锌挥发回转窑|锌冶炼回转窑工作原理就是煅烧锌、处理含锌物的整个过程和原理。一般多采用氧化锌回转窑处理含锌的滤饼。滤饼中的锌主要以铁酸锌、氧化物和硫酸盐形态存在，在氧化锌回转窑的高温下，铁酸锌和固体碳作用，还原为金属锌，同时锌、铅、镉的硫酸盐也被还原，井以硫化物和金屈形态挥发出来。从固相中还原和挥发出来的金属，在窑气氛作用下，又重新氧化，最后主要以氧化物形态产出。

锌挥发回转窑红外解决方案：

HIRDA-NK-A系列内窥式气动超高温红外热成像温度检测与分析系统，为锌挥发回转窑温度监控，提供了一整套全面的解决方案。

安装图：

HIRDA-NK-A系列内窥式气动超高温红外热成像温度检测与分析系统由红外热成像机芯、耐高温红外热成像镜头、自动回缩保护装置、炉壁安装套件、空气过滤系统和现场设备箱、算法服务器以及智能测温软件等组成。

将耐高温红外热成像镜头安装在能够伸缩的金属防护罩中，通过伸缩装置将耐高温红外热成像镜头直接伸入至窑炉内（1600℃以下），红外热成像机芯停留在炉外，实现对窑内运行工作状态的连续实时监视。

通过压缩的冷却空气或冷却水，对护罩进行冷却，使红外镜头工作在较适宜的温度；同时对镜头进行吹扫，防止炉内灰尘附着在镜头保护窗口上；系统内置高温保护电路，一旦冷却气体或冷却水发生循环异常，即回缩镜头，防止被窑内高温损伤。

具有耐高温、耐腐蚀、免维护的特点，能够实时显示窑炉内部各种复杂的工况，在摄像探头吹扫压缩空气正常的情况下，适用于各种正压窑炉。

系统特点：

• 具备全天候被动红外测温功能
• 采用自研测温校正算法，实现精确温度测量
• 支持onvif协议，可接入主流NVR；
• 不依赖系统平台，可直接网页登录ip进行访问图像和配置，可直接输出报警信号到PLC或者报警器；
• 伸缩长度可定制，适合各种壁厚的窑炉
• 螺旋风幕设计，镜头不积灰
• 整体不锈钢材料，耐腐耐温
• 直视型内窥镜头
• 自动退出保护装置, 退出故障指示
• 气动传动机构
• 耐高温光学针孔镜头，带防尘高温镜片
• 超温、欠压、停电自动退出炉膛

铝灰(渣)在潮湿的空气中易发生反应生成氨气、甲烷、氢气等有毒、有害、易爆气体，是一种需要及时处理的危险固体废弃物。铝灰中含有铝单质、氧化铝、碳化铝、硅、氟化物、氯化物等成分。其中，氧化铝占70%以上，具有较高的回收利用价值。铝灰回转窑工艺流程处置二次铝灰主要是由高温煅烧，使铝灰和石灰石高温发生反应，生成铝酸钙。温度控制对于生产具有非常重要的作用。

HIRDA-NK-A系列内窥式气动超高温红外热成像温度检测与分析系统，为铝灰回转窑温度监控，提供了一整套全面的解决方案。

系统简介：

HIRDA-NK-A系列内窥式气动超高温红外热成像温度检测与分析系统由红外热成像机芯、耐高温红外热成像镜头、自动回缩保护装置、炉壁安装套件、空气过滤系统和现场设备箱、算法服务器以及智能测温软件等组成。

安装图：

将耐高温红外热成像镜头安装在能够伸缩的金属防护罩中，通过伸缩装置将耐高温红外热成像镜头直接伸入至窑炉内（1600℃以下），红外热成像机芯停留在炉外，实现对窑内运行工作状态的连续实时监视。

通过压缩的冷却空气或冷却水，对护罩进行冷却，使红外镜头工作在较适宜的温度；同时对镜头进行吹扫，防止炉内灰尘附着在镜头保护窗口上；系统内置高温保护电路，一旦冷却气体或冷却水发生循环异常，即回缩镜头，防止被窑内高温损伤。

具有耐高温、耐腐蚀、免维护的特点，能够实时显示窑炉内部各种复杂的工况，在摄像探头吹扫压缩空气正常的情况下，适用于各种正压窑炉。

系统特点：

• 具备全天候被动红外测温功能
• 采用自研测温校正算法，实现精确温度测量
• 支持onvif协议，可接入主流NVR；
• 不依赖系统平台，可直接网页登录ip进行访问图像和配置，可直接输出报警信号到PLC或者报警器；
• 伸缩长度可定制，适合各种壁厚的窑炉
• 螺旋风幕设计，镜头不积灰
• 整体不锈钢材料，耐腐耐温
• 直视型内窥镜头
• 自动退出保护装置, 退出故障指示
• 气动传动机构
• 耐高温光学针孔镜头，带防尘高温镜片
• 超温、欠压、停电自动退出炉膛

窑在旋转过程中的可能发生弯曲和扭转会损坏耐火材料，必须进行修复，修复过程涉及耐火材料的浇注。否则，在定期维护期间需要更换耐火材料。

在某些场景，可以根据窑的外表面温度来确定内部耐火材料的厚度。这其中涉及许多未知因素，包括表面发射率、传热变化、材料温差和燃烧器火焰影响。估算衬里厚度时必须考虑这些因素。

HJK-FBTS-XC在线式防爆红外热成像监控系统通过卓越的性能提供准确的温度数据，为了衬里耐火材料厚度的计算助力。

HJK-FBTS-XC在线式防爆红外热成像监控系统功能特性：

1. 采用非制冷焦平面探测器、高性能红外镜头、型号处理电路、并嵌入先进的图像处理算法，具备功耗低、启动快速、成像质量优异、测温精准等特点；
2. It has all-weather passive thermal imaging function, has strong smoke penetration performance, and can be used in a wide range of ambient temperatures;
3. Adopt self-developed temperature measurement correction algorithm to realize accurate temperature measurement;
4. 防护罩采用耐高温合金材料制成，具有耐腐蚀、耐高温性能。窥孔直径2mm，在冷却介质及风吹扫后，在耐高温、防粉尘等性能方面更为优良，大大提高使用寿命。
5. 在镜头前采用多道风屏，既可以起到降温的作用，更重要的作用是挡去了窑内的飞砂、熔融物等，使镜头不受污染和侵蚀，保持图象永久清晰。
6. 对压缩空气采用空气净化器，始终保持镜头无污，保证图像清晰。
7. 具有断水、断气、断电、温度高自动退出功能。
8. 全自动进入功能，气压压力、水流量、高于设定值，温度低于设定值，探头自动伸进窑炉监测炉内情况。

西南国有大型钢厂石灰窑红外与视频监控项目。

之前工人是通过手拿面罩的方式在观察孔看窑内熟料情况，此方法有安全隐患且人工强度大，业主想通过7*24小时不间断的方式监测窑内情况，并且把所获取的温度数据和数字化系统对接。

窑侧视图

项目存在的问题

1、业主每8个月要大修，炉膛成像装置不能进入太深，以免维修的时候不好开门；

2、大修的时候周边会有小车还有耐火砖，可以选择安装的地方不多；

3、气管支撑架在进出的炉口，会妨碍人员流动；

4、人员通过观察孔观看，全凭经验，无法准确获得窑内的温度；

5、数据不好记录和上传。

远景图

Programme

通过在窑头罩右侧布置两台炉膛成像装置，装置进入深度不超过20cm，在氮气源下方安装接线箱把气源接入进来，从平台下方打孔，用波纹管从下方穿入再从另外一头穿出接入炉膛成像装置，通过7*24小时不间断的检测输出高清视频和红外视频到中控室。

安装位置侧视图

气源

方案特点

1、一体化方案：无需配置任何其他设备即可使用；

2、退出保护装置：在高温或者断气的情况下退出保护炉膛成像装置里面的设备；

3、大视场角镜头：在插入不深的情况下可以看清楚窑内情况；

4、网络机芯：压缩数据或者全码流可以传输给业主系统。

炉膛成像系统安装点

应用系统

在线式防爆红外热成像监控系统HJK-FBTS-XC

回转窑窑内视频监控HJK-FBTS-PG

带来的价值

7*24小时检测，将温度数据传至现场人员，有利于去判断石灰熟料烧成情况，将数据传至业主的数据化大平台，做到数据可以追源、记录、后期分析。

红外图

中控室

国有大型钢企在西南的特殊金属制品生产基地2个回转窑的测温。该回转窑平台上面已经部署了结圈料机器人，但是滚筒时常会有大的结圈料掉落砸到机器人或者压着机器人破碎杵使机器人无法正常工作，因此需要有一套预警系统给机器人提示，当大的结圈料到来时，提前3S发报警信号给到机器人。另外机器人在结圈料堆积的时候没有对应坐标提示导致无法精准破碎。

部分识别区域示意图

2号窑红外视频

项目存在的问题：

1、结圈料掉落砸到机器人或者压着机器人无法工作；

2、没有对应的结圈料坐标给到机器人去打结圈料。

现场人工捣结圈料工具

具体方案：

通过在窑头罩正门布置红外热成像系统，红外捕捉物体热辐射，形成高清图片，提取坐标信息，指导机器人作业。同时在侧面安装炉膛热成像系统，该系统选取大视场角的镜头，可以覆盖滚筒4点到7点的方向以及结圈料掉落区域，通过特有的结圈料识别算法，在料还没到滚筒边缘时，就开始识别，识别成功后发出报警信号，让机器人手臂先退出窑内部。

1号窑正面相机位置

2号窑正面相机位置

侧面安装位置

方案特点：

一体化方案：无需配置任何其他设备即可使用；

退出保护装置：在高温或者断气的情况下退出，保护炉膛成像装置里面的设备；

大视场角镜头：在装置插入不深的情况下可以看清楚窑内情况；

网络机芯：压缩数据或者全码流可以传输给业主系统；

精准算法：结圈料来料报警以及结圈料空间位置坐标输出。

应用系统：

在线式防爆红外热成像监控系统HJK-FBTS-XC

带来的价值:

此两套系统能有效的保护机器人，同时提高破碎作业效率。

现场安装图

Heat treatment is the most effective method to treat hazardous waste, and rotary kiln is the most effective equipment in hazardous waste treatment. The external surface temperature of the rotary kiln barrel is an important process parameter for the design and operation of the rotary kiln. The design of the external surface temperature of the rotary kiln barrel is too high, which is not conducive to the on-site operation of personnel and the improvement of the thermal efficiency in the kiln; The design of the outer surface temperature of the rotary kiln shell is too low. On the one hand, it increases the investment and operation cost. On the other hand, the acidic substances (sulfur dioxide, hydrogen chloride, etc.) in the flue gas generated by the incineration of hazardous waste mix with water vapor to corrode the refractory bricks and shell. The on-line infrared thermal imaging temperature measurement system can continuously monitor, analyze and predict the surface temperature of the rotary kiln shell in the metallurgical non-ferrous industry, prevent the damage of the kiln lining and kiln shell due to overburning and other reasons, and improve the production efficiency. Based on the on-line infrared thermal imaging temperature measurement monitoring system, this paper collects and analyzes the production process data. The results show that the on-line infrared thermal imaging temperature measurement monitoring system can ensure the real-time and long-term temperature measurement of the shell surface of the rotary kiln (RK), and monitor the establishment and operation of the kiln skin.

1.Application of infrared thermography temperature measurement to rotary kiln operation

1 . 1. Ensure the real-time and long-term temperature measurement of the shell surface of the rotary kiln

At present, the instrument commonly used to measure the outer surface temperature of the hazardous waste incineration rotary kiln is a hand-held portable infrared thermometer. This instrument is inspected manually on site, and the cost is low, but it is too dependent on manpower to measure comprehensively and timely. The on-line infrared thermal imaging temperature measurement monitoring system has the advantages of friendly interface, efficient data acquisition, permanent data storage, and diversified functions. As shown in Figure 1 to figure 4.

Figure 1 Interface of online infrared thermal imaging system

Figure 2 Sectional and regional picture of rotary kiln online infrared thermal imaging

Figure 3 Temperature curve screen of real-time monitoring of a certain area

Figure 4 Temperature picture of rotary kiln after one revolution

1.2 Establishment of monitoring kiln skin

Most of the main facilities for incineration and disposal of industrial hazardous wastes draw on and adopt the rotary kiln equipment in the cement industry, which is very mature. At the same time, it also adopts its kiln skin hanging technology. In order to prolong the service life and operation cycle of refractory bricks and reduce the operation cost, it is necessary to add a solid protective layer on its surface, that is, to cover a layer of "kiln skin" on the brick surface, so as to prolong the service life and operation cycle of refractory bricks and reduce the operation cost. However, the establishment and operation of kiln skin rely on the on-site personnel to judge whether the kiln skin is established through the kiln tail mirror and the kiln tail temperature, and there is no quantifiable standard. Using infrared thermal imaging temperature measurement technology to monitor the surface temperature change of the rotary kiln shell has reference value for monitoring the establishment and operation of the rotary kiln skin.

Figure 5 Infrared temperature measurement curve of rotary kiln shell surface when establishing kiln skin

The establishment of rotary kiln should comprehensively consider the specific gravity, water content, pH value and other parameters of materials entering the kiln. Figure 5 shows the infrared temperature measurement curve of the outer surface of the rotary kiln shell when establishing the kiln skin. 11 groups of data are collected according to the time of establishing the kiln skin. The order of the first to eighth sections in Figure 5 is based on the segmentation principle from the kiln head to the kiln tail. The establishment of kiln skin mainly goes through the process of heating, melting and cooling. As can be seen from Figure 5, curves a, B, C and D are the temperature rise curves of the outer surface of the rotary kiln shell when establishing the kiln skin. In this process, the materials required for the establishment of kiln skin enter the rotary kiln evenly, and the injection of auxiliary fuel oil provides sufficient heat for combustion to continuously melt the materials. The melting of materials into kiln skin can be observed through the kiln tail mirror; Curve e is the curve of the highest point of the outer surface temperature of the rotary kiln shell when the kiln skin is established, and the highest section is the fourth section (293.2 ℃). At this time, the materials required for the establishment of the kiln skin have stopped entering the rotary kiln; Curves F, G, h, I, J and K are the cooling curve of the outer surface temperature of the rotary kiln shell when the kiln skin is established. In this process, the consumption of auxiliary fuel is reduced until the kiln skin is formed. At this time, the kiln skin can be observed through the mirror. The eighth section is the kiln tail. Because the kiln tail is equipped with the kiln tail cooling fan and is the material burnout area, the shell surface temperature is the lowest.

Figure 6 Infrared temperature measurement curve of the shell surface of rotary kiln without feeding and when feeding

The kiln skin has a protective effect on the rotary kiln shell and refractory materials. Figure 6 shows the infrared temperature measurement curve of the outer surface of the rotary kiln shell when it is not fed and when it is fed. It can be seen from Figure 6 that after the kiln skin is built, the highest section of the outer surface temperature of the rotary kiln shell when it is not fed is the fourth section (206.1 ℃), and the lowest section is the eighth section (154.8 ℃); After the kiln skin is built, the highest section of the shell surface temperature of the rotary kiln during feeding is the fourth section (202.9 ℃) and it is a peak. It is speculated that the fourth section is the best combustion section of the material, and the lowest temperature section is the eighth section (149.5 ℃). The eighth section is the kiln tail. The reason for the low surface temperature of the barrel is that the kiln tail is equipped with a kiln tail cooling fan. In addition, the kiln tail is the material burnout area, and the surface temperature of the barrel is low.

1.3 Monitor the operation of kiln skin

Generally, the thinning of kiln skin is judged by operation time and manual observation through the rear-view mirror at the end of the kiln, but this method is only empirical judgment, which has limitations for production personnel. By accumulating the infrared thermography temperature measurement data of the outer surface of the rotary kiln shell, a method to judge the thinning of the kiln skin can be provided. Figure 7 shows the infrared temperature measurement curve of the shell surface during the normal operation of the rotary kiln after the kiln skin is established. It can be seen from Figure 7 that curve A is the infrared thermal imaging temperature measurement curve of the shell surface of the rotary kiln in normal operation after the kiln skin has just been built. The highest segment is the fourth segment (214.0 ℃), and the lowest temperature segment is the eighth segment (150.6 ℃). Curves B to G are the infrared thermal imaging temperature measurement curves of the shell surface within 20 days of the operation of the kiln skin. From curves B to g, it can be seen that with the increase of the operation time of the kiln skin, the temperature of each section of the shell surface of the rotary kiln shows an upward trend, indicating that the thickness of the kiln skin is gradually thinning with the increase of the operation time. The highest section of curve h is the fourth section (292.1 ℃), which is not much different from the maximum temperature of the fourth section (293.2 ℃) when the kiln skin is established; The lowest temperature section is the eighth section (196.6 ℃), which indicates that the kiln skin has disappeared and needs to be rebuilt.

Figure 7 Infrared temperature measurement curve of cylinder surface during operation of rotary kiln

2.Summary

This paper introduces the real-time and long-term characteristics of on-line infrared thermography temperature measurement, and analyzes the relationship between the establishment and operation of the kiln shell and the surface temperature curve of the rotary kiln. The results show that in the process of establishing the kiln shell, the surface temperature curve of the kiln shell increases first and then decreases; During the operation of the kiln skin, the temperature curve of the shell surface changes to a gradually decreasing trend. The kiln skin has a protective effect on the rotary kiln shell and refractory materials, so the relationship between the external temperature curve of the rotary kiln shell and the establishment and operation of the kiln skin is worthy of further study.

Based on the real-time and long-term nature of on-line infrared thermal imaging temperature measurement, the on-line infrared thermal imaging temperature measurement system can also be used to monitor and analyze the corrosion and thinning of the rotary kiln barrel or refractory bricks, and monitor the combustion conditions of the rotary kiln incinerated materials.

Applicable Machine