【Ten Years of Rapid Development in Chemical Processing Equipment】Automation of dry slag discharge from acetylene dry-process unit generators from 1264 to 2023

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Recently, with the successful completion of the automatic control commissioning for the dry slag discharge devices in the acetylene dry-process units of Beiyuan Group’s chemical subsidiary, the automatic control systems for all 16 such discharge devices have been put into full use, enabling automated operation of slag discharge from the dry-process generators. Before the automatic control of the acetylene dry generator was put into use, the most frequently performed operation by the DCS operators was adjusting the frequency of the dry slag discharge device. Manual monitoring and adjustment operations are prone to improper execution, which may lead to incidents such as generator shutdowns and emptying of the material seal. By monitoring the operation mode of the generator’s dry slag discharge device, the Chemicals Branch developed logic programs for the automatic control of the generator’s stirring current and the dry slag discharge device, thereby achieving effective automatic control of slag discharge. Additionally, a low-pressure protection interlock was implemented to prevent the material seal from being emptied. After the automatic control of the acetylene dry generator was put into use, DCS operators could perform 1,152 fewer operations per day, **reducing their workload and effectively preventing the occurrence of operational errors. Automatic and accurate, timely frequency adjustment ensures that the calcium carbide reaction driven by the generator becomes increasingly stable, effectively solving the problem of excessive acetylene levels in the dry slag bin and the six-unit cement storage facility. It also lays a solid foundation for achieving full automatic control of the acetylene dry-process system in the future.