DemisterThe gas enters the demister from top. The vertica
6、l demister ensures the optimized separation and droplets, which are separated at the demister shell, are not re-entering the gas stream. The gas passes through vanes that give the gas stream an angular momentum. Centrifugal forces move the water droplets contained in the gas stream to the wall. Here
7、 the water is collected at the end of the demister and flows down into the sump from where it is drained to the recirculation main. 2.3 Plant Process Data1 BF dataUseful volume: 2000 m3Normal top pressure: 2 bar, gMax design pressure: 2,2 bar, gMin top gas flow rate: 220000 Nm3/hNormal top gas flow
8、rate: 330000 Nm3/hMax. top gas flow rate: 350000 Nm3/hNormal top gas temperature: 250 CMax top gas temperature 400 CAverage particle density 1500 Kg/m3Top gas dust content 15 g/Nm3Moisture content of BF gas: 30 g/Nm32.2 脱水器煤气从顶部进入脱水器。立式脱水器有较优的分离效果，而且在脱水器筒体分离出的水滴也不会在进入煤气流。煤气通过能给予它角动量的叶片。离心力使煤气中的水滴甩向内
9、壁。水在脱水器的末端收集起来然后流向下集水池，流到循环水总管。2.3 系统工艺参数1 高炉参数有效体积: 2000 m3正常顶部压力: 2 bar, g最大设计炉顶压力: 2,2 bar, g最小煤气流量: 220000 Nm3/h正常煤气流速: 330000 Nm3/h最大煤气流速: 350000 Nm3/h正常炉顶煤气温度: 250 C最大炉顶煤气温度 400 C平均颗粒含量 1500 Kg/m3旋风除尘器入口煤气含尘量 15 g/Nm3高炉煤气含水量: 30 g/Nm3本文件以英文版为准，中文版仅供参考Project : Tangshan Iron & Steel Co. Operati
10、on & Maintenance Manual 项目 ： 唐钢 GCS 操作维护手册Project No : 2801956 项目号 ： 2801956Prepared : ECN 作者 ： ECNE:wenkufile2018-122740dc4515-89fe-4f0e-b97c-d0d8b214d0704b70066cf7339e74c1700fa4bb4450dd.pdf Page: 8 of 56- Gas analysisCO 22,5 vol %CO2 19 vol %H2 0,5 vol %N2 56 vol %Below figures are based on normal
11、 gas inlet temperature, pressure and flow rate2 Annular Gap ScrubberWater flow rates and water conditionsTotal clarified water requirement 500 m3/h Recirculation flow rate 330 m3/hInlet conditions water Clarified water inlet temperature 20 CSuspended solids 100 mg/lHardness (CaCO3) 1000 mg/lChloride
12、 content 400 mg/l- 煤气成分CO 22,5 vol %CO2 19 vol %H2 0,5 vol %N2 56 vol %以下数据基于正常的煤气温度、压力和流速2 环缝洗涤塔水流速及水的条件净化水总的需求量 500 m3/h 循环水流量 330 m3/h入口条件水质净化水入口温度 20 C固体悬浮物 100 mg/l硬度 (CaCO3) 1000 mg/l氯含量 400 mg/l本文件以英文版为准，中文版仅供参考Project : Tangshan Iron & Steel Co. Operation & Maintenance Manual 项目 ： 唐钢 GCS 操作维
13、护手册Project No : 2801956 项目号 ： 2801956Prepared : ECN 作者 ： ECNE:wenkufile2018-122740dc4515-89fe-4f0e-b97c-d0d8b214d0704b70066cf7339e74c1700fa4bb4450dd.pdf Page: 9 of 56Inlet/ Outlet conditions cycloneDust content at cyclone inlet 15 g/Nm3Dust content at cyclone outlet 2,25 g/Nm33 Vertical DemisterDust
14、 content at normal operation pressure 5 mg/Nm3Demister outlet pressure with TRT in operation 1,86 bar, gClean gas pressure 0,1 bar, gCleaning efficiency 85-90 %Clean gas temperature 40 C4 Gas Cleaning Plant General ConditionsNoise (TRT not in operation) of annular gap scrubber and vertical demister
15、1 m outside gas cleaning plant.- dB (A)BF top pressure control accuracy if TRT is not in operation and annular gap elements controlling the top pressure.- kPa3 Inspection, Pressurizing and AdjustmentFor the start-up of gas cleaning plant the following points have to be checked and recorded:旋风除尘器入口出口
16、条件入口含尘量 15 g/Nm3出口含尘量 2,25 g/Nm33 立式脱水器正常运行压力时含尘量 5 mg/Nm3TRT 运行时脱水器出口压力 1,86 bar, g净化后煤气压力 0,1 bar, g净化效率 85-90 %净化后煤气温度 40 C4 煤气净化系统总体条件环缝洗涤塔及煤气净化系统 1 米外的立式脱水器的噪音（TRT不运行时）- dB (A)当 TRT 不运行以及由环缝元件控制炉顶压力时，高炉炉顶压力的控制精确度。- kPa3 检查、加压和调整为了煤气净化系统的开车以下几点必须进行检查和记录：本文件以英文版为准，中文版仅供参考Project : Tangshan Iron &
17、 Steel Co. Operation & Maintenance Manual 项目 ： 唐钢 GCS 操作维护手册Project No : 2801956 项目号 ： 2801956Prepared : ECN 作者 ： ECNE:wenkufile2018-122740dc4515-89fe-4f0e-b97c-d0d8b214d0704b70066cf7339e74c1700fa4bb4450dd.pdf Page: 10 of 56 Foreign parts in the plant, for instance metal- wooden-, plastic material,
18、glass parts as well as screws, wires, bottles, cans, insulating material, tools, scaffold etc. have to be removed The pipe work must be flushed and the cleaned from foreign parts Mud agglomeration or dust deposits have to be removed All manholes, openings and inspection holes must be closed and gas
19、tight The greasing system must be ready for operation and the stuffing boxes of the rods must be checked for tightness The shut-off devices on the discharge side of the pump must be closed The hydraulic and electric actuated water valves must be checked and ready for operation All primary shut-off v
20、alves and other fittings to measurement and instrumentation must be opened All pumps must be ready for operation All measuring-, control- and regulation instruments must be checked and ready for operation All required utilities and consumables, like water, grease, lubricants, nitrogen, steam etc mus
21、t be available for filling in The inert gas connection must be ready for operation4 Safety Requirements 系统内的外来物：如金属材料、木制材料、塑料、玻璃器件以及螺钉、电线、瓶子、罐头、绝缘材料、工具、脚手架等必须清除 管道必须清洗干净，没有外来部件。 泥团和灰尘必须清除 必须关闭所有人孔、开口及观察孔，并保持气密性。 干油润滑系统须做好运行准备，要检查支承杆的密封箱是否紧密。 必须将泵出口端的旁通装置处于关的状态。 必须检查液动和电动水阀处于准备运行状态。 所有主要的短路阀门及其它的测量器件
22、及仪表必须打开 所有的泵做好运行准备 必须检查所有测量仪器、控制仪器以及调解仪器准备运行 所有需要的介质及消耗品，例如水、油脂、润滑油、氮气、蒸汽等随时准备添加 内通气体管线必须准备运行4 安全要求本文件以英文版为准，中文版仅供参考Project : Tangshan Iron & Steel Co. Operation & Maintenance Manual 项目 ： 唐钢 GCS 操作维护手册Project No : 2801956 项目号 ： 2801956Prepared : ECN 作者 ： ECNE:wenkufile2018-122740dc4515-89fe-4f0e-b97
23、c-d0d8b214d0704b70066cf7339e74c1700fa4bb4450dd.pdf Page: 11 of 56For safety reasons the site should be in clean condition. Stairways platforms and direct surrounding of the Gas Cleaning Plant shall be clear and scaffolding and hoisting equipment should be removed. The inside of the scrubber bottom a
24、s well as all stairways platforms and surrounding areas of the GCP need to be illuminated by sufficient lighting.5 Re-Commissioning after Long Time Shut DownAfter the measures required under chapter 5 have be carried out and the requirements for commissioning of all plant parts according to the inst
25、ructions of the manufacturer are fulfilled, the entire plant can be putting into operation as described below.The safety technical regulation to the individual plant components have to be considered. To avoid explosive gas mixture the gas-bearing components are to be purged oxygen-free. As inert gas
26、 is nitrogen or steam required. The blanketing of the plant is required before first commissioning at least and always when the plant for walkways or inspection is made gas-free.The entire plant has to be put into operation as follows: Hydraulic system Measuring and control devices Water cycle syste
27、m Gas cleaning system5.1 Rotation Control为了安全起见，现场必须保持干净。楼梯平台和煤气净化系统的周围环境必须保持清洁，脚手架和提升设备必须清除。洗涤塔底部以及所有的楼梯平台和煤气净化系统周围区域必须保持有充足的照明。5 长时间停车后的再开车当第五章要求的方法已经执行，以及系统内所有的设备都根据生产厂家的说明书上的要求调试后，整个系统就可以根据以下程序投入运行必须考虑系统内单个设备的安全技术规程。为了防止易爆气体的混合，含有煤气的部件必须保证处于无氧状况。要求内通氮气或蒸汽。至少在第一次开车前系统要求密封 ，当需要进行无煤气条件下的检查时系统必须一直密封
28、。整个系统需依照如下顺序投入运行： 液压传动系统 测量和控制装置 水循环系统 煤气净化系统5.1 转动控制本文件以英文版为准，中文版仅供参考Project : Tangshan Iron & Steel Co. Operation & Maintenance Manual 项目 ： 唐钢 GCS 操作维护手册Project No : 2801956 项目号 ： 2801956Prepared : ECN 作者 ： ECNE:wenkufile2018-122740dc4515-89fe-4f0e-b97c-d0d8b214d0704b70066cf7339e74c1700fa4bb4450dd
29、.pdf Page: 12 of 56In case of replacement of rotating equipment a rotation test has to be done before re-commissioning.Pumps or other rotating equipment shall be checked for rotation direction of motor resp. impeller. This is to avoid damages and proper cooling is warranted. The hydraulic pumps shal
30、l be switched on only for a short time to prevent damages in case of wrong rotation.For water pumps the pump manual shall be checked to find out if it is required by the manufacturer to disconnect the coupling to separate motor from the impeller.The pump manual has to be checked in any case for addi
31、tional advises and further manufacturer demands. For instance a few greasing pumps have optional rotation direction but with regard to the gear tooth system right rotation is recommended. 5.2 Filling of MediaAs far as piping or components has been renewed the piping system should be inspected for ti
32、ghtness of all flange connections. All pipes should have been cleaned from debris and flushed by water or chemicals in case of stainless steel material to be pickled. A pressure test with water (or oil in case of hydraulic pipes) for new pipe sections should have been done with all water as test med
33、ium drained. After these test procedures media can be filled to the system.5.2.1 Filling of OilIf the hydraulic system has been renewed or modified and a refill is required the following items should be checked before the specified oil is filled to the hydraulic oil tank:在更换了转动设备的情况下，在再次开车前必须对转动设备进行
34、转动测试。为了防止损坏泵或其它转动设备，在运转前必须检查电机的转动方向，另外必须保证有适当的冷却。为了防止在错误的转动方向下运转造成损坏，液压泵只能短时间试转。对于水泵，使用前必须检查操作手册看厂家是否要求断开联轴器以使电机和叶轮分开。无论如何必须检查泵的操作手册以便得到其它的一些建议、及生产厂家的其它要求。例如一些润滑泵可以任意方向旋转，但是若是齿轮啮合系统则推荐向右转动。 5.2 介质的充入当管道或者部件更新时，必须检查管道系统、所有法兰连接处的气密性。所有管道上的碎片杂物须清除、用水冲洗，不锈钢材料可用化学药品清洗。必须用水（当是液压管道时则用油）进行试压，当试压介质是水时试压完毕将水排
35、放干净。经过这些测试后工作介质就可以充入系统了。5.2.1 加油如果液压系统进行了更新或改进而需要进行重新加油时，在往液压油箱中加油之前必须检查以下项目：本文件以英文版为准，中文版仅供参考Project : Tangshan Iron & Steel Co. Operation & Maintenance Manual 项目 ： 唐钢 GCS 操作维护手册Project No : 2801956 项目号 ： 2801956Prepared : ECN 作者 ： ECNE:wenkufile2018-122740dc4515-89fe-4f0e-b97c-d0d8b214d0704b70066c
36、f7339e74c1700fa4bb4450dd.pdf Page: 13 of 56 The hydraulic oil tank is cleaned The sealings and the paint is resistant to hydraulic oil Filters with specified mesh size are installed Filters are installed in flow direction Measuring devices have to be checked and ready for operation Electrical connec
37、tions to MCC and from MCC to consumers have to be checked and ready for operation The accumulators are filled with nitrogen t the specified pressureAfter checking these items hydraulic oil can be filled up to the upper oil level mark.5.2.2 Filling of WaterAfter checking the cleanliness of all pipes,
38、 tanks and pumps water shall be filled into the systems installed on ground level up to the highest spray nozzle. The water will be fed by using the pressurized cold water supply system. The following safety measures have to be taken care of to protect the pump: 液压油箱是否清洁 密封和油漆是否是耐油的 是否安装指定网孔尺寸的过滤器 过
39、滤器是否安装在流动方向 必须检查测量装置是否准备运行 必须检查连接主控制台以及从主控制台到用电设备之间的线路是否准备运行 蓄能器充氮至指定的压力检查了这些项目后，就可以将液压油加至油液位刻度的上限标志。5.2.2 加水经过检查所有的管道、液位罐和泵保持清洁后，就可以往系统中加水。可以通过加入冷却水供给系统向系统加水。为了保护泵，须采取以下的安全措施： 保证密封水管的连接和密封系统（机械密封）的运行，保证密封垫正确包覆以及紧固的均匀性。本文件以英文版为准，中文版仅供参考Project : Tangshan Iron & Steel Co. Operation & Maintenance Manu
40、al 项目 ： 唐钢 GCS 操作维护手册Project No : 2801956 项目号 ： 2801956Prepared : ECN 作者 ： ECNE:wenkufile2018-122740dc4515-89fe-4f0e-b97c-d0d8b214d0704b70066cf7339e74c1700fa4bb4450dd.pdf Page: 14 of 56 Assure that sealing water lines are connected and the sealing system is in operation (mech. seal) or that the glan
41、d packing is properly packed and not tightened unevenly. Regulate flow rate with const. velocity to avoid water hammer and at discharge side only If no bypass line is integrated (minimal flow) pump shall not be operated longer than 2 min with discharge valve closed. The number of pump starts and sto
42、ps per hour should not exceed the value given in the manufacturer manual Before re-starting make sure that the pump shaft is at rest and does not rotate in opposite direction.All valves should be in normal operation position during this procedure. Secondary water supply lines like i.e. flushing wate
43、r to level tanks shall remain closed. Venting valves of pumps, tanks and pipes shall be watched carefully and if bubble free water escapes from them they should be closed.The demister overflow or an inspection hole at the demister can be opened during water filling for the use of over flow in order
44、not to overfill the system.ATTENTION: The venting valves on top of the level tanks must be closed after water filling otherwise clean gas can be blown out during hot commissioning. Nevertheless the balance line between tank and scrubber must always be open. 为了防止出现水锤，必须保证水流速度的恒定 当管线中没有旁路时（最小流量），在出口阀门
45、关闭的情况下泵的运行时间不能超过 2 分钟。 每小时开泵和停泵的次数不应该超过生产厂家操作手册中规定的值。 在重启前必须保证泵轴是静止的而且不会反方向转动。在此程序中，所有的阀门必须处于正常的运行状态。辅助供水，如水位罐的冲洗水管，应该保持关闭。泵、水位罐和管道的排气阀必须密切观察，一旦有无水的气泡从这冒出就应该关闭。为了不使系统装得过满，可以打开脱水器的溢流管或脱水器上的一个检查孔。注意： 当水加满后水位罐顶部的放空阀必须关闭，否则在热启动时净煤气会从该阀冒出。尽管如此，水位罐与洗涤塔之间的平衡管必须保持常开。开启水循环时开关阀的状态 :本文件以英文版为准，中文版仅供参考Project :
46、Tangshan Iron & Steel Co. Operation & Maintenance Manual 项目 ： 唐钢 GCS 操作维护手册Project No : 2801956 项目号 ： 2801956Prepared : ECN 作者 ： ECNE:wenkufile2018-122740dc4515-89fe-4f0e-b97c-d0d8b214d0704b70066cf7339e74c1700fa4bb4450dd.pdf Page: 15 of 56Conditions of shut off valves to start the water cycles:No De
47、scription GCP- CodeStatus1 Nozzle water valves pre-sc. 2 GNU06 AA103-105 OPEN2 Nozzles water valves pre-sc. 2 GNK02 AA101-103 OPEN3 Nozzles water valves AG-sc. 2 GNK03 AA101-103 OPEN4 Disch. level tank vent valve 2 GNS02 AA 581 CLOSE5 Disch. level tank gas valves 2 GNS02-03 AA 101 OPEN6 Reci level t
48、ank gas valves 2 GNU02-03 AA 101 OPEN7 Reci level tank vent valve 2 GNU02 AA 581 CLOSE8 Disch. level tank drain valves 2 GNS02,03 AA 102 OPEN9 Reci level tank drain valves 2 GNU02,03 AA 102 OPEN10 Reci station isolation valves 2 GNU06 AA 101-112 OPEN11 Discharge station isol. valves 2 GNS01 AA101-11
49、2 OPEN12 Reci pumps isolation valves 2 GNU04,05 AA 101,102 OPEN13 Demister drain valve 2 GNG01 AA 102 CLOSE14 Demister isolation valves 2 GNU01 AA 101,102 OPEN15 Condensate traps isol. valve 2 GNU01 AA 103 OPEN16 Water supply valve (nozzles) 2 GNK01 AA 201 OPEN17 Reci station control valve 2 GNU06 AA 221 OPEN18 Recirculation drain s/o valve 2 GNG01 AA 021 CLOSE19 Recirculation drain isolation 2 GNG01 AA101
