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

Current situation and demand analysis of rotary kiln

As the core facility in the cement production process, the combustion temperature in the kiln and the outer wall temperature of the barrel are very important to the product quality and production safety. Through on-site investigation and communication, the existing risks are as follows:

• The firing temperature in the rotary kiln directly affects whether the reaction is complete and effective. The reaction temperature is too low, the clinker quality is poor, the rotary kiln is forced to slow down, and the unit heat consumption increases.
• The firing temperature of dense rotary kiln is too high, which is easy to burn out the kiln lining materials and affect the long-term safe operation of the kiln.
• Because the clinker is easy to agglomerate, it is very easy to cause ring formation, and the ring is stacked at the tail, which affects the product quality, so that the kiln needs to be stopped for coke removal, which affects the reliability of equipment operation.
• The internal refractory materials gradually erode and fall off, and the steel plate will be directly exposed to the high temperature environment, softening and even melting corrosion, which will seriously threaten the production safety and cause unplanned kiln shutdown or accident.
• When the fuel is burned in the rotary kiln, due to the structural characteristics of the rotary kiln, it is impossible to take direct means to measure the internal temperature distribution, and it is impossible to judge the location of the combustion center and the internal temperature condition, which will cause insufficient combustion or excessive combustion.

In order to ensure the safe and efficient operation of the rotary kiln, an effective online temperature monitoring system is urgently needed for the areas inside and outside the rotary kiln, so as to improve the safety of the production process and the ability of risk early warning. The monitoring system shall meet the following requirements:

• Carry out non-contact temperature measurement, and comprehensively and accurately monitor the temperature at the kiln head and outside the kiln, so that the normal operation of the kiln will not be affected during the operation of the equipment.
• High stability and applicability: the monitoring equipment in the kiln can work stably under high temperature conditions, and the temperature measurement range covers the normal and abnormal temperatures in the kiln. The monitoring equipment outside the kiln can monitor the whole rotary kiln barrel;
• Risk warning and high temperature alarm: it can realize rapid alarm for high-temperature objects;
• Data storage: it can trigger video storage in the whole process or alarm, and can query and playback previous historical images;
• The power supply ensures the uninterrupted power supply of the system in an all-weather environment.

Characteristics of infrared monitoring system for rotary kiln

1. High performance infrared thermal imager

For the high temperature environment in the kiln, the temperature measurement range of the thermal imager is up to 1600 ℃; The thermal imager outside the kiln has large field angle and wide coverage, which meets the needs of cylinder monitoring

2. Collect temperature flow around the clock

The collected full radiation infrared image stream is connected to the central control room all day, and the temperature distribution, the highest temperature, the lowest temperature and the average temperature in each area of the rotary kiln are checked in the real-time picture

3. Five abnormal temperature alarms

You can customize the alarms of overtemperature, high temperature range, temperature, temperature range and outside the temperature range. Five types of alarms are pushed by wechat or SMS, and the alarms are timely sent to the relevant person in charge for action

4. Draw the temperature change curve in real time

Draw the temperature change curve of the rotary kiln in real time, and display the trend diagram of the highest temperature change at each position of the cross section and longitudinal section of the outer wall, so as to provide a reference for analyzing the position and state of internal coking or refractory mud falling off

5. Record the temperature distribution of kiln wall tiling

The system can record the temperature distribution after the expansion of the outer surface of the kiln wall every week, and display the maximum and minimum temperature values in different areas in this week

6. The rotary kiln distance identification point can be set

Different distance identification points of the rotary kiln can be set in the picture to indicate the actual position of the area on the rotary kiln, so that the observer can better identify the abnormal temperature points

7. Automatically generate the highest temperature curve

Automatically generate the highest temperature change curve of the region 'to guide the adjustment of the position of the combustion Center

8. User permissions can be set

In order to facilitate user management, the system can set the permissions of different personnel

9. Automatic reconnection after failure

System self inspection, automatic reconnection after failure, support remote fault handling, and ensure stable and reliable operation of the system

Inner wall monitoring function

Video display is mainly used, including burner flame shape monitoring, regional temperature extreme value display, pellet movement track monitoring in the kiln, ring position and shape display, and corrosion resistance display. The temperature at any point in the picture can be obtained through the mouse, and the monitoring video can also be recorded.

Outer wall monitoring function

The monitoring function of the outer wall of the rotary kiln includes the distance marking function of the outer wall of the rotary kiln, the temperature of any point in the picture can be obtained through the mouse, and the monitoring video can also be recorded.

Outer wall data analysis function

In order to facilitate users to have an intuitive understanding of the temperature of the whole kiln barrel, huajingkang has exclusively developed the all-weather three-dimensional continuous monitoring technology of the outer wall temperature of the rotary kiln.

The infrared continuous three-dimensional measurement technology of the surface temperature of the outer wall of the rotary kiln combines the positioning technology of the temperature measuring point of the kiln body, the system temperature compensation technology and the infrared thermal imager 'to display the temperature distribution of the kiln body in real time during the operation of the rotary kiln, so as to realize the all-weather three-dimensional continuous monitoring of the rotary kiln, directly display the temperature information in the axial and circumferential directions during the operation of the kiln body, and display the specific temperature value at any position of the outer wall of the kiln at the same time. The temperature distribution cloud map of the outer wall of the kiln unfolds the surface of the kiln body, which can display the temperature distribution of the outer wall in real time when the kiln body rotates for one cycle. The system can take out the maximum and minimum values of the temperature in the axial and circumferential directions of the kiln body for separate display, and display the temperature extreme value in the circumferential direction at the specific position of each meter. In the software, the temperature of the kiln barrel can be displayed from the cross section and longitudinal section, and the on-site operators can judge the position of the high temperature zone, the position of the formation of the ring and the position of the falling off of the refractory in the kiln, so as to provide a visual reference for the on-site production.

Applicable Machine