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Operation Manual for Natural Gypsum Powder Boiling Kiln with Heat-conducting Oil
.Usage of equipment
The boiling kiln, an equipment for calcining gypsum powder, is mainly applied to calcine natural dihydrate gypsum powder into semi-hydrated gypsum. It is a kind of high-efficiency special equipment with adoption of fluid calcining technology.
.Technical specifications&performance parameters of equipment
1.The technical specifications are calculated according to the user's Requirements.
2. Hourly capacity of equipment.
3. The power, flow, air pressure, etc depend on Roots blower according to the yearly capacity.
4. Heat conducting oil furnace produces oil of certain kcal according to yearly capacity, the boiling point of heat-conducting oil is above 320 ºC.
.Working principles&structures of equipment
1.The body of boiling kiln, composed of main part and minor part, is a rectangular container, connected with air blowing box by grid plate at the bottom. In the body, there are heat conductive oil ducts, whose quantity depends on the yearly capacity. These ducts form the main rectangular body.
2.There is a draught distrubiting box connecting with the furnace at the top of the furnace body.
3.The body is full of gypsum powder and the air is blowed into it through the grid plate at the kiln bottom, to make powder fluidized.
4.The heat-conducting oil ducts transform heat to the powder.When the temperature in the kiln is up to 150ºC-170ºC, natural gypsum powder is changed into semi-hydrated gypsum powder after fast dehydration and then overflow from the top of minor fluidized bed.
5.The material is heated and dehydrated in the body. The water vapour produced in dehydration is vented through the dedusting tank connecting with draught distributing box. The vapour contains a small quantity of gypsum powder, which falls into the body according to the high-pressure electrostatic principle, while the water vapour leaves.
6.The boiling kiln is a continuous-production equipment and the whole bed is in dynamic equilibrium of material and heat.
7.The increasing of material and the temperature in the kiln body affect directly the quality of semi-hydrated gypsum powder. Therefore, it should be controlled strictly through experiences.
.Requirements of equipment installation, commissioning & operation
1.Equipment installation
1.1 The load of equipment depends on the yearly capacity, a separate upright should be set up.
1.2 The equipment upright should be made of angle steel or concrete according to the yearly capacity.
1.3 Asbestos cord should be used in connection of the whole body. Stop valves should be equipped to oil supply system to control oil supply. At the upper part of heat conducting oil furnace, vent valve should be equipped to vent air; at the lower part of furnace, oil draining cock should be equipped.
1.4 After installing bleeder valve and discharging valve, insultation layer should be installed.
2. Equipment commissioning
2.1 Correct the platform of equipment upright to ensure the equipment and Roots blower in a flat position.
2.2 There should be no leak in oil inlet and outlet of kiln, material inlet and oveerflow port, and so on.
3. Equipment operation
3.1 The temperature of heat-conducting oil should be up to production requirement. Roots blower and heat exchanger are in normal state.
3.2 Material inlet and overflow port operate normally.
3.3 Dedusting equipments operate normally. Make sure whether it is safe around electrostatic precipitator transformer.
.Operating rules of equipment
1. Inspection before starting equipment
1.1 Check Roots blower to make sure that there is nothing wrong with its fastening piece, filter cleaner and muffle. Turn on blower to make sure its operation direction is right.
1.2 Check to make sure that operation directions of bucket elevators for raw meal and calcined gypsum powder and also FU conveyor are right.
1.3 Check if the circulation of heat supply valve and temperature instrument is in normal place.
1.4 Check if vibrating device in electrostatic precipitator is in conformity with the operation requirements.
2. Procedures of starting equipment
2.1 Turn on Roots blower when the temperature in the kiln is up to the requirement. Turn on dust-precipitator when blower operates normally.
2.2 Turn on bucket elevator for raw meal and electronic scale and feed material progressively.
2.3 Increase temperature in the kiln and feed material properly to reach the capacity of kiln.
2.4 Turn on bucket elevator for calcined gypsum powder and FU conveyor when the powder flows from overflow duct. Inform people in laboratory to take sample and do labaratory test to make sure the quality is up to grade.
3. Normal inspection
3.1 There is nothing wrong with equipment. The lubrication and bearing temperature is normal. There should be no offtrack, drop or leak.
3.2 There is nothing unusual with all the control parameters. The feeding and discharging of material is in good order.
3.3 There is nothing wrong with air venting device and vibrating device in dust-precipitator. There is no dust emission. The feeding of silo is in normal state.
4. Procedures of normal stopping of kiln
4.1 Turn off raw meal valve, and stop the elevator for raw meal after raw meal is conveyed.
4.2 Inform the furnace room to keep cooling circulation pump working on.
4.3 Stop Roots blower when no powder flows from the overflow duct(about half an hour).
4.4 Open dumping valve, and stop elevator for calcined powder after finishing dumping. At the same time, turn on and off Roots blower discontinously.
4.5 Stop FU conveyor and electrostatic precipitator.
5. Cleaning of kiln
After stopping for a long time, open grid plate and clean the obstruent on the plate and the powder on oil duct. Replace them after cleaning. Clean once a month usually.
6. Treatment of urgent stopping kiln
6.1 If stopping kiln for a day, it is enough to dump material normally, and cleaning is not necessary.
6.2 If there is something wrong in the process of production, stop material feeding and cooling. It is not necessary to stop Roots blower. Increase the temperature and feed material after clearing of fault. Pay attention to the flowing of overflow duct to prevent the powder from condensing.
6.3 If electricity is off suddenly, turn off the power supply of all equipments. If the electricity is off for three to five hours, try starting the equipment according to the procedures. If the temperature of kiln is abnormal and material discharging is also abnormal, it can be concluded that the fluidized powder is condensed in the kiln. Start production again after stopping and cleaning the kiln.
6.4 If the electricity is off for more than 8 hours, empty the kiln urgently by experiences and deal with it well, and then start the equipments to begin production.
.Inspection of products
1.In order to test the quality of products, do a sample test first and take samples every one hour.
2.Gypsum Powder(Building Plaster): Crystal water is in conformity with Chinese national standard GB/T176692-1999, and there is also a test procedure. In general, crystal water content is 3% to 5%.
3.Time for condesation: if there is a need, generally, first condensation is about 3 to 6 minutes and last condensation is 6 to 12 minutes. There is also a procedure for test.
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