立磨工艺和功能说明 - 图文

Process and Function Description

工艺和功能说明

of a Typical Slag Grinding Plant

with POLYSIUS Vertical Roller Mill Type RMS

伯利休斯典型的RMS矿渣立磨系统

(Issue Aug. 2004) 2004年8月发行

2004年10月26日

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Contents目录

1. Plant description工厂说明..... ............................................................................... 4

Design and function of the slag grinding plant矿渣研磨厂的设计和功能... ................ 6

1.1.1 Raw material feeding原料进料......................................................................................................6 1.1.2 Roller mill RMS 51/26 辊式磨. ....................................................................................................7 Figure 1: Design of the roller mill 图1: 立式辊磨的设计…………………………………………..错误！未定义书签。

1.1.2.1 Mill housing 磨机外壳 .................................................................................. 错误！未定义书签。 1.1.2.2 Feed chute 围料槽 .......................................................................................... 错误！未定义书签。 1.1.2.4 Grinding table 磨盘 ........................................................................................ 错误！未定义书签。 1.1.2.5 Wear of grinding elements and dam ring heightener 耐磨件的磨损和挡料圈高度 错误！未定义书签。

1.1.2.6 External circulation of material 外循环物料 ............................................. 错误！未定义书签。 1.1.2.7 Drive unit 驱动装置 ....................................................................................... 错误！未定义书签。 1.1.2.8 Water injection (item 5F1.RM01.WTJ01) 喷水装置 ............................... 错误！未定义书签。 1.1.2.9 Confining air system (item 5F1.RM01.CAS01 and 5F1.RM01.CAS02) 密封风机系统 ...... 错误！未定义书签。

1.1.3 Dynamic separator SEPOL RMS (Item项目5F1.RM01.SDR01) 动态选粉机........................18 1.1.4 Gas routes风管路径 ..................................................................................... ...............................20 1.1.5 Finished product route 产品路 径 ..........................................................................................20

Control concept 控制方案 .............................................................................................21

1.2.1 Control of gearbox lubrication (5F1.RM01.GLS01) 减速机润滑的控制................................23 1.2.2 Control of auxiliaries 辅助设备的控制........................................................... ... .......................24 1.2.3 Control of finished product conveyance 成品输送的控制............ ......... ... .............................25 1.2.4 Control of gas routes (5F1.GP01 to 5F1.GP05)气体路线的控制..... ........ ...............................25 1.2.5 Control of the hot gas producer (5F1.HG01)热风炉的控制............................................ ........25 1.2.6 Control of main drive unit of mill (5F1.RM01.DRU01) and of new material delivery

磨机主传动装置和原料供给的控制 ............ .......................................................... ....... .......26 1.2.7 Control of water injection (5F1.RM01.WTJ01) 喷水的控制 ..................................................26 1.2.8 Control of grinding pressure 碾磨压力的控制..........................................................................26

2. Material properties 物料特性.... ........................................................................ 27

3.Operation of the grinding plant 碾磨厂的操作..................................................... 29

3.1 Philosophy of operation 操作原理...................................................................................29 3.2 Start-up / Shutdown sequence 启动 /停机顺序 ...........................................................31

3.2.1 Start-up sequence 启动顺序..... ..................................................................................................31 3.2.2 Shutdown sequence 停机顺序......................................................................................................32

3.3 Control loops 控制回路环......... ......................................................................................33

3.3.1 Control of differential pressure of mill 磨机压差的控制................................. ...... ................34 3.3.2 Control of temperature downstream of mill 磨机后温度的控制.............................. ............34

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3.3.3 Control of pressure upstream of mill 磨机前压力的控制.. ................. ....................................35

3.4 Operation under extraordinary conditions 特殊情况下的操作..................................35

3.4.1 Start-up of plant 系统设备启动..... ............................................................................................35 3.4.2 Shutdown of plant 系统设备的停止... ........................................................................................36 3.4.3 Operation with insufficient material quantity 喂料不足的操作............... ........... .................36 3.4.4 Overfilling of mill磨机过量喂料........... .....................................................................................36 3.5.5 Significant decrease of mill exit gas temperature 磨机出口风温度明显降低……….............37

List of figures插图清单

Figure 1: Design of the roller mill图 1: 辊式立磨的设计.......................................................................8 Figure 2: Wear protection of the feed chute图 2: 进料料槽的耐磨保护. ...............................................9 Figure 3: Grinding roller carrier with roller pair unit图 3: 磨辊桥架和磨辊对装置..........................10 Figure 4: Grinding table图 4: 碾磨磨盘 ............................................................ ..................................11 Figure 5: Arrangement of the dam rings图 5: 挡料圈的设置................................................................12 Figure 6: Dam ring heightener图 6: 挡料圈增高...................................................................................13 Figure 7: Materials at the nozzle ring图 7:喷嘴环处的物料.................................................................14 Figure 8: Collector for light section steel图 8:小铁颗粒收集...............................................................15 Figure 9: Mill drive system with lubrication system图 9: 带润滑系统的磨机传动系统......................16 Figure 10: Confining air system for grinding roller bearings图 10:磨辊轴承的密封空气系统……...17 Figure 11: Structure of the SEPOL separator图 11: SEPOL选粉机的结构..........................................18 Figure 12: Basic setting of guide vanes图 12: 导向叶片的基本设定...................................................19 Figure 13: Control scheme图 13: 控制方案..... .....................................................................................33

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1. Plant description 工厂说明

Below, please find a process and function description of a typical slag grinding plant. The designations (item numbers) used in the text refer to the flowsheets.

以下是一个典型的矿渣粉磨系统的工艺和功能说明。文中用到的代码(项目号)参考流程图中的设备编号。

The slag grinding plant basically consists of the raw slag feeding system, the roller mill with the dynamic separator and external material circuit with the fine metal extraction unit, a hot gas generator, the gas routes including the system fan, the bag filter and finished material transport.

矿渣粉磨系统由：矿渣喂入装置、动态选粉机、带除细铁颗粒装置外物料循环、磨机本体、一台热风炉、包括风机的热风管路、袋收尘器和和产品输送装置。

The roller mill is a POLYSIUS mill type RMS with a dynamic separator type SEPOL RMS. The grinding plant is heated by a hot gas generator, which normally is fired with blast furnace gas, natural gas, heavy oil, light oil or coal dust.

立磨型号为RMS的伯利休斯磨配有型号为SEPOL RMS的动态选粉机。粉磨系统由一台热风炉供热风，热风炉一般采用高炉煤气、天燃气、重油、轻油或用煤粉。

The following basis values apply to a typical 90 t/h slag grinding plant only: 下列基本参数仅适用于一个典型的 90 t/ h矿渣粉磨系统：

Mill feed material磨机喂料: blast furnace slag 高炉矿渣 Mill type磨机型号: RMC 51/26/435 Throughput产量: 90 tph (吨/每小时)

Product fineness产品细度: 4200 cm2/g ~ 4500 cm2/g Diameter of mill housing磨壳直径: 7000 mm Diameter of grinding table磨盘直径: 5260 mm Diameter of grinding rollers磨辊直径: 2600 mm Width of the grinding rollers磨辊宽度: 730 mm Quantity of the grinding rollers磨辊数量: 4

Inst. power of main drive unit安装的主马达功率: 2800 kW

Separator type选粉机型号: SEPOL 435 RMS Diameter of separator rotor选粉机转子直径: 4350 mm Diameter of separator housing选粉机壳体直径: 8500 mm Inst. drive unit安装的马达功率: 250 kW

Rotor speed转子速度: 26 - 154 1/min Hot gas producer热风炉: ............. Max. heating capacity最大的加热容量: 45 ~ 55 GJ/h Max. hot gas quantity最大的热气量: ...... m3/h

Fuels燃料: natural gas or blast furnace gas: 高炉煤气, 天燃气, 重油, 轻油或煤粉 Filter area收尘面积: 约 5000 m2 Dust load粉尘浓度: 300 ~ 350 g/m

Exhaust air volume 排气量: 28,000 ~ 31,000 m3/h Filter medium 过滤介质: Polyacrylonitrile聚丙烯月青 Air to cloth ratio:空气对滤布比例 < 1.2 m3/(m2*min) Pressure drop: 压降 < 15 mbar

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Compressed air consumption: 压缩空气消耗 约 500 Nm3/h at 7 bar

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1.1 Design and function of the slag grinding plant 矿渣研磨厂的设计和功能

Details of the design and functioning of the individual machines or plant components of the slag grinding plant are given below.

以下是矿渣粉磨系统内各单个设备或部件的设计和功能。

1.1.1 Raw material feeding 原料进料

The raw material which consists of slag and gypsum is conveyed via the speed-controlled weighbelts, item no. 5D1.WE01, 5D1.WE02 and 5D1.WE03 and is guided in a

controlled flow rate in the troughed belt conveyor 5D1.BC01 in accordance with the set mix-ture.

原料包括矿渣和石膏，经过调速皮带称(项目号5D1.WE01，5D1.WE02)流量控制，按照设定的混合比用槽形皮带机(5D1.BC01)输送。

To protect the roller mill from metallic foreign bodies a suspended magnetic separator, item 5D1.MS01.MSJ01 and a metal detector, item 5D1.MT01.MTJ01 are installed above the common conveyor belt 5D1.BC02 of the raw material components. The suspended mag-netic separator basically consists of a permanent magnet, which is enclosed by a belt con-veyor provided with transverse galleries. During operation the iron parts attracted by the magnet are brought with this belt conveyor out of the area of the magnetic field and are dis-charged in a collecting container.

为保护辊磨，清除金属异物，原料输送皮带机(5D1.BC02)上装有悬挂式电磁除铁器和金属探测器(项目号5D1.MS01.MSJ01和5D1.MT01.MTJ01)。悬挂式电磁除铁器主要包括一个永磁铁，配有一条横向的回转皮带。在操作中铁块物被磁铁吸起，当回转皮带超出磁力范围后铁块物掉落至收集箱内。

We know from experience that the suspended magnetic separator alone does not remove all iron parts. Thick material layers on the troughed belt conveyor, coarse grain size ranges or sticky and moist material can make removal of the iron more difficult. Non-magnetic tramp metal also is no collected. Therefore, an additional metal detector (item 5D1.MT01.MTJ01) also is installed.

根据经验，我们知道仅仅使用悬挂式电磁除铁器是不能除去所有铁颗粒的。皮带机上较厚的料层，较粗的进料粒径以及粘稠潮湿的物料都使除铁变得更加困难。另外，也无法除去无磁性的夹杂金属物，因此，需增加安装金属探测器。

The metal detector contains transmitting and receiving coils with an alternating magnetic field of high frequency between them which is generated by an oscillator in the controller. When a metal part passes the field, eddy currents form as a result of induction and take away energy from the oscillator. A signal is formed from this which is relayed to the control system of the change-over flap, item 5D1.CF01.CFJ01. The change-over flap removes the metal con-taining new feed material and discharges it in a container. To avoid frequent removals, it is necessary not to detect tramp metal which is not greater than a minimum size. The small tramp metal passes in the raw mill and is collected for the most part in the collecting device for light section steel of the bucket elevator.

金属探测器包括转换器和在控制器中由振荡器产生高频的交变磁场的接收组件。当金属物通过 磁场时会产生涡流，结果形成感应并从振荡器中带走能量。从这里产生一个信号并延时传给转向阀(项目号5D1.CF01.CFJ01)的控制系统。转向阀将夹杂金属物的物料排放至收集箱中。为避免频繁的除去，不需要探测小于最小尺寸的夹杂金属。小的夹杂金属通过磨机进入提升机，大部分细铁颗粒在提升机装置内的收集器被收集。

The rotary airlock feeder, item 5F1.CV01.CVJ01 is used as airlock for the roller mill. To avoid caking of the slag the rotary airlock feeder is heated by a gas stream. The material is guided onto the grinding table via a chute which is also heated.

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锁风转饲机(项目号5F1.CV01.CVJ01)为辊磨密封空气用。为避免矿渣结块旋转喂料机通有热气加热。物料导入磨盘经过的料槽也被加热。

1.1.2 Roller mill RMC 51/26 立式辊磨

The general design of the roller mill is explained with Figure 1. 立磨总图设计见图 1。

The essential component of the roller mill is the grinding table with two concave grinding tracks (on the inside and outside) and the two roller pair units (designation 3) which run on the bed of material. The grinding table is driven by the motor (2), the grinding rollers are fixed in their position. The raw material is fed to the mill via a chute and falls directly onto the centre of the grinding table. The material is then carried under the rollers by the rotation of the table. The ground material is flung outwards over the edge of the grinding table and en-trained in the stream of gas from the nozzle ring (9). All of the material ejected from the grinding table, or a certain proportion of it is carried in the gas stream to the separator (10). 辊式磨主要是由有2道凹形磨辊轨迹(内轨和外轨)的磨盘和运转在料床上的2组磨辊对(每组一对磨辊，标示3)组成。磨盘由马达(标示2)驱动，磨辊被固定在原位置。原料通过一个喂料槽直接落在磨盘的中心。然后料被转动的磨盘带动进入磨辊。被碾磨过的料向外甩出越过磨盘的边界进入从喷嘴环(标示9)来的气流中。被磨盘甩出的物料，全部或者一部分被气流带至选粉机(标示10)。

The grinding force of the rollers is hydraulically applied on the material via the tie rods (5). The confining air system (7) protects the grinding roller bearings from entering dust. The bed of material can be stabilised with the water injection system (11).

磨辊的碾磨压力来自液压系统，通过拉杆(标示5)加载在碾磨物料上。空气密封系统(标示7)保护磨辊轴承防止灰尘进入。喷水(标示11)可以稳定料床。

The separator (10) classifies the ground material into finished product and oversize. The oversize material falls back onto the centre of the grinding table (4), while the finished prod-uct is carried to the downstream filter by the stream of gas.

选粉机(标示10)将研磨过的料分离成成品和过粗料。粗粉料落回磨盘(标示4)中心，成品则被气流带入下一步的收尘机中。

The gas velocity in the nozzle ring (9) of the roller mill can be adapted to the grinding plant requirements by adjusting the nozzle segments. Material lumps which cannot be carried to the separator in the hot gas stream fall through the nozzle ring and are returned to the mill via the recirculating bucket elevator.

磨机内喷嘴环(标示9)处的气流速度可以通过调整喷嘴截面来满足粉磨系统要求。粗物料无法被热气带至选粉机而掉落入喷嘴环内，通过外循环提升机送回到磨中。

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伯利休斯水泥

第 8 頁，共 37 頁

圖1：立磨总图設計

Housing (1)壳体

Drive Unit (2)驱动装置 Roller pair units (3)辊轮组 Grinding table (4)磨盘 Tie rods (5)拉杆

Hydraulic system (6)液压系统 Confining air system (7)空气密封系统 Dismounting device (8)拆解装置 Nozzle ring (9)喷嘴环 Seperator (10)选粉机 Water injection (11)喷水

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1.1.2.1 Mill housing 磨机外壳

Doors for inspection, maintenance, assembly and installation purposes are installed in the upper housing section of the roller mill. In sections particularly exposed to wear, the housing is provided with replaceable wear protection. The nozzle ring consists of Hard Faced Com-pound Steel Plate (VAUTID, EURODUR; or similar). Above the nozzle ring, DENSIT cas-settes(Ceramic Mortar) are installed at the lower end, and above them a scaled wear lining made of a special AR-plate (CREUSABRO 4000).

安装在磨机上部外壳上的门是为了检查、维护保养、组装及安装的目的。尤其在易受磨损的部位，磨机外壳提供了可更换的磨损保护件。喷嘴环是由表面硬化的复合耐磨钢板(VAUTID, EURODUR;或类似的)构成。在喷嘴环上面，较低部位安装的是DENSIT盒(陶磁砂浆)，上面部位是由特别的AR板(CREUSABRO 4000)制成的片状耐磨衬板。

Hot gas is supplied to the roller mill housing via two hot gas pipe sockets. The seal between the casing and the grinding table is a sliding contact seal. Dust cannot deposit, as always small quantities of false air enter through this seal.

热风通过2个热风进口管接口进入磨机。在磨机外壳和磨盘间的密封是滑动接触式密封。因为密封间总是存在少量漏风，粉尘不能附着。

To control the hot gas supply in the mill interior, the nozzle ring is installed above the hot gas pipe socket. The nozzle ring consists of several adjusting segments for varying the gas ve-locity by altering the cross-sections. The hot gas stream emerges at high velocity, entrains the material from the grinding table and carries it upwards to the SEPOL separator. The gas velocity in the nozzle ring is a crucial parameter for the grinding process. The cross-section of the nozzle ring can be altered from outside.

为控制磨机内的热风量，喷嘴环位于热风管接口之上。喷嘴环由数个可调节阀块组成，通过改变喷嘴截面可以调整气流速度。热风以高速流入，夹带着从磨盘甩出的物料，并将其向上带入SEPOL选粉机。在粉磨工艺操作中喷嘴环的气体流速是极重要的参数。喷嘴环的截面可以从磨机外面调整。

進 料

盒 子

復合式耐磨鋼板

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1.1.2.2 Grinding rollers 磨辊

The material on the grinding table is carried under the rollers by the rotation of the table. The grinding is performed by a total of 4 grinding rollers set in pairs which can rotate independ-ently. The bearing assembly is sealed by the rotary shaft seal. With the roller carrier,

confining air is carried to the rollers in order to prevent dust from entering the grinding roller bear-ings. The roller tyres consist of wear-resistant Ni HARD IV or similar and are fixed on the roller body with clamping rings and studs.

磨盘上的物料被转动的磨盘带入磨辊下。共有4个磨辊以对辊方式作用，对辊中每个磨辊轮可以独立旋转。轴承组由旋转轴封密封。在磨辊架，密封空气被带入目的是为了防止灰尘进入磨辊的轴承。辊轮的辊胎是由耐磨的Ni HARD IV或类似的材料组成，辊胎用紧固夹和双头螺栓固定在辊体上。

密封空氣接口

磨輥架

磨 輥

The grinding roller guide and the single grinding-force application system allows the roller pair units freedom of movement in all three planes. They can, for instance, move vertically and pivot horizontally on their guide axle. If the inner roller is raised by coarse feed, the outer roller presses down with greater force on the material. Each roller thus supports the action of the other. This interactive functioning of the rollers results in highly efficient grind-ing.

磨辊导向轴和单辊压力平衡系统允许磨辊对可在3个自由度上移动。例如，它们能在垂直和水平方向围绕它的导向轴移动。如果内辊轮被加入的粗料顶起，则外辊轮会向下以更大的压力压料。每一对磨辊如此这般互相作用。这样的相互配合的功能实现了高效率的碾磨。

The grinding force required for grinding the material is generated by a hydraulic system.

Each grinding roller is running in antifriction bearings on an axle clamped in the roller carrier. The roller pair units are so guided by pins in corresponding guides that they can move verti-cally and pivot horizontally on their horizontal axle. They can therefore very well adapt them-selves to changes in the material bed depth and the entire grinding surface always remains fully effective.

粉磨物料需要的粉磨压力是由液压系统产生的。每个辊轮装在耐磨滚动轴承上，轴承安装于紧固在磨辊桥架的辊轴上。磨辊对由导向销引导，使得它们可以在垂直和中心水平围绕着水平轴运动。它们由此可在改变料床的深度时很好的调整自己，并使得整个碾磨表面一直保持有效的碾磨。

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1.1.2.3 Grinding table 磨盘

The material falls directly onto the centre of the grinding table and is carried by the centrifu-gal force before the rollers.

入磨物料直接落在磨盘中心上，并且通过离心力被带至磨辊下面。

磨盘衬板

磨 盘

The grinding table is mounted direct onto the driving flange of the gear unit. It consists es-sentially of the following components:

磨盘直接被固定在减速机的转动法兰上。它包括以下最主要的组件： _ the grinding table body磨盘本体

_ the segmented, replaceable grinding track耐磨的，可替换的磨轨（磨盘衬板） _ the table liner fastenings磨盘衬板的固定连接装置

_ the dam rings with the dam ring extension 带挡料圈附件的挡料圈

_ the insulation which protects the grinding table from thermal overloading by the hot gases 保护过热风量对磨盘过热冲击的绝缘材料

The bed of material on the grinding table forms between the concave grinding track and the convex grinding rollers. An optimum bed of material is decisive for effective grinding. The bed of material is set by the height of the dam ring installed on the outer grinding table rim. 在凹形槽轨道和凸起的辊轮间的磨盘上形成料床。决定碾磨效率的一个很重要因素是选择合理的料床厚度。料床厚度由安装在磨盘边缘的挡料圈的高度设定。 加高的外部擋料圈

前部擋料圈

外 軌 內 軌

As the grinding track depth (measured from the upper edge of the grinding track) increases

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with increasing wear of the grinding track, the height of the material bed on the grinding track also changes. When material with great internal supporting properties is ground which tends to formation of a very stable material bed, a super proportional increase of the material layer may occur due to the thicker material bed, and this may result in an increase of the rolling resistance at the grinding rollers. This increases the specific energy consumption of the grinding process. It is therefore necessary to adapt the dam ring height to the increasing wear during the grinding process. A material bed which is too low or too deep also upsets the smooth running of the mill and may lead to vibrations during operation.

由于碾磨轨道的深度(从碾磨轨道的上缘量测) 随着碾磨轨道的增大磨损而增大， 碾磨轨道的料厚也随着变化。当物料特性比较稳定时，碾磨时容易形成一个稳定的料床。随着料层的厚度增加也容易产生超特性的粘滞料层，这样粘滞料层会增加磨辊的碾磨阻力，也就增加了碾磨过程中的能量消耗。因此在磨损增加时有必要改变挡料圈的高度。料床太薄或太厚同样会扰乱磨机的平稳运行，并且在操作中可能导致振动。

When the raw material is very fine and dry, it may be necessary to form a stable bed of mate-rial by means of a second dam ring. This dam ring (dam ring extension) is installed before the first dam ring.

当原料很细好很干时，通过加装第2个挡料圈可能可以形成稳定的料床。这个挡料圈(挡料圈附件)安装在第1个挡料圈之前。

The dam ring height can be adapted by selecting rings of different heights (dam ring exten-sion). The sketch below shows three examples of different wear conditions.

挡料圈的高度通过选择不一样高度的环可以改变(挡料圈附件)。下面绘制表示的是3种不同的磨耗情况。

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新的狀況

低磨損

相當大磨損

Below the grinding table the nozzle ring is installed which is the ?narrowest location“ of the roller mill. The hot gas stream emerges at high velocity, entrains the material from the grinding table and carries it to the SEPOL separator.

喷嘴环安装在磨盘以下，此处是磨机的“狭窄位置”。热气流产生高速度，从磨盘上把物料带走至SEPOL选粉机。

The gas velocity in the nozzle ring is a crucial parameter for the grinding process. The

velocity in the nozzle ring is so selected that only very coarse components (e.g. not commin-uted iron parts) can fall through the nozzle ring. The ground material, however, must be conveyed to the separator or returned on the grinding table.

在碾磨工艺操作中喷嘴环的气体流速是极重要的参数。喷嘴环的风速选择使得只有非常粗的物料(比如未经破碎的铁颗粒)能通过喷嘴环掉落。被碾磨过的物料要么被送到选粉机或是重新回到磨盘。

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The free cross-sectional area of the nozzle ring can be adjusted from outside without having to interrupt the production.

喷嘴环的自由截面区域可以在不打断生产的情况下从外面被调整。

The area around the nozzle ring is protected against abrasion by the mounting of wear re-sistant materials such as Creusabro and Vautid (see Figure 7).

喷嘴环周围区域为保护磨损安装固定了如Creusabro 和 Vautid材料的耐磨板(见图7)

1.1.2.4 External circulation of material 料的外部循环

Material which falls through the nozzle ring is guided via a chute and tipping valve to the re-circulating bucket elevator, item 5F1.BE01. The change-over flap, item

5F1.CF01.CFJ01 is designed for emptying the mill for maintenance purpose only.

通过喷嘴环掉落的料通过一个袖斗和翻板阀到再循环提运机，项目号5F1.BE01。转向阀，项目号5F1.CF01.CFJ01的目的只是被设计用来为维护保养而清空磨机用的。

When the tailings are returned from the bucket elevator to the roller mill, the material passes a vibrating trough, item 5F1.VC01.VCJ01 with a downstream removal system for light sec-tion steel with a permanent magnetic drum, item 5F1.MG01.MGJ01.

当粗料从提运机 送回到磨机时，过一个槽形振动给料机（项目号5F1.VC01.VCJ01），然后进入1个带永磁滚筒的磁鼓除铁器（项目号5F1.MG01.MGJ01）清除循环物料中的小颗粒铁。

An effectively functioning iron removal system is very important for the production, as otherwise, the circulating iron in the slag would accumulate and cause extreme wear. The vibrating trough makes the flow of material from the bucket elevator uniform and ensures material feeding to the magnetic drum over the total width.

对生产而言一个有效的除铁系统是相当重要的，否则在矿渣中循环的铁会累积并导致对耐磨件严厉的磨损。振动机使从提升机的料流均匀并且确保料通过永磁滚筒的整个宽度。

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当增加选粉机转子的转速，可以生产更细的成品。这个效果也可以通过调整（加大）动态选粉机的导风叶片的切线角得以实现和加强。反之，当降低选粉机转速或者调整选粉机的导风叶片至径向方向时会生产出较粗的料。

Basic setting of the SEPOL guide vanes is with an angle of 60 to 70° referred to the radial line, and the long guide vane shank points to the inside. Commissioning of the SEPOL is at a rated speed of 85 to 90 % (approx. 30 m/s of circumferential speed). The speed is then ad-justed according to the produced fineness of the finished product. SEPOL导风叶片得基本设定是与径向成60~70°角度，并且导风叶片长柄向内指。SEPOL试运转速率在85~90%(圆周速度大约30米/秒)。然后根据生产产品的细度调整速度。

1.7 Adjusting device调整装置 1.9 Guide vanes导风叶片

2.1 Setting of spacing between导风叶片与转子间隙设定 guide vanes and rotor

1.1.4 Gas routes 热风管路

A hot gas generator (item 5F1.HG01) is provided for combined grinding and drying. It produces exhaust gas temperatures of approx. 800°C. Before entering the mill, the hot gas is cooled down by admixture of circulating mill air. The circulating mill air volume is controlled by means of the throttle valve (item 5F1.TV01).

热风炉(项目号5F1.HG01)提供热风用于粉磨系统干燥。它产生的热风温度大约800°C。在进入磨机前，热风与磨机循环风混合后冷却。磨机循环风量通过节流阀控制(项目号5F1.TV01)

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Considering the risk of incrustations for slag grinding, a certain amount of the hot gas sup-plied by the hot gas producer is used for heating the recirculating bucket elevator (item

5F1.BE01), the feed chute and the rotary airlock feeder (item 5F1.CV01.CVJ01). The gas for heating the recirculating bucket elevator is taken from the hot gas generator and mixed up with fresh air to approx. 250°C. The throttle valve (item 5F1.TV03) controls the hot gas flow rate whereas the fresh air flap (item 5F1.TV02) controls the temperature for heating up.

Heating of the rotary airlock feeder and feed chute is not subject to control and hand-operated flaps are used for adjusting purposes.

考虑到矿渣粉磨过程中存在结料的问题，由热风炉产生的部分热风用于加热循环提升机(项目号5F1. BE01)、喂料料槽和旋转锁风喂料机(项目号5F1.CV01.CVJ01)。用来加热循环提升机的热风从热风炉来并和新鲜空气混合到大约250°C。节流阀(项目号

5F1.TV03)控制其热风风量，而冷风阀(项目号5F1.TV02)控制加热风温度。旋转锁风喂料机和喂料料槽的热风加热比较不容易控制，故用手动挡板为调整。

The finished product leaves the mill together with the gas stream from the SEPOL separator. To protect the downstream bag filter, the bag filter is internally equipped with a fresh air flap. As soon as the filter-specific, maximum temperature is exceeded, this flap will open and cooler fresh air is admixed to the gas stream.

成品和气流一起从选粉机离开磨机。为保护下一步的收尘机，收尘机内装有一个冷风风阀。当进收尘机风温超出温度上限，风阀就会打开，冷空气混入进收尘器的气流中。

The louvre damper (item 5F1.FN01.TVJ01) downstream of the filter controls the gas quantity flowing through the mill. The return air duct downstream of the mill fan (item 5F1.FN01) re-turns the gas to the mill inlet, and the excessive gas is discharged through the stack (item 5F1.GP03) into the atmosphere.

百叶阀(项目号5F1.FN01.TVJ01)位于收尘机之后，控制着通过磨机的总风量。磨机风机之后的循环风管把热风送回到磨机进风口，过量部分的风量通过烟囱(项目号5F1.GP03)排入大气中。

1.1.5 Finished product route成品路径

In the bag filter (item 5F1.BF01) the finished product is separated from the gas stream. Then, the screw conveyors and the rotary airlock feeders under the bag filter convey it to the con-veying equipment for finished product which conveys the finished product to the silos. Then a conveyor and a bucket elevator transport the finished product extracted from the silos either to the mixing station –where it is mixed with clinker dust- or to the loading station, as re-quested.

在袋式收尘机(项目号5F1.BF01)内成品和气流分离。位于袋式收尘机之下的螺旋输送机和旋转喂料机将成品送入库中。然后通过输送设备提升机从库中选取成品根据需要送往搅拌站，在这里与熟料粉拌合，或者送往装车站。

1.2 Control concept 控制原理

In principle, several machines with their drive units are combined to form useful start-up groups. Under normal operating conditions, the whole group is centrally operated from the control panel in “automatic“ mode. This means, it is possible to start and stop this group pro-vided the switch-on and switch-off conditions have been fulfilled for the respective group and the individual drive units of this group. Generally, the start-up of a group follows a certain sequence. Usually, additional machine protection conditions and process-technological inter locking conditions must be taken into account for the start-up of a group. A message is displayed after the start-up of a complete group, and possibly the start-up of the following group is enabled.

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原则上，几台设备的驱动装置整合起来形成联锁起动组。在一般的操作情形下，整个组在“自动模式”下在控制中心通过控制盘操作。也就是说，只有相关组的‘开’、‘停’条件以及该组内各设备的‘开’、‘停’条件满足，则可以进行该组的启动/停止操作。组的启动或停止操作遵循一定的顺序。通常，组的启动/停止操作要考虑到相关设备的保护条件和工艺过程的联锁条件。在一组设备启动/停止的完毕信息显示后，才有可能进行下一组设备的启动/停止操作。

Alternatively it is possible to operate the drive units of a group individually or in groups, lo-cally in the “local“ mode.

一组设备可以选择组内各设备的单机操作，也可选择组设备操作。现场操作需把系统设置到现场模式。

In the “automatic“ mode, however, the protective machine interlocks ( PMI ) as well as the process-technological interlockings ( ILC ) are active either for the complete group or the respective drive units.

在自动模式下，不管是整组操作还是单一设备操作，设备的保护联锁( PMI )和工艺过程联锁( ILC )均起作用。

Belong to the PMI among others :属于PMI（设备保护联锁）的包含其中： _ Motor winding temperatures马达运转温度 _ Gear oil temperature齿轮油温 _ Oil level油位 _ Oil pressure油压

_ Emergency switch紧急开关

_ Local/remote selector switch (“automatic“ or “local“) 现场/自动选择开关(“自动”或“现场”)

Examples for interlockings (ILC) are : ILC（工艺联锁）的例子

_ Message that the next group in flow direction of the material is in operation 在物料流程上下一个组的运转信号 _ Off-track belt switch 皮带跑偏开关 _ Bearing temperatures 轴承温度

_ Min/Min level or Max/Max-level最低或最高料位 _ Temperatures 温度 _ Pressures 压力

Is the local mode of operation of the drive units selected locally, this condition must be en-abled from the control panel. In local operation it is then possible to locally start or stop the respective drive unit of the respective group by means of the local/remote selector switch without operational or process-technological inter locking being active. Merely the protective machine interlocks (PMI) remain active to protect operators and machines.

要想在现场操作设备，需在控制操作台选择现场操作模式。在现场操作，可以通过现场/中心选择开关，对组内的的各个设备进行开/停操作。一般没有操作或工艺联锁，只有设备的保护联锁(PMI)保留激活以保护操作者和设备。

The local/remote selector switches installed in the vicinity of machines normally have the following positions: 现场/中心选择开关安装靠近设备，通常有如下位置： _ Stop 关

_ Automatic (or even Remote) 自动(或者中心)

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_ Local 现场

Moreover, the local/remote selector switch can be turned by hand from the “local“ position to the “start“ position and be kept there until the motor contactor picked up and the drive unit starts running. Afterwards the switch can be released and returns to the “local“ position. In the case of reversible drive units or actuators for flaps there are, instead of the “start“ position of the local/remote selector switch, two further positions for the respective sense of rotation of the drive unit.

此外，现场/中心选择开关可以手动旋转从“现场”位置转向“启动” 位置，保持住直到马达接触器投入作用并且设备运行为止。其后开关可以松开并回到“现场”位置。如果是正反转设备或是阀门电动执行机构，现场/中心选择开关的开启位置换成2个相应的旋转方向或阀位指示。

Return of the switch to “automatic“ mode is possible at any time in order to ensure that a lo-cally started drive unit is available again in automatic mode via the control system, and the complete group can be started once again from the control panel.

在任何时候打回开关至“自动”模式是为了确保一个现场运转的转动装置通过控制系统回到自动模式，并使整个组可以从控制盘再次被起动。

Operation of the drive unit is stopped immediately in the switch position “stop“ irrespective of the fact whether operation of the drive unit had been started via the control system in auto-matic mode or locally in local mode. In this switch position the drive unit is not available on the control panel and cannot be started there.

开关打到停止位置时转动装置的操作会马上停止，而不论转动装置是通过控制系统在自动模式或是现场模式启动的事实。在这个停止位置设备不能从控制盘上被启动。

All in all, the following groups can be defined for operation in a precisely defined way from the control system: 总之，下面的几组设备的操作，从控制系统的说明中能得到准确的操作控制程序说明：

_ Gearbox lubrication (5F1.RM01.GLS01) 减速机润滑 _ Auxiliaries 辅助设备

– Hydraulic system (5F1.RM01.HYS01) 液压系统

– Separator drive unit (5F1.RM01.SDR01) 选粉机传动装置 – Coarse feed valve (5F1.CV01.CVJ01) 粗料进料阀

– Removal of fine iron particles (5F1.MG01.MGJ01)小铁颗粒的去除 – Recirculating bucket elevator (5F1.BE01)循环式提升机

– Confining air fans (5F1.RM01.CAS01 and 5F1.RM01.CAS02)空气密封风机 _ Finished product conveyance成品输送 _ Gas routes (5F1.GP01 to 5F1.GP05) and

separation of finished product (5F1.RM01.SDR01)气体通路和成品分离 _ Hot gas producer (5F1.HG01)热风炉

_ Main drive unit of mill (5F1.RM01.DRU01) and fresh material conveyance 磨机主马达和原料输送

_ Water injection (5F1.RM01.WTJ01)喷水

1.2.1 Control of gearbox lubrication (5F1.RM01.GLS01) 减速机润滑控制

A hydrodynamic lubrication system is concerned which uses a low-pressure oil pump to sup-ply oil to the individual lubrication points in the gearbox (gear wheels, bearings, etc.). 液压润滑系统使用一台低压油泵供油给减速机的各个润滑点(齿轮，轴承等)

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The lubrication system represents a compact unit with 润滑系统组合地集成以下部件： _ oil tank and level indicator 油箱和液位指示 _ low-pressure oil pump低压油泵

_ heat exchanger for indirect oil cooling, using cooling water 水冷式冷油热交换器 _ thermostat-controlled immersion heater with resistance thermometer 浸入式热电阻温控电加热器

_ disk filter as change-over duplex filter with differential pressure monitor 差压监控可换式双路圆盘式过滤器

_ flow monitor in the low-pressure oil circuit低压油循环流量计

_ 2 pressure switches in the low-pressure oil circuit 低压油循环回路上的2个压力开关

including several resistance temperature sensors installed in the gearbox for measuring the bearing temperature, etc.

包括数个安装在减速机上热电阻，用于测量轴承温度等。

As the oil employed for lubricating various points must have a certain temperature and viscosity, the gearbox lubrication control system also controls the thermostat-controlled

heater and the oil cooling system. As, usually, the oil must be heated up for the start-up phase, the gearbox lubrication system will be started as group in automatic mode several hours before starting mill operation, and it will continue operation even during shorter mill stops. Only for planned mill stops of more than 30 hours, necessary repair or maintenance work it will be expedient to stop operation of the gearbox operation system.

由于润滑的各个点的油必须有一个合适的温度和粘度，减速机润滑控制系统同样控制温控电加热器和油冷却系统。通常，润滑油必须加热至可运行状态，在自动模式下，减速机的润滑系统需在磨机启动前几个小时就开始运行。并且在磨机短暂停机时也会保持运转。只有计划停磨超过30小时的必须维修或维护保养工作时，才会考虑停止减速机的润滑系统。

Alternatively, it is possible to locally start in “local“ mode operation of the low-pressure oil pump for test purposes or to stop it.

也可选择在现场模式启动/停止低压油泵，为了测试目的。

1.2.2 Control of auxiliaries 辅助设备的控制

The grinding force required for material comminution is produced by a hydraulic system and transmitted onto the grinding rollers by means of tie rods. The hydraulic system allows con-tinuous adjustment for the purpose of bringing the grinding force into line with the operating condition of the mill.

对物料粉磨所需的碾磨压力由液压系统产生，通过拉杆传递到磨辊上。为了适应磨机的操作需要，液压系统在磨机运行中可连续的调整压力，以提供稳定合适的碾磨压力。

For starting the roller mill, the grinding force is reduced by lowering the hydraulic pressure. By this measure, the starting torque of the main drive unit of the mill is reduced accordingly. The following functional steps are executed when starting the hydraulic system of the mill: 启动磨机时，液压系统降低磨辊的压力，这样，主电机的启动扭矩就相应减少。当开启磨机的液压系统时，按以下步骤进行：

_ All solenoid valves are in a de-energised condition (items 5F1.RM01.HYS01-M6101 to 5F1.RM01.HYS01-M6108). 所有的电磁阀均在失电状态。

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_ The motors (items 5F1.RM01.HYS01-M2001 and 5F1.RM01.HYS01-M2002) of the hydraulic pump start operation. 液压泵马达启动运转。

_ The pumps delivers, at atmospheric pressure, oil via the filter (items 5F1.RM01.HYS01-B7001 to 5F1.RM01.HYS01-B7004) and the directional valve (items 5F1.RM01.HYS01-M6101 to 5F1.RM01.HYS01-M6108) into the reservoir.

油泵工作，在大气压下，油通过滤芯和定向阀进入蓄能器。

_ The solenoid valve (items 5F1.RM01.HYS01-M6101 to 5F1.RM01.HYS01-M6108) re-sponds after 10 sec. and the hydraulic system is pressurised up to the start-up pressure. At the same time, the hydraulic oil passes the non-return valve and flows to the piston rod sides (Piston 1 and Piston 2) of the hydraulic cylinders as well as to the oil sides of the piston accumulators (Piston 3 and Piston 4).

电磁阀在10秒钟后响应，液压系统增压至启动压力，同时，液压油通过单向阀流入液压缸的拉杆侧活塞(活塞1和活塞2)，液压油也进入蓄能器活塞的油室。

_ The preset start-up pressure of approx. 60 bar having been reached, operation of the hydraulic pump is stopped and the solenoid valve is de-energized. On account of the

function of the non-return valve, the built-up hydraulic pressure is maintained in the system. 当预设置的启动压力达到大约60bar时，液压油泵停止，电磁阀失电。基于单向阀的功能，系统内的油压得以维持。

_ Pressurisation of the hydraulic system to the preset working pressure is initiated either by the starting command “working pressure“ from the control panel and/or by a timer after approx. 1 minute, after start-up of the main drive unit of the mill.

液压系统要达到预设的工作压力值，可从控制盘启动“工作压力”命令，也可以由定时器在启动磨机的主马达后约1分钟自动执行。

_ Pressure build-up to the preset working pressure of approx. 120 bar is made analogously to that of the start-up pressure by starting operation of the hydraulic pump, which first re-cycles, at atmospheric pressure, the oil via filter and directional valve to the reservoir.

预设置的工作压力大约在120bar左右，达到工作压力的过程跟达到启动压力类似，也是通过运行液压系统压力油泵产生，液压油，初循环在大气压作用下，通过滤芯和和定向阀进入蓄能器。

_ The solenoid valve responds after 10 sec., and pressurisation of the hydraulic system is continued until the preset working pressure is reached at the measuring point by delivering hydraulic oil via non-return valve to the piston rod sides of the hydraulic cylinders and to the oil sides of the piston accumulators.

电磁阀在10秒钟后响应，液压系统持续增压至在监测点的预设工作压力，液压油通过单向阀流入拉杆侧活塞的液压缸和蓄能器活塞的油室。

_ If, during operation, the hydraulic pressure differs from the preset operating range by approx. 5 bar for reasons of, for instance, variation of the material bed depth, temperature Fluctuations or leakage in the hydraulic system, oil will be discharged through a throttle by opening the solenoid valve or oil will be fed by starting the pump and response of the solenoid valves.

在实际运行中，如果由于某种原因例如：料床厚度的变化，温度波动，或者液压系统的泄漏等等，液压压力和预设的工作压力偏离超过一定范围，比如说5 bar，那么液压油会通过打开的电磁阀从节流阀释放，或者被启动的油泵通过相应的电磁阀钸打入。

伯利休斯水泥 第 26 頁，共 37 頁

1.2.3 Control of finished product conveyance成品输送的控制

Finished material conveyance is initiated by first starting operation of the blowers for the air-slides. Then, operation of the rotary airlock feeders of the bag filter (item 5F1.BF01) is started. There is a zero-speed monitor per rotary airlock feeder supplying a signal in case of failure of a rotary airlock feeder. Finally, the screw conveyors underneath the filter are put into operation. Zero-speed monitoring is also provided for these components.

成品输送由启动气动斜槽的鼓风机开始，然后袋收尘机的转饲机启动激活，每个旋转给料机按有一个零速监测器，旋转给料机不转时给出信号。最后启动袋收尘机下的螺旋输送机，它也按有一个零速监测器。

1.2.4 Control of gas routes (5F1.GP01 to 5F1.GP05) 热风管路的控制

Operation of the mill exit air fan (item 5F1.FN01) is started with closed louvre damper (item 5F1.TVJ01). The fan is provided with a vibration monitor (5F1.FN01.BEA01-T9601). 磨机的排风机在百叶阀处于关闭位时启动。该风机配备一个振动监测器。

Together with the gas route also the cleaning cycle of the bag filter is started provided, however, that finished material conveyance has been successfully put into service.

风机管路启动同时，袋收尘机的清吹循环也开始启动，当然这是在成品输送已成功地投入使用的前提下。

The pressure difference over the filter is monitored and an alarm is released as soon as the maximum admissible limit is exceeded, thus protecting the filter bags from excessive mechanical stress.

袋收尘的压差会被监测，当最大的允许界限值一被超过就会产生一个警报，这样保护 收尘袋不被过量的机械应力破坏。

The gas temperature into the filter is controlled by the fresh air flap, which integral to the bag filter, to protect the filter bags against excessive temperature. The maximum admissible

temperature depends on the filter bag cloth employed. A maximum long-term temperature of approx. 110°C shall be admitted.

进入袋收尘器的废气温度通过组装在袋收尘上的冷风阀控制，以防止过高的气体温度对收尘袋布袋的损坏。最大的允许温度取决于收尘袋的布袋材料，长期运行的最高允许温度大约在110°C。

1.2.5 Control of the hot gas producer (5F1.HG01)热风炉的控制

Hot gas supply to the mill is ensured by a hot gas producer (5F1.HG01) using blast furnace gas and natural gas as fuel. A certain amount of the produced hot gas is taken for heating the recirculating bucket elevator (5F1.BE01) and the feed chute (5F1.CH01) with coarse feed valve (5F1.CV01.CVJ01).

磨机所需的热风由热风炉提供。热风炉采用高炉煤气、天燃气、重油或煤粉为燃料。一部分热风被用来加热循环提升机，粗粉喂料阀和进料料槽。

The gas flame is ignited by means of a gas-electric ignition device. The hot gas producer supplies a constant hot gas temperature of 800 °C. Control of the hot gas volume is by the temperature in the gas route downstream of the mill.

燃料火焰由气-电点火装置点燃。热风炉提供温度恒定约800 °C的热风。热风量的控制取决出磨废气温度。

The combustion chamber is equipped with a flame guard emitting an alarm signal as soon as the flame goes out. Moreover, a pressure monitor is provided to protect from overpressure in the combustion chamber. Thermocouples are located in the refractory lining of the

伯利休斯水泥 第 27 頁，共 37 頁

combustion chamber which signal the temperature increase in case of damage to the lining. 燃烧室装有一个火焰安全保护装置，当火焰一排出燃烧室其就会马上发出警报。此外还装有压力监测器以保证燃烧室中维持正压。热电偶安装在燃烧室的耐火材料内衬中，其在温度上升时会发出一个信号以保护燃烧室不被损坏。

1.2.6 Control of main drive unit of mill (5F1.RM01.DRU01) and of new material

delivery 磨机主传动装置和喂料的控制

Mill feeding is started together with the main drive unit of the mill in a start-up group. This ensures that neither the main drive unit of the mill can be started without material supply to the mill nor material supply can be started without the main drive unit of the mill. Start-up preconditions for the group “main drive unit of mill and new material delivery“ are the signals that finished material conveyance, auxiliaries, gearbox lubrication and gas routes are in op-eration. Moreover, it is necessary to have more material in the mill feed bins than minimum level (e.g. 20%).

磨机喂料和磨机主传动在同一个组中被启动。这确保了在没有物料进入磨机时磨机主传动不会被启动，也使磨机主传动没有被激活时不会有料进入磨机。

1.2.7 Control of water injection (5F1.RM01.WTJ01)喷水的控制

To improve the material bed, water is injected into the raw mill, if necessary. The water pump (item 5F1.RM01.WTJ01-M2001) brings the filtered water to a working pressure of 6 bar, and controlled injection into the mill is via a valve. The water quantity can be controlled from the control panel.

为了改善磨内料床特性，需向磨内物料喷入适量的水。水泵提供经过滤的水，工作压力一般在6 bar, 通过一个调节阀控制磨机内的喷水量。水量可从控制室操作台调节。

1.2.8 Control of grinding pressure碾磨压力的控制

Another possibility to influence the grinding efficiency lies in the possible adjustment of the hydraulic pressure of the grinding tools. When increasing the pressure, pressing of the grinding tools onto the material bed is correspondingly stronger and the grinding effect is improved. But smooth running of the mill decreases with an increasing grinding pressure. The limit of the maximally possible hydraulic pressure is an operation with the grinding tools rolling on the material bed without neither producing strong vibrations nor getting into contact with the grinding table liners.

粉磨效率的另一个影响因素是磨辊的压力调节。当增加压力，磨辊磨盘间施加到料床上的压力变强，碾磨效果被改善。但是当增大压力时磨机运行的稳定性下降。最大可能的液压碾磨压力界限是磨辊压在料床上既不产生强烈的振动，也不会进一步接触到磨盘衬板。

2. Material properties 原料特性

The POLYSIUS Roller Mill RMS is designed to grinding blast furnace slag. The granulated and vitreous slag shows latently hydraulic properties. Decisive for the hydraulic activity are the fractions of reactive calcium oxide, silicium dioxide and aluminium oxide which, in the presence of water, can form calcium silicate hydrates and calcium alumina hydrates capable of hardening.

伯利休斯的RMS辊式磨是被设计用来碾磨高炉矿渣的。颗粒的和玻璃的矿渣显示出潜在的水硬特性。可以确定水硬活性是有少量的活性氧化钙、SiO2和Al2O3，它们在水中会形成CaSi氢氧化物和CaAl氢氧化物，能使其变得坚硬。

Without changing the chemical composition of the blast furnace slag, its properties can be decisively influenced by controlling the cooling-down conditions for the transition from

伯利休斯水泥 第 28 頁，共 37 頁

liquid state to solid state. Abrupt cooling down of the blast furnace slag supplies a highly

vitreous granular material with distinct, latently hydraulic setting strength, which is preferably used for the production of cement. Slowly cooled down blast furnace slag is of crystalline quality after hardening and represents a rock with a pore structure being influence able according to size and quantity. This raw slag is treated in purposive steps to produce

marketable finished products being used for civil engineering works, in particular for road construction and build-ing construction, and mainly taken as admixture for lightweight concrete.

在不改变高炉矿渣的化学组分的情况下，它的特性受其从液态转变为固态时的冷却过程条件的影响，高炉矿渣突然急速冷却会产生高活性的颗粒料，它有着明显的潜在的水硬特性，非常适合用于水泥的生产。慢速冷却的高炉矿渣在硬化后有着晶体特性，并形成受颗粒尺寸和晶体数量影响的毛孔状结构的岩石。这类矿渣按市场的不同需求被制成各种产品出售，用在土建工程上，特别是在道路建设和建筑建设上，主要是作为混合材用于轻质混凝土。

Blast furnace slag is particularly brittle and abrasive. For this reason it is necessary to take special, plant-specific precautions counteracting the high wear rate.

高炉矿渣特别硬而易碎，并且磨蚀性很强。因此要采取特别的、工业实用的抗磨蚀措施。

Before grinding, the moisture content of the blast furnace slag is 7% to 15%, and it therefore quickly forms deposits on walls. To ensure a continuous material flow, it is necessary to pro-vide continuous heating for those parts coming into contact with the moist slag.

在粉磨前高炉矿渣的含水量大约在7% ~15%，因此它容易在触壁上形成结料。为确保顺畅的料流，有必要给接触到湿矿渣的触壁提供连续的加热。

The following table shows a typical chemical composition of a blast furnace slag: 下表所列的是高炉矿渣典型的化学组分：

Chemical components Percentage [%] SiO2 37.98 Al2O3 8.50 TiO2 0.32 Fe2O3 0.60 Mn2O3 0.01 CaO 44.47 MgO 8.62 SO3 (total sulphur) 1.85 P2O5 0.02 Na2O 0.22 K2O 0.35 Cl 0.003 Loss on ignition 1.06 Total 102.94 Silicia ratio 4.03 Alumina ratio 14.46

伯利休斯水泥 第 29 頁，共 37 頁

3. Operation of the grinding plant 粉磨系统的操作 3.1 Philosophy of operation 操作观点

The following requirements must be fulfilled by the plant components as optimally as possible: 以下的要求作为粉磨系统的组成部分，必须尽可能做好： _ Drying of the material to be ground 碾磨物料的干燥

_ Grinding of the necessary fineness 碾磨物料所必须的细度

_ Defined slope factor for product grain size 确定产品颗粒细度级配 _ Safe and troublefree operation 安全且无故障操作

_ Minimisation of expenditure of auxiliary energy 最少的额外能量消耗

_ Elimination of health risks for the operating staff 排除对操作人员的健康隐患 _ Low vibration level of operation 低振动条件下的操作

All these tasks and conditions are fulfilled by observing the operating conditions, by a system of process-technological interlocking and by the installed open-loop and closed-loop control system.

所有这些工作任务、条件的执行和落实，需要熟悉并遵守操作规程，系统的工艺联锁控制以及建立系统的闭环和开环操作控制回路。

The constancy of the differential pressure of the mill, of the static negative pressure in the hot gas duct upstream of the mill and of the circulating mill air temperature ensures that the con-stant gas velocities in the mill, in the separator and in the exhaust gas system are attained as they are important for a stable mill operation and a constant product quality.

稳定的磨机压差，稳定的磨机进口负压，以及稳定的磨机循环风温，是确保稳定的磨内风速、选粉机风速，和废气处理系统风速的重要条件。它们也是磨机稳定操作和产品质量稳定的前提。

The grinding efficiency of roller mills substantially depends on the filling ratio of this mill. It is influenced by the material lying on the grinding table as well as by the material flow circulating between nozzle ring, separator and grinding table. Decisive factors for the grinding efficiency are also the moisture content, the hardness and the grain size of the material to be ground. Taking latter as given values, the filling ratio must be considered as controlled variable serving as manipulated variable for the feed quantity. The measure applied for determining the filling ratio is the differential pressure between mill inlet and mill outlet. 立磨的粉磨效率很大程度上取决于该磨内的物料填充率。它受铺在磨盘上的进料影响，同时也受喷嘴环，选粉机和磨盘间的循环料流影响。决定碾磨效率的重要因素还有物料的含水量、硬度和被碾磨物料的颗粒尺寸。后面给出的数值，填充率作为一个操作变量被看成是由喂料量控制的变量。确定填充率的检测依据是磨机进出口的压差值。

According to the moisture content of the feed material, a certain quantity of hot gas is sup-plied to the grinding plant. Sufficient drying of the material can be assumed at a gas tem-perature of 90 °C downstream of the mill. During operation endeavors are made to keep this temperature constant on a preset level. This is ensured by adjusting accordingly the fuel gas supply to the hot gas producer.

根据进料的含水量，粉磨系统需要一定的热风量。当出磨后气体温度在90 °C时，物料被认为已获得了有效干燥。在操作中要设法保持稳定的出磨废气温度。可以用出口风温调节热风炉的燃气供给量，从而使其一致。

In order to obtain a constant product quality, it is necessary to operate the roller mill with a constant and sufficient gas quantity. Among others, this is ensured by adding the necessary quantity of return gas to the hot gas coming from the hot gas producer. The negative pressure

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upstream of the mill serves as controlled variable for the return gas quantity with the return gas damper as final control element.

为获得稳定的产品质量，有必要在操作磨机时保持稳定和有效的热风量。除了其它措施，也可以加入必要量的循环风量至热风炉出来的热风中实现。磨机前的静压作为循环风量的控制变量，而循环风阀门作为循环风量的最终控制手段。

During operation of the grinding plant it is necessary to find out the optimal solution between efficient grinding, which is reached with a low material bed and high grinding pressures, and a high degree of smooth running.

在粉磨系统的操作中，在料床厚度和碾磨压力，以及平稳运行之间，找出有效碾磨的最佳操作方法。

Some materials are susceptible to overpressing. This means that no grinding progress is to be expected with increasing grinding pressures. Consequently, an identical product quality can be achieved at a lower grinding pressure, and the specific power requirement going down accordingly.

有些料易受过压影响。这意味增加碾磨压力不会对碾磨效率有多大影响。因此，在用较低的碾磨压力达到相同的粉磨质量的话，相应的额定电耗会下降。

The external circuit via the bucket elevator should be used as far as possible because

mechanical material handling requires less energy than pneumatic material handling to the separator. The quantity of the material being recirculated should amount to approx. two times the new material quantity. The quantity of recirculated material can be influenced by the se-lection of the dam ring and the gas velocity in the nozzle ring. A lower gas velocity caused by a larger, free cross section of the nozzle ring results in a higher quantity of recirculated mate-rial.

应尽可能通过提升机增加外循环物料量，因为机械提升物料相对用气力提升物料至选粉机只需较少的能耗。循环物料量应该是磨机喂料量的约两倍。循环物料量受所选择的挡料圈高度和喷嘴环处的气体流速影响。大截面，小阻力的喷嘴环使得通过的风速降，从而导致大的循环物料量。

Another goal to strive for is safe removal of the fine iron particles from the external circuit. If only an insufficient quantity of iron particles is removed, the specific power requirement will go up.

另一个努力争取的目标是安全地从外部循环中除去细铁颗粒。如果铁颗粒去除的不够，则额定能耗会上升。

3.2 Start-up / Shutdown sequence 启动/停机顺序

3.2.1 Start-up sequence 启动顺序

The exact sequence of mill start-up is shown in the process functional diagrams. The listed order comprises the general sequence steps for a start-up procedure.

正确的磨机启动顺序显示在工艺流程内。表中列示的是常规的开机顺序步骤。 Start-up conditionsContinuous Start-up激活 运行状态 conditions继续条件 Start of oil lubrication system for mill None None 1 gearbox 无 无 启动磨机减速机的油循环系统 伯利休斯水泥 第 31 頁，共 37 頁

2 3 Start of auxiliaries: 附件设备启动 _ Hydraulic system of mill磨机液压系统 _ Separator drive unit选粉机传动 _ Coarse feed valve 粗料进料阀 _ Fine iron particle removal 颗粒铁去除 _ Recirculating bucket elevator 外循环提升机 _ Circulating lubrica-tion of grinding roll-ers 磨辊循环润滑油 _ Confining air fans 启动密封风机 Start of product handling 启动成品输送 None 无 None 无 None 无 Silo level < Max/Max库料位小于最大值 4 5 6 7 _ Temperature downstream of mill < Max/Max _Temperature down-磨机后温度小于最streamof mill < Max 大值 磨机后温度小于 _ Temperature 最大值 downstreamof filter _ Group product han-< Max/Max dling works 袋收尘机后温度小Start gas routes 成品输送组工作 于最大值 启动废气处理 _ Group auxiliaries _ Group product works handling works 附件设备组工作 (timer) _ Compressed air sys-成品输送组工作tem> p min (定时) 压缩空气大于最小_ Group auxiliaries p值 works(timer) 附件设备组工作(定时) Group gas routes Group gas routes Start hot gas producerworks works 热风炉起动 废气处理工作 废气处理工作 Heating of grinding plant加热碾磨车间 _ Level slag silo _ Group product > Min/Min handlingworks 矿渣粉库料位大于Start of group mill 成品输送组工作 driveunit and mill feed 最小值 磨机主传动和进料 _ Level gypsum silo _ Group gas routes works 启动 > Min/Min 废气处理工作 石膏库料位大于最_ Material feed in 小值 伯利休斯水泥 第 32 頁，共 37 頁

_ Group product han-operation dlingworks 进料在运转 成品输送组工作 _ Main mill drive _ Group gas routes works works 磨机主传动工作 废气处理工作 _ Group auxiliaries _ Material feed avail- works附件设备组able进料有效 工作 _ Group auxiliaries works附件设备组工作 _ Temperature down-stream of filter > 80°C 袋收尘机后温度大于80°C 8 Hydraulic system of mill set to working Main drive unit worksMain drive unit workspressure 磨机主传动工作 磨机主传动工作 磨机液压系统设定至工作压力

3.2.2 Shutdown sequence 停机顺序

In principle, shutdown of the grinding plant is made in reverse order. For normal shutdown of the roller mill, material feed must first be reduced to approx. 60-70% of the rated throughput. When stopping the material feed, operation of the main drive unit of the mill is stopped si-multaneously.

原则上，粉磨系统的停机顺序是相反的。正常的立磨停机时进料量必须减至大约通过量的60~70%。当停止进料，磨机的主马达装置同步停止。

The detailed shutdown program for normal stopping of operation, including EMERGENCY-OFF is contained in the process functional diagrams.

正常操作时的详细停机程序（包含紧急停）在过程控制功能块流程中介绍。

3.3 Control loops控制回路

伯利休斯水泥 第 33 頁，共 37 頁

The following control loops are provided and described below: 所提供的下述控制回路介绍如下：

3.3.1 Control of differential pressure of mill 磨机压差的控制

The differential pressure of the mill is the best indication for the filling ratio of the mill. For

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this reason it is extremely important to use the differential pressure control from the very beginning of commissioning. After the first operating hours, the differential pressure typical for the respective mill is very quickly reached so that this value can serve as basis for further optimisation.

磨机的压差是磨机内物料填充率的最好指示。因此，从调试开始就采用压差控制是非常重要的。磨机运行几小时后，针对该磨机的进出口压差值特征就显示出来， 它被用作进一步优化的基础。

If the differential pressure is so low that there are still reserves available in the static head of the fan, the set point of the differential pressure controller can be slowly raised, i.e. the feed quantity is slowly increased without changing the grinding force.

如果压差太低，仍有保留可利用的风机静压头，压差设定控制器可以慢慢地提高，在不改变碾磨压力情况下，慢慢地增加进料量。

The limit of the differential pressure has been reached as soon as the following conditions exist: specified static pressure head of the fan has been reached, too much fines pass through the nozzle ring, or the power consumption of the main drive unit exceeds the maxi-mum value.

当存在以下情况时，会出现压差达到极限值：风机的额定静压头已经达到；太多的细粉通过喷嘴环；或者主电机的电耗超过最大值。

In such a case it is necessary to reduce the feed quantity because otherwise the mill will fail as a consequence of overfilling.

在这种情况下必须减少进料量，因为不然会发生填料过载的后果。

The correct value of the differential pressure of the mill having been reached, the mill

throughput should only be varied by changing the grinding force. A reduction of the differen-tial pressure of the mill can be attained either by increasing the grinding force (better grinding result) or by reducing the feed quantity.

正常的磨机进出口压差已达到时，磨机产量只能通过改变碾磨压力来实现。要降低磨机的压差可以通过增加碾磨压力(更好的碾磨结果)或者减少进料量实现。

3.3.2 Control of temperature downstream of mill 磨机出口风温的控制

The purpose of the control is to keep the temperature downstream of the mill constant on a preset setpoint level (approx. 90°C). The manipulated variable is in this case the fuel gas supply to the hot gas producer.

控制的目的是为了保持出磨风温维持在设定值(大约90°C)。此种情况下，热风炉的燃料共给是控制出口温度的操作变量。

A certain quantity of hot gas is required for the combined grinding and drying process ac-cording to the moisture content of the material. Sufficient drying of the material can be con-sidered in the case of a gas temperature of approx. 90°C downstream of the mill. If the tem-perature increases too much, fuel gas supply to the hot gas producer will be throttled until the requested temperature level has been restored. On the other hand, the fuel gas temperature will be increased if the temperature downstream of the mill goes down too much.

根据物料的水份含量，在粉磨和烘干过程中需要一定的热风量。有效的物料干燥可以认为出磨后的气体温度保持在90 °C。如果温度上升太快，供给热风炉的燃气将被节流阀调节减少，直到所需的风温被保持。相反，若出磨后的风温降低太快则燃气增加热风温度会提高。

3.3.3 Control of pressure upstream of mill 磨机入口前静压的控制

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The purpose of the control is to keep the pressure upstream of the mill constant on a preset Set point level. The manipulated variable is in this case the position of the throttle valve in the return gas duct. Generally, a change in pressure is due to temperature control varying the fuel gas supply to the hot gas producer, with the consequence of a different hot gas volume being produced.

控制的目的是保持入磨前的风压稳定在一定的设定值。在这个控制回路中操作的变量是在循环风管的节流阀阀板的位置。通常，压力的变化是由于温度的控制改变了供给热风炉的燃气量，是改变了入磨的热风量的结果。

However, to ensure a uniform product quality, it is indispensable to operate the roller mill with a constant gas volume. This is achieved with a compensation of the varying hot gas volume by a corresponding return gas volume.

然而，为了保证稳定的产品质量，磨机在稳定的风量条件下操作是必不可少的。这可以通过用相应的循环风量补偿系统热风量达到系统的风量平衡。

3.4 Operation under extraordinary conditions 特别情况下的操作

3.4.1 Start-up of plant 系统启动

The start-up sequence of the individual components was already described under “3.2.1 Start-up sequence“. Generally, the philosophy applies to put the various control loops as early as possible in the automatic mode, in order to simplify the operator’s work and to save his attention for more important things.

单个设备的启动顺序已经在“3.2.1启动顺序”中介绍过了。一般来说，各个自动控制回路在自动模式下要尽可能的早投入使用， 此是为了简化操作者的工作使其更注意重要的事。

The raw material transport, the auxiliaries of the roller mill and the gas routes being in opera-tion, the mill must first be heated. To avoid mechanical damage, the temperature for heating up the mill must be limited to 250 °C at the roller mill inlet. Moreover, heating up should be made slowly. The heating up period is over as soon as a temperature of approx. 120 °C ex-ists downstream of the mill.

在系统操作中，喂料输送、立磨的附件设备及废气处理管道先被加热。为避免设备机械损坏，在立磨磨机进口加热磨机的温度限制值为250 °C。而且加热应缓慢进行。在加热期间磨机出口存在大约120 °C的温度。

Before starting the drive unit of the grinding table, the hydraulic system of the mill is set to 50 - 60 bar and the feed to 60 – 70% of the rated throughput. After starting the material feed, the mill fan is immediately accelerated to approx. ca. 80 – 85% of the rated speed.

在启动磨盘的驱动装置时，磨机液压系统设定至50- 60 bar和料通过量的60 – 70%的进料量。在启动喂料后，磨机风机立即加速至大约80 – 85%的速率。

Then, the operator must manually adjust the return air flap and the hot gas flap in order to ensure a sufficient negative pressure level upstream of the mill. But the pressure down-stream of the mill must not fall below 80 °C. Appro x. 1 minute after starting operation of the main drive unit, the working pressure is built up in the hydraulic system.

然后，操作者必须主要调整循环风阀门和热风阀门以确保磨机前有效的静压值。但是出磨后的风温必须不低于80 °C。在主马达启动后大约..1分钟，液压系统建立起了工作压力。

Mill operation being stable, operation of the controllers is started and the feed quantity in-

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creased in steps.

磨机的操作应保持稳定，控制（回路）器的操作投入使用，一步一步增加进料量。

3.4.2 Shutdown of plant 系统的停机

For a normal shutdown of the roller mill, the material feed is reduced in steps to approx. 60 -70% of the rated throughput. The return air flap and the hot gas flap must be adjusted ac-cordingly in order to avoid that the temperature downstream of the mill increases too much. 立磨正常停机时，进料量应逐步减至通过料量的大约60 -70%。循环风阀门和热风阀门应同时调整以避免出磨后风温增加的太快。

At the same time of interrupting material feed, operation of the main drive unit is stopped. Then, the speed of the mill fan must immediately be reduced to approx. 20%. Moreover, the hot gas flap must be closed as quickly as possible. The return air flap must be adjusted so that no overpressure is produced upstream of the mill.

中断进料的的同时，主马达停止。然后，磨机风机的转速必须降至20%。而热风风阀必须尽可能的迅速关闭。循环风阀门必须调整至入磨风无正压。

3.4.3 Operation with insufficient material quantity 不足料量的操作

If the mill is operated with an insufficient material quantity, the following displays in the con-trol panel inform accordingly:

如果磨机操作在不足料量的情况下，在控制台会出现以下相应的显示：

Displays: 显示

_ Stronger vibrations occur on the mill drive unit because, due to insufficient material feed, the material bed considerably decreases and the grinding rollers partly contact the table liners. Mill operation is stopped at a vibration level of more than 8 – 10 mm/s.

主马达传动装置上会有强烈的振动，由于不足的喂料量，料床会相应减少并且辊轮会部分的接触磨盘衬板。在振动值超过8 – 10 mm/s时磨机操作会被停止。

_ Decrease of the differential pressure of the mill is displayed in the control panel room. If the mill is operated with a differential pressure controller, the controller will automatically increase the material feed.

磨机压差的降低显示在中控室内。如果磨机操作是由压差控制器控制，则控制器会自动增加进料量。

Possible causes:可能的原因

_ Material feed insufficient or disturbed 进料量不足或者波动 _ Better grindability of the material feed 进料有更好的易磨性

_ Reduced number of material circuits inside the mill due to separator adjustment (towards coarser finished product) 由于选粉机的调整，磨机内料循环的次数减少(产品变粗)

3.4.4 Overfilling of mill 磨机过量进料

In case of overfilling of the mill, the displays inform as follows: 若发生磨机过量进料，会有如下之显示：

_ Strong vibrations occur on the mill drive unit because the higher material bed can produce a super proportional increase of the material bed depth which entails a higher rolling resistance of the grinding rollers. This also raises the specific energy consumption for the grinding process.

主马达传动装置上会有强烈的振动是由料床增厚磨内料量增加而引起。增加的料床高度需要更高的碾磨阻力。这也增加了碾磨过程的额定电耗。

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_ Significant increase of mill differential pressure. 磨机压差的显著增加。

_ Power consumption (kW) of the main drive unit of the mill considerably increases as a consequence of the higher rolling resistance. 主传动装置的电耗由于更高的碾磨阻力而增加。

Possible causes:可能的原因

_ Material feed is excessive. 过度的进料

_ Grinding force is insufficient. 碾磨压力不足

_ Discharge of ground material is not correct. 排出的碾磨料不好 _ Nozzle ring is blocked. 喷嘴环堵塞

_ Decrease of gas volume passing the mill. 通过磨机的气体量减少

_ Increased number of material circuits inside the mill by separator adjustment (towards finer finished product). 由于选粉机的调整，磨机内料循环的次数增加(产品更细)

3.5.5 Significant decrease of mill exit gas temperature

磨机存在的气体温度显著地降低

The causes for a decrease of the mill exit gas temperature can be as follows: 磨机存在的气体温度降低的原因如下：

_ Feed quantity for the coal mill is excessive. 煤磨喂料过多

_ Decrease of exhaust gas temperature of the heat exchanger or reduction of the hot gas quantity supplied by the heat exchanger.热风炉的热风温度降低或者热风炉提供的热风量减少。

_ Reduction of the hot gas quantity supplied to the mill due to increase of mill differential pressure (filling ratio) or of filter differential pressure.提供给磨机的热风量由于磨机压差增加(磨内填充料增加)而减少，或者收尘机的压差增高而使磨机的压差降低。 _ Considerably higher moisture content of the feed material.进料的含水量相当高 _ Heating-up of the plant was made too quickly.系统加热过快

_ Mill operation started at insufficient temperature downstream of the mill.磨机在出磨风温不足的情况下启动磨机。

If the controller “gas temperature downstream of mill” is unable to set the requested tem-perature level, the operator shall reduce the material feed quantity in order to ensure a sat-isfactory grinding and drying process.

如果控制回路控制器调节“出磨风温”不能达到设定的温度值，控制器会降低进料量以保证合适的粉磨和干燥过程。

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