随着回转窑的使用时间不断增加，内衬在高温不断的侵蚀和熟料的摩擦下会导致内衬变薄甚至脱落，人工巡检过程中很难准确发现异常区域，同时由于熟料颗粒太细，粉料过多易结块，在窑体中间部位靠近窑头方向极易导致内衬结圈，结圈堆积过深会影响熟料的正常下滑，造成熟料过烧乃至影响熟料品质。因此建设一套实时监测回转窑状态的诊断分析系统尤为关键。

二．解决方案

本系统基于红外测温技术设计，进行回转窑窑体运行状态监测分析，系统给用户提供窑体温度的分布、各区域温度变化趋势等关键数据，能够为用户分析回转窑健康状态、调节球团煅烧工艺带来极大帮助。

系统可自动获取回转窑平铺图，“分段式”自动分析回转窑截面的温度分布情况，自动形成温度变化趋势图。

三．窑体温度成像系统

窑体热成像系统附带高配热像镜头监控所有高温工艺的流程,结合实时和存储的回转窑关键数据,扫描仪为全窑温、耐火砖提供精确的测量:监视事件的演变，绘制趋势,安排预防性维护操作。

1. 全天候将前端热像仪采集的全辐射红外图像流接入中控室,实时显示转窑运行状态。
2. 根据回转窑内的燃烧过程在表面壁温不同，划分干燥、热解、燃烧、燃尽各种所需区域。
3. 在实时画面中查着炉窑各个区域最高温度值,分析定位转窑内部结焦或耐火泥脱落位置与状态,尽早预警每一个热点的形成及其发展。
4. 对实时画面储存备查,显示各区域位置最高温与颜色,根据数据处理完成的高温带变化超限报警,显示燃烧中心位置变化并用于指导调整进料与燃烧控制。
5. 系统具备自检功能,故障后自动重新连接,支持远程故障处理,保证系统稳定可靠运行。

Applicable Machine

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