Relevant materials for the drum cooling section

Daily operation arrangements for Cold Drum workers. I. Shift supervisors: 1. Responsible for conducting a comprehensive inspection within the work section every day. 2. Monitor whether all process parameters are within the specified range. 3. Monitor the recording of various indicators. 4. Check the operating condition of the equipment in use, as well as its status for standby maintenance. 5. Responsible for all production-related matters within the work section, as well as any ad-hoc tasks assigned by the workshop. II. Fan Operator: 1. Purge the liquid return tube of the fan once. 2. Conduct inspections along the prescribed inspection routes. 3. Monitor the liquid level in the fan’s water seal tank, and start the pump to pump out the condensate in a timely manner. 4. Turn the standby fan manually once per hour. Check the operation of the running fans and the maintenance of the standby fans. 5. Measure the vibration of the operating fans every hour and keep records. 6. Clean the assigned equipment and areas. 7. The gas water seal at the back of the machine is replaced every Tuesday and Saturday. 8. Obey the arrangements of the team leader. III. Primary cooler operator: 1. Purge the liquid return tube of the primary cooler once. 2. Conduct inspections along the designated route. 3. Adjust the liquid level in the condensate tank of the primary cooler and the temperature of the gas after the primary cooler in a timely manner. 4. Check the operating status of the associated equipment to determine if there are any abnormalities. 5. Take timely action based on the resistance situation. 6. Clean the assigned equipment and areas. 7. Obey the arrangements made by the class monitor. IV. Electrostatic precipitator operator: 1. Purge the liquid drain pipe of the electrostatic precipitator once. 2. Conduct inspections along the designated route. 3. Observe the liquid level in the electric trap water seal tank, and start the pump in time to pump out the condensate. 4. Record the operating data of the electrostatic precipitator hourly, and adjust the temperature of the insulation box promptly. 5. Perform manual oxygen analysis hourly. 6. Check whether the equipment is operating normally, and clean it promptly as necessary. 7. Clean the assigned equipment and areas. 8. Obey the arrangements of the team leader. V. Central Control: 1. Monitor changes in various indicators, promptly notify on-site staff to make adjustments, and keep records. 2. Record the start-up, shutdown, and switching times of various devices, and report them promptly. 3. Keep the suction force in front of the device within the specified range to ensure normal pressure in the gas collection pipe. 4. Maintain proper communication with other departments according to production needs. 5. Clean all areas inside the fan room. 6. Obey the arrangements of the team leader. 6: Condensation Operator: 1. Conduct hourly inspections and record indicators such as the liquid level and temperature in each tank. 2. The ammonia tank is drained twice per shift. 3. Measure the tar level in the large vessel every hour to ensure that ammonia does not contain tar, and that tar does not contain ammonia, thereby ensuring a consistent tar production rate. 4. Ensure proper transfer of tar to the storage tanks, keep proper records, and carry out dehydration in a timely manner to maintain the quality of the tar. 5. Check whether the operating equipment is functioning properly, and carry out maintenance on the backup equipment in a timely manner. 6. Dispose of tar residues in a timely manner and keep the road surfaces clean to prevent environmental pollution caused by waste residues. 7. Clean the area as well as the equipment. 8. Obey the arrangements of the team leader.

I. Process Overview: The raw gas, at around -80°C from the coke oven, first passes through a gas-liquid separator to achieve separation of gas and liquid; the resulting crude gas exits from the upper part and then enters a cross-tube primary cooler, where it is cooled from both ends. The separated tar, ammonia water, and tar residue all go into a mechanical ammonia water clarification tank for separation. The primary cooler consists of upper and lower sections. The gas enters from the top and exits from the bottom, while the cooling water enters from the bottom and exits from the top. In the upper section of the primary cooler, the gas exchanges heat with the circulating water in the cooling tubes; as a result, its temperature drops from ~80°C to ~45°C, while the temperature of the circulating water rises from 32°C to 40°C. Subsequently, the gas enters the lower section of the primary cooler, where it exchanges heat with the chilled water in the cooling tubes. Here, the gas is cooled from ~45°C to 21–22°C, and the temperature of the chilled water increases from 16°C to 23°C. After initial cooling, the gas enters the electrostatic tar catcher from the bottom, passing upward through its honeycomb tubes. Thanks to the high-voltage electric field present within the electrostatic tar catcher, the tar droplets in the gas are ionized (it is required that the tar content in the gas after electrostatic treatment be less than 20 mg/m3). After this treatment, the gas proceeds to a centrifugal blower for pressurization before being sent to the ammonium sulfate production section. The gas condensate from the primary cooler flows out from its upper and lower sections; it passes through the water seal tanks of the cooler before entering the upper and lower condensate circulation tanks respectively. After being pressurized by the upper and lower condensate pumps, it is sent to the upper and lower spray nozzles of the primary cooler, where it circulates in this manner to remove impurities such as tar and naphthalene from the pipe walls, thereby ensuring the cooling efficiency of the primary cooler. The excess condensate is pumped by the lower condensate circulation pump to the raw coal gas pipeline ahead of the gas-liquid separator. The naphthalene content in the tar from the condensate is frequently analyzed, and light tar is periodically transferred from the mechanized ammonia clarification tank to the upper and lower sections of the condensate tanks, in order to improve the ability of the condensate tar to absorb naphthalene. This ensures the initial cooling effect. The tar, ammonia water, and tar residue separated from the gas-liquid separator flow by gravity to the mechanical ammonia water clarifier; after clarification, they are separated into three layers: the upper layer is ammonia water, the middle layer is tar, and the lower layer is tar residue. The separated ammonia water overflows into the circulating ammonia water tank, and is then pumped by the circulating ammonia water pump to the coke oven gas collection pipe for circulating spray to cool the raw gas. Periodically, a portion of the liquid is pumped using a high-pressure ammonia water pump to clean the gas collection pipes in the coke oven. Initially, when the cooler, electrostatic tar catcher, and the final cooling tower for benzene extraction needed to be cleaned, a portion of the ammonia water was drawn off from behind the circulating ammonia water pump for regular cleaning. The excess ammonia water was pumped by the circulating ammonia water pump to the residual ammonia water tank; after the tar in the residual ammonia water had settled and separated fully, it was pumped by the residual ammonia water pump to the ammonium sulfate production section for ammonia vaporization. The tar is directed to an intermediate tar tank for storage. Once a certain liquid level is reached, it is pumped by a tar pump to a tar storage tank for dehydration. Periodically, it is pumped by the tar pump to the tank farm or loading platform for loading and external sale. The separated tar residue is regularly sent to the boiler coal yard as fuel. The steam condensate from each device is directed into the condensate tank; it is then periodically pumped by a condensate pump to the boiler room. The tar captured thereby is discharged into the electric tar trap tank, from where it is pumped, via an underwater pump, to the main raw gas pipeline ahead of the gas-liquid separator. When the sedimentation tube is washed with circulating ammonia water, the wash liquid is sent to the electric tar trap tank and, under pressure, pumped to the raw gas pipeline ahead of the gas-liquid separator using an underwater pump in that tank. The condensate from the blower unit and the gas pipelines also flows into the blower’s water seal tank, and from there it is pumped, under pressure, to the main raw gas pipeline ahead of the gas-liquid separator using an underwater pump in that tank. The drainage from each device is led to a waste liquid collection tank via hoses, and periodically, the liquid in this tank is pumped using submersible pumps to a mechanical ammonia clarification tank for clarification and separation. To protect the environment, the exhaust gases from various storage tanks are collected and then drawn by an exhaust fan to an exhaust gas scrubbing tower. After being scrubbed using recirculated water, the gases are discharged. To ensure effective scrubbing, the recirculated water is continuously replenished via a water circulation system; a portion of this water is also continuously pumped by an exhaust scrubbing pump for biochemical treatment. II. Technical specifications:
1. Primary cooler section:
1). Gas temperature before the primary cooler: 78–82°C
2). Gas temperature after the primary cooler: 21–22°C
3). Temperature of circulating water entering the equipment: ~32°C
4). Temperature of circulating water returning from the equipment: ~40°C
5). Inlet temperature of chilled water: ~16°C
6). Return temperature of chilled water: ~22°C
7). Suction pressure before primary cooling: <1500 MPa
8). Suction pressure after primary cooling: ~2500 MPa
9). Pressure drop across the primary cooler: ≤1500 MPa
10). Temperature difference between outlets of each primary cooler: <3°C

2. Electrostatic tar precipitator section:
1). Oxygen content in gas: <0.8% (alarm at 1.0%, interlock at 1.2%)
2). Gas flow rate processed: 48,000–58,000 m³/h
3). Temperature of insulation box: 90–110°C
4). Secondary voltage: 40–60 kV
5). Secondary current: <500 mA
6). Pressure drop across electrostatic precipitator: ~500 Pa
7). Tar content in gas after electrostatic precipitation: <20 mg/m³
8). Nitrogen flow rate into insulation box: 75 m³/h
9). Nitrogen pressure: >15 kPa

3. Blower section:
1). Suction pressure before blower: 3500–5000 Pa
2). Pressure after blower: ~18,000 Pa
3). Gas inlet temperature before blower: ~25°C
4). Gas outlet temperature after blower: <45°C
5). Normal operating temperature of bearing bushes: <60°C (alarm at 75°C, interlock at 85°C)
6). Axial displacement of blower shaft: ≤0.4 mm (alarm at 0.5 mm, interlock at 0.8 mm)
7). Critical rotational speed: 3000–3300 r/min
8). Vibration level: ≤7 units
9). Temperature of motor bearings: <60°C (alarm at 75°C, interlock at 85°C)
10). Temperature of motor stator: ~120°C (alarm at 135°C, interlock at ≥145°C)
11). Rated current of motor: I = 68.3 A

4. Oil station system:
1). Oil temperature after oil cooler: ~35°C
2). Oil pressure supplied to lubrication points: 0.11–0.18 MPa (<0.08 MPa triggers auxiliary oil pump; >0.25 MPa shuts down auxiliary oil pump)
3). Oil temperature at inlet of hydraulic coupling: ~45°C

Note: Electric heating system for oil station: It activates automatically when temperature drops below 20°C and deactivates when temperature exceeds 35°C. 4). Lubricant specifications: 46# turbine oil. 5. Tank areas and pump rooms: 1). Outlet pressure of the circulating ammonia water pump: 0.4–0.5 MPa. 2). Outlet pressure of the high-pressure ammonia water pump: ~3.0 MPa. 3). Outlet pressure of the residual ammonia water pump: ~0.4 MPa. 4). Temperature of each motor: <65°C. 5). Temperature of the circulating ammonia water: 70–75°C. 6). Oil-water interface level in the mechanical ammonia water clarification tank: 1.5–1.8 m. 7). Liquid level in the circulating ammonia water tank: 3.5–4.0 m. 8). Bearing temperature of each pump: <70°C. 6. Quality standards for tar: Density (at 20°C): 1.15–1.2 g/cm3; Naphthalene content: ≤7.0%; Moisture content: <4.0%; Ash content: <0.13%; Toluene-insoluble substances: 3.5%–7%; Viscosity (E80): <4. IV. Job responsibilities: ㈠. Responsibilities of the blower operator: 1. Under the supervision of the shift supervisor and team leader, be responsible for the production operations in this area, equipment maintenance, environmental protection, and maintaining a clean and orderly working environment. 2. Stabilize the operation of the fans to ensure that various process parameters such as the pressure in the coke oven gas collection system, the fan suction, and other pressures meet the required standards. 3. Responsible for turning the standby fans manually, as well as cleaning the condensate in the fan system to ensure that the drainage pipes remain unobstructed. 4. Responsible for starting up, stopping, and cleaning the primary cooler to ensure that the temperature of the gas after the primary cooler meets the specified requirements. 5. Responsible for the startup, shutdown, and cleaning of the electrostatic tar catcher. 6. Responsible for inspecting the condensate drain pipes of the gas system, adjusting and maintaining the water seals and the upper/lower spray systems of the primary cooler, as well as adjusting the proportion of the spray liquid. 7. Strictly follow the operating procedures; do not give instructions in violation of regulations, nor simplify the operations. 8. Thoroughly inspect, identify, address, and report any abnormalities in production, ensuring early reporting and prompt resolution. 9. Keep production records carefully; the handwriting should be clear and the records accurate. (ii) Responsibilities of the Condensation Worker: 1. Responsible for starting, stopping, and switching between the circulating ammonia water pumps, high-pressure ammonia water pumps, tar pumps, condensate water pumps, and washing pumps located in the condensation pump room. 2. Responsible for adjusting the oil level in the mechanical ammonia clarifier, ensuring proper separation of tar residues and ammonia in this clarifier, and guaranteeing that the ammonia from the coke oven does not contain tar. 3. Responsible for the steam heating system in the tar tank area, tar dehydration operations, and the loading of tar into external containers. 4. Responsible for the operation of the exhaust gas cleaning tower. 5. Responsible for the production operations related to the waste liquid collection tank, recirculating ammonia water tank, residual ammonia water tank, and condensate tank; promptly transport the residual ammonia water and condensate off-site. V. Operating procedures: (I) Normal operations: 1. Normal operation of the primary cooler: 1). Adjust the cooling water flow rates in the upper and lower sections of the primary cooler to ensure that the gas temperatures in both sections are appropriate, so that the temperature of the gas after primary cooling meets the technical specifications. 2). Check the resistance of the primary cooler; ensure that the condensate spray pipes in the upper and lower sections are unobstructed. Periodically flush the primary cooler with hot ammonia water to prevent an increase in resistance. 3). Adjust the amount of gas flowing in and out of each primary cooler, as well as the volume of cooling water used, to ensure that the temperature difference at the outlet of each primary cooler is no more than 3°C. 4). Check whether the drainage pipes and water seal drainage pipes associated with the primary coolers and the gas pipelines before and after them are unobstructed; these pipes should be flushed once per shift to ensure they remain clear. 5). Inspect equipment, pipes, and valves for any signs of cracks, leaks, or drips; address any issues promptly. 2. Normal operation of the blower: 1). Check whether the bearing temperature, shaft displacement, and machine vibration are within normal ranges; it is strictly prohibited to operate the unit at its critical speed, and it is necessary to ensure smooth operation of the unit as well as stable motor current. 2). Ensure that the suction and pressure of the blower remain within specified values, thereby ensuring that the pressure in the gas collection duct meets the requirements. Based on changes in the amount of coke oven gas, the speed of the hydraulic coupler is adjusted, or the large circulation pipe is used to control the pressure in the coke oven gas collection system. The fan’s suction and pressure are stable. 3). The fan condensate pipe should be cleaned with steam at least once per shift, and twice in winter to ensure smooth flow. 4). Check whether the lubrication system, oil temperature, and oil pressure of the oil station are normal, and ensure that the oil level, oil temperature, and oil pressure in the oil station meet the required standards. 5). Check that the oil level in the hydraulic coupler’s oil tank is within the specified range, and verify that the oil temperatures at the inlet and outlet of the coupler, as well as the outlet oil pressure, are normal. 6). Regularly test the quality of the lubricating oil to ensure it meets the requirements; if it does not meet them, it should be replaced promptly. Also, apply lubricant to all lubrication points in various systems on a regular basis as specified. 7). Check the level of condensate in the water seal trough of the fan, and promptly start the submersible pump to drain it. 8). Check the oil return at each lubrication point of the fan; if any abnormalities are found, promptly identify the cause and take corrective action. 9). The standby fan should be turned manually once per shift, by 1/4 turn each time. 10). Keep proper original records, recording once per hour; the entries must be accurate, clear, and fair. 3. Normal operation of the electrostatic tar catcher: 1). Adjust and control the temperature of the electrostatic insulating box to between 90–110°C. 2). Adjust the nitrogen pressure and flow rate used for protecting the porcelain insulators in the box, so as to prevent the insulating box from being contaminated. 3). Check the resistance of the electric precipitator and flush it regularly with hot ammonia water. 4). Adjust the secondary voltage according to the tar content in the gas, so that the tar content in the gas after the electrostatic tar catcher is within the acceptable range. 5). Check that the electrostatic precipitator drainage pipe and water seal are unobstructed, drain the condensate promptly, and clean the drainage pipe once per shift. 6). Stabilize the oxygen content in the gas; when the oxygen content exceeds the specified level, promptly identify the cause and eliminate it. 4. Normal operation of various pump tanks in the condensation unit: 1) Adjust the pump pressure of the circulating ammonia water pump to maintain the ammonia water spraying pressure in the coke oven gas collection duct at 0.2–0.25 MPa; the high-pressure ammonia water pump should be started periodically to ensure that the pressure is sufficient for cleaning the gas collection duct. 2). Ensure that the liquid level in each tank is normal, with no overflow or depletion. 3). Conduct regular inspections of the equipment’s operation, and check the lubrication status of each pump; it is required that the sight glasses be checked at 2/3 of their range. 4). Adjust the flow rate of the residual ammonia water pump so that it matches the processing capacity required by the ammonia water treatment unit. 5). Dispose of the tar accumulated at the bottom of each ammonia tank on time to ensure that the ammonia supplied externally is free of tar. 6). Check the operation of the scraper machine in the mechanized ammonia water clarification tank, as well as the quality and quantity of oil in the reducer, and ensure that the sludge is removed promptly. 7). Adjust the oil-water interface in the machine groove, top up oil promptly to ensure that tar is free of water and ammonia is free of oil. 8). Check the waste liquid collection tank; the level in the condensate tank should be removed promptly. 9). Check the operation of the exhaust gas washing tower and the effectiveness of the washing liquid; discharge wastewater regularly and replenish fresh circulating water to ensure effective washing. 10). Dehydration in the tar tank; steam is used for heating and insulation to ensure that the tar meets the required standards. The pipelines used for transporting tar must be cleaned with steam before and after transportation. (ii) Starting, stopping, and switching operations: (1) Operations for starting, stopping, and switching the primary cooler: 1. Starting the primary cooler: 1). Check the tightness of all valves to ensure they function properly. 2). Check whether the water supply to the upper and lower cooling water systems is normal. 3) All water seal tanks have been filled with water, and all instruments are complete and in good condition. 4). Open the drain valves for the upper and lower sections of the primary cooler to be activated, and purge with steam to ensure unobstructed flow. 5). Open the vent at the top of the primary cooler, and open the valve for the steam (or nitrogen) to be introduced into the vessel. Allow steam (or nitrogen) to flow in; once most of the steam (or nitrogen) has been discharged from the vent, take a sample for oxygen analysis. Once the analysis shows satisfactory results, reduce the flow of steam (or nitrogen). 6). Once the gas system is operating normally, start the upper and lower condensate spray pumps according to the startup procedures for centrifugal pumps, and adjust the pump pressure and flow rate to enable circulation within the system. 7). Open the inlet valve for the circulating cooling water in the upper section, and slowly open the outlet valve of the primary cooler. 8). Open the gas inlet valve to supply gas, while closing the steam (or nitrogen) valve and turning off the vent. 9). Once the gas flow is established, open the outlet valve of the lower-stage cooling water supply valve based on the temperature of the gas, and adjust the amount of cooling water to ensure that the temperature of the gas after the primary cooler meets the required standards. 2. Stop the primary cooler: 1). Close the gas inlet and outlet valves. 2). Sequentially close the circulating water and chilled water inlet valves, and drain the cooling water from each section. 3). Close the outlet valve of the condensate circulation spray pump, shut down the upper and lower spray pumps, drain the condensate in the pipes, and purge the condensate pipes with steam. 4). Open the top vent; open the steam pipeline valve to expel the gas from the primary cooler. Once a large amount of steam begins to emerge from the vent, close the steam supply and also close the vent. After cooling, drain all the condensate from the cooler, and fill the primary cooler with nitrogen to put it in standby mode. 3. Primary cooler: 1). Start the standby primary cooler according to the startup procedures. 2). Once normal operation is restored, close the gas inlet and outlet valves of the pre-cooler, close the cooling water inlet and outlet valves, drain any accumulated liquid in the system, and clean it for use as a spare unit or for maintenance. 3). Adjust the cooling water flow rate of the initial cooler to bring the temperature within the required range. 4). Start the condensate spraying system of the primary cooler. 4. Flush the primary cooler with hot ammonia water: 1) When the resistance of the primary cooler exceeds 1000 Pa, the temperature of the gas after primary cooling does not meet the requirements, and cleaning is necessary. 2). Open the ammonia pipe valve from the circulating ammonia water pump to the primary cooler, and stop the upper-stage condensate spray pump. 3). Open the ammonia valve at the upper section of the primary cooler to clean it by spraying hot ammonia. 4). Pay attention to changes in gas temperature and adjust the cooling water volume promptly. 5). After cleaning is complete, close the ammonia valve and start the upper-stage condensate spray pump. ⑵. Operation for starting, stopping, and switching of the electrostatic tar catcher: 1. Starting the electrostatic tar catcher: 1). The water seal tank of the electrostatic tar catcher has been filled with water; ensure that the liquid discharge pipe is unobstructed and that all valves are in the closed position. 2). The electrical instruments were found to be in normal condition after inspection, and the insulation box was heated with steam to a temperature of 90–110°C to meet the technical specifications. 3). The electrostatic capture air drop test was successful, and the electrician confirmed that the insulation resistance of the insulation and electrical components was within acceptable limits. 4). Open the vent pipe and introduce steam (or nitrogen) into the electrostatic precipitator; once a large amount of steam (or nitrogen) is emitted from the vent, and the oxygen content is found to be within acceptable limits, reduce the flow rate of the steam (or nitrogen) so that a slight positive pressure is maintained. 5). Open the valve on the pipeline leading nitrogen into the insulation box, and adjust the nitrogen pressure so that the flow rate meets the specified requirements. 6). Close the vent pipe and steam valves, supply gas, and open the gas inlet and outlet valves (inlet quickly, outlet slowly). 7). Supply power to the electrostatic precipitator, gradually increasing the voltage to the specified value; pay attention to changes in the secondary voltage and current of the electrostatic precipitator. 8). Open the valve of the lower liquid pipe, check whether the drainage in the liquid return pipe is unobstructed, and make a record. 2. Operation of the electrostatic tar catcher during power outages: 1) Gradually reduce the voltage from the high setting to the low setting as required for electrostatic capture operation; bring the operating voltage to 0, cut off the power supply, and switch the three-way switch to the grounding/discharge mode. 2). Open the electric capture bypass valve and close the gas inlet and outlet valves to direct the gas through the bypass. 3). Close the electric capture insulation box and the nitrogen protection valve of the feed box. 4). Clean the drain pipe with steam to ensure it remains unobstructed. 5). Rinse the electrostatic precipitator with hot ammonia water, or open the vent at the top of the electrostatic precipitator and use steam to purge it in order to remove all the gas from inside it. 6). After cleaning is complete, once the temperature inside the electrostatic precipitator drops to <60°C, close the steam vent pipe and introduce a small amount of nitrogen to maintain pressure for future use. 7). Drain the liquid accumulated in the purger, close the liquid return tube, and turn off the heating system of the insulation box. 3. Operation for switching electric tar capturers: 1). Turn on the electric tar capturer in accordance with the startup procedures. 2). After the electrostatic precipitator is activated and operating normally, shut it down by cutting off the power supply; then verify that grounding discharge has occurred. 3). Close the inlet and outlet valves for power outage capture, clean the cleaner body, drain all condensate from the device, and turn off the heating system of the insulation box to put it in standby mode. 4. Cleaning of the electrostatic tar catcher: ⑴. Steam cleaning: 1). Follow the shutdown procedures for the electrostatic tar catcher by turning off the power, grounding it to discharge electricity, shutting down the insulation box, steam heating system, and nitrogen protection system; open the gas bypass valve, and close the gas inlet and outlet valves of the electrostatic tar catcher. 2). Open the top vent and use steam for cleaning for 30 minutes. 3). Open the nitrogen valve, shut off the steam; once the electrostatic precipitator has cooled to room temperature, shut off the nitrogen and the vent, then start the electrostatic precipitator following the startup procedures. ⑵.Ammonia water cleaning: 1). De-energize, ground, and discharge the electrostatic tar precipitator. 2). Route the gas through the bypass and close the gas inlet and outlet valves. 3). Open the valve of the pipeline for cleaning with hot ammonia water from the electric trap; allow hot ammonia water to flow through the electric trap for cleaning. 4). After cleaning is complete, open the inlet and outlet valves of the electrostatic precipitator, close the bypass valve, and start up the equipment by powering it on according to the electrostatic precipitator startup procedure. ⑶. Startup, shutdown, and reversal operations of the blower: 1. Startup procedure for the blower: 1). Prepare a stethoscope, vibration meter, thermometer, pressure gauge, and a notebook. 2). Check that the electrical wiring, instruments, insulation, etc. are in good mechanical condition. 3). Check whether the oil level, oil temperature, and the opening/closing status of oil circuit valves at the oil station comply with technical specifications, and whether the oil level in the hydraulic coupling is normal. 4). All relevant personnel such as electricians, instrument technicians, maintenance workers, and operators are in place and ready. 5). Start the lubricating oil pump; set the standby oil pump to automatic mode. Adjust the oil pressure and temperature, and check whether the oil return condition is normal. 6). Clean the machine body and the drain pipes before and after the fan to ensure they are unobstructed; verify that the liquid level in the water seal tank is normal. 7). Turn the shaft by hand and install the fan end cover properly. 8). Open the steam valve of the lower drain pipe of the unit to supply steam for warming it up; once the temperature of the unit reaches 60°C–70°C, turn off the steam and drain all the condensate from the unit. 9). Close the valves for the machine’s drainage pipe as well as those for the drainage pipes at the front and rear of the machine. 10). Open the gas inlet valve of the fan to ~2/3; operate the outlet valve. Open the large recirculation pipe valve to ~1/2. First, set the coupling control to manual mode. 11). Notify the substation to supply high-voltage power, and inform relevant units such as those in the coke oven basement to get ready for startup. 12) Upon receiving instructions from a superior, start the motor. 13). Manually adjust the coupler actuator to start the output shaft running at low speed, and check whether the oil temperature, oil pressure, return oil flow, bearing temperatures of various devices, as well as the temperature of the device itself, are all within normal ranges. 14). Adjust the opening degrees of the inlet and outlet valves of the fan. 15). Based on the changes in gas volume, gradually increase the fan speed. When it approaches the critical speed, quickly adjust the coupling to enable the fan to swiftly pass through the critical range. 16). During the initial start-up, due to the relatively low volume of gas, in order to maintain stable pressure in the collector main and ensure the normal operation of the blower, regulation should be carried out using the large recirculation pipe. Subsequently, as the gas volume increases, the use of this large recirculation pipe should be gradually reduced until it is completely shut off. It is adjusted by the hydraulic coupling based on changes in the pressure of the coke oven gas collection pipe. 17). When the oil temperature at the fuel station reaches 38–40°C, increase the flow of cooling water to the cooler; when the oil temperature of the coupling reaches 55–58°C, further increase the cooling water flow to keep the oil temperature within the required range. 18). Once the fan is running stably, open the valves of the drainage pipes located in the fan housing and in areas with negative pressure to allow drainage, ensuring smooth flow of liquid. 19). Once the fan is operating stably, establish communication with the coke oven rising pipe and the basement, and switch the actuator of the blower’s hydraulic coupling from manual to automatic mode (automatic operation for the coke oven π-type flap and the basement flap). 20). Once the blower is operating properly, normal production can resume; regular inspections should be carried out to check whether all parameters meet the requirements, with relevant records kept. 2. Shutdown procedures for the blower: 1). Coordinate with relevant units such as various main pipelines, substations, and coke ovens to prepare for shutdown and gas isolation. 2). Upon receiving the shutdown command from the superior supervisor, switch the coupling control from automatic to manual mode, and manually reduce the output speed of the coupling gradually (when the speed is close to the critical value, quickly adjust the actuator so that the fan speed can drop below this critical value rapidly), while simultaneously closing the gas outlet valve slowly. 3). Once the fan speed drops to 0, close the gas inlet and outlet valves, shut down the motor, and stop the main motor. 4). Use steam to clean the fan body and various condensate drainage pipes, while also performing rotor turning to remove any tar adhering to the rotor. After cleaning is complete, stop the steam supply, cool the machine down, and drain the condensate. 5). When the temperature of the bearings in all locations drops to 40°C and the oil temperature at the oil station falls to 30°C, stop the cooling water supply to the oil cooler and shut down the oil pump at the oil station. 6). Turn the machine once every half hour after it has stopped running; once per shift after the temperature of the machine body and bearings has dropped to normal levels. 7). During prolonged shutdowns, the liquid in the cooler should be drained to prevent the equipment from being damaged by freezing in winter. 3. Shutdown procedure for the blower: 1). Before carrying out the shutdown procedure, it is necessary to contact the relevant parties in advance and inform the relevant staff to make preparations for the shutdown. 2). Prepare for starting the fan: switch the coupler to manual mode, open the inlet of the fan to about 2/3, and adjust the outlet. Under the guidance of the supervisor, start the motor of the fan by following the standard startup procedures. 3). Start the main motor of the pre-opening fan and adjust it manually to gradually increase its speed; slowly open the outlet valve. At the same time, gradually reduce the speed of the shutdown fan and slowly close its outlet valve, so as to achieve balance and maintain stable pressure in the coke oven and the gas collection system. 4). When the speed to be brought to a stop drops to 0, close the gas inlet and outlet valves; at the same time, ensure that the opening degrees of the fan’s inlet and outlet valves are normal, and adjust the speed to its normal level. 5). Shutting down the fan shall follow the procedures after shutdown as a backup. ⑷Operation of the exhaust gas cleaning tower: 1. Startup procedure: 1). Fill the tail gas liquid seal tank with water. 2). Inject circulating water from the pipeline into the tower from the upper part of the washing tower, so that the water level at the bottom of the tower reaches 2/3 of the indicated level, then close the circulating water inlet valve. 3). Open the valve on the circulation pipeline of the exhaust cleaning pump to activate the circulation line. 4). Start the exhaust cleaning pump according to the startup procedures of the centrifugal pump to establish a circulation, and adjust the circulation spray volume to meet the exhaust cleaning requirements. 5). Open the inlet valve of the exhaust fan, start the exhaust fan, and direct the exhaust gas from each storage tank into the scrubber tower. 6). Once the exhaust washing cycle is operating normally, appropriately open the valve leading to the biochemical treatment unit to discharge an appropriate amount of washing wastewater for biochemical treatment; also open the valve for supplying fresh circulating water in order to maintain a stable liquid level at the bottom of the tower. 2. Shutdown procedure: 1). Close the inlet valve of the exhaust fan and shut down the exhaust fan. 2). Close the circulating water feed valve. 3). After stopping the washing pump, drain all the liquid from the pump body and pipelines. 4). Drain the washing liquid from the tower. ⑸. Startup procedures for the mechanical clarifier tank: 1. Startup procedures: 1). Contact the electrician to check the condition of the electrical equipment. 2). Remove debris from the cleaner; the fitter shall verify that the scraper machine is operating properly and that the level regulator is functioning correctly. 3). Open the ammonia outlet of the clarification tank and the inlet valve for the mixture; once the tank is filled with liquid, turn on the scraper machine. 4). When the tar level in the mechanized ammonia clarification tank reaches ~1.7 m, open the tar outlet pipeline and adjust the level controller to maintain a stable interface between the tar and ammonia in the tank. 2. Shutdown procedure: 1). Close the condensate inlet valve and the ammonia outlet valve. 2). Pump out the tar in the tank and stop the scraper conveyor. 3). Drain all the liquid from the tank. ⑹. Operations for starting, stopping, and switching centrifugal pumps: 1. Process for starting a centrifugal pump: Check in advance that the oil level in the pump tank is normal, that the instruments, electrical components, and liquid levels in the storage tanks are appropriate, that the valves function properly, and that the pipelines are unobstructed; ensure all preparatory work is completed. Note: The tar pump requires steam to clean the pipes before and after it, and in winter the oil pump must also be preheated to ensure smooth cranking. 2. Shutdown procedure for centrifugal pumps: Note: After stopping the tar pump, it is necessary to purge the pump body and the pipes before and after the pump with steam to prevent blockages. 3. Reverse pumping procedure for centrifugal pumps: ㈢ Special operations: 1. Blower section: ⑴ Sudden power outage: Cut off the high-voltage power supply: 1). Quickly close the gas outlet valve and switch the main motor to the shutdown position. 2). The control of the hydraulic coupler is switched from automatic to manual, and the control actuator is reset to zero. 3). Close the gas inlet valve and purge the unit and all downflow pipes. 4). Contact the relevant departments to inquire about the cause of the power outage, keep records, and prepare to start the vehicle once power is restored. Cut off low-voltage power: If the oil station’s pumps are not stopped and this does not affect the operation of the fans, production should continue; inform the relevant supervisors and contact the appropriate departments to restore power as soon as possible. If the fan stops due to a power outage in the low-pressure control circuit, it shall be treated as a shutdown. ⑵.Sudden water cutoff: The oil cooler switches to an alternate water supply to maintain production; relevant supervisors are notified. Notify the relevant departments to restore water supply as soon as possible; if both water supplies are cut off and the temperature of the turbine bearing exceeds the specified value while no water is supplied, stop the machine immediately. Once the water supply has been restored, get ready to drive. ⑶.Sudden steam shutdown: Investigate the cause with the relevant departments and restore service as soon as possible to enable purging of the drain pipe. ⑷In any of the following situations, the blower operator has the right to perform an emergency shutdown: 1) When the unit suddenly experiences severe vibration or there are grinding noises inside the machine ； 2). When smoke occurs at any bearing or seal ； 3). When the oil pressure in the oil inlet pipeline drops to 0.08 MPa, and even after the standby auxiliary oil pump is activated, the oil pressure remains below 0.05 MPa ； 4). When the bearing temperature rises sharply to above 75°C and cannot be reduced despite various measures being taken ； 5). If the axial displacement of the blower rotor exceeds 0.5 mm, and this displacement continues to increase despite various measures being taken ； 6). When the gas pipeline in front of the fan catches fire ； 7). When the oil level in the tank drops to the minimum level line and new oil is added, yet the level continues to drop uncontrollably ； 2. Electrostatic tar catcher section: ⑴. Sudden power outage: Immediately pull the switch of the electrostatic tar catcher, discharge it by grounding, and report to the superior supervisor. Prepare to resume operation once power is restored, keep records, inquire about the cause of the outage and the time when power will be supplied; if the outage lasts for a long time, treat it as a shutdown. ⑵.Sudden shutdown of steam supply: Monitor the temperature of the electric capture insulation box; when its temperature drops below 80°C, stop the power supply for electric capture. Determine the reason for the shutdown, note the time when cooling is resumed, keep proper records, and prepare to restart the system after steam supply is restored. 3. Primary cooler section: ⑴ Sudden shutdown of circulating water: In the case of a short-term water outage, increase the amount of cooling water used by the primary cooler; ensure that the temperature of the gas after the controller is below 30°C. In the event of a long-term water outage, activate the backup primary cooler to increase the cooling capacity and maintain production. Determine the reason for the water outage and the time when supply will be restored, and keep proper records. ⑵ .Sudden shutdown of cooling water: In the case of a short-term water outage, increase the flow rate of water in the primary cooler; if the temperature of the gas after the controller is below 30°C, use a backup primary cooler and increase the water flow rate to maintain production. Find out the reason for the water outage and the time when supply will be restored, and prepare to resume normal production operations once the water supply is back in order. ⑶ . Suddenly stop the circulating water and both the cooling water supplies: once both supplies are stopped, production comes to a halt immediately. Determine the reason for the water outage and the time when water supply will resume, then make preparations to resume operations once the water supply is restored. 4. Condensation unit section: ⑴. Sudden power outage: Cut off the power supply to all operating pumps, close the outlet valves, and contact the relevant departments; if power is restored in a short time, be prepared ； If the power outage lasts for a long time, stop the pumps; pay attention to changes in the liquid level in each tank and ensure that none of the tanks become overfilled. In the event of a power outage while the tar pump is delivering oil normally, immediately cut off the power supply and close the outlet valve ； If the power outage lasts for a long time, the oil delivery pipeline must be purged with steam. ⑵. If the cooling water supply is stopped suddenly, contact the integrated water supply pump room to inquire about the reason for the interruption and the duration of it; if the downtime is short, continue production while increasing inspections ； If the time is long, consult the relevant departments and proceed with shutdown procedures. ⑶.Sudden stop of instrument air: Close the valves before and after the automatic control regulating valve, open the bypass valve, and use it to manually regulate the process in order to maintain production. Once the air supply is restored, close the bypass valve and open the valves before and after the regulating valve to resume automatic control, making sure to keep a record of this. Note: The entire cold drum section is powered off. After power is restored, the circulating ammonia water pump must be started first; once circulation is normal, the fan can be turned on, followed by the sequential startup of other equipment. VI. Post safety rules: 1. Strictly follow the operating procedures for starting and stopping high-voltage motors. 2. Smoking is prohibited; it is strictly forbidden to bring any kind of flame to this work area. 3. Personal protective equipment must be worn in full before entering the operation area to carry out tasks; it is prohibited to wear shoes with iron studs or metal soles when entering the chemical processing area. 4. When checking tank equipment with gas-liquid overflow tanks, it is required to stand on the upwind side and hold onto the railing firmly. 5. When performing maintenance on fan rooms and gas facilities, it is strictly prohibited to use iron tools for striking; copper tools must be used instead. 6. It is prohibited to power on the electrostatic tar catcher while it is in operation. When performing maintenance during a power outage, the power must first be turned off and the device grounded to discharge any residual static electricity, thereby preventing damage caused by such electricity. 7. When it is necessary to enter equipment, tanks, vats, or towers for inspection or maintenance, the area must be cleaned first, and a gas analysis test must show satisfactory results before entry is permitted. All manholes should be opened to ensure ventilation; when entering gas equipment, blind flanges must be used to block the gas inlets and outlets. 8. When checking the temperatures of the motor and fan bearings as well as those of the pumps, use the back of your hand for touch; never use the palm. 9. To operate the valves at a high position, at least 2 people are required to work together; ensure that the ladder is secured to prevent slipping. 10. When filling tar and taking samples, stand to the side to prevent hot oil from splashing and causing burns. 11. In the event of a gas leak, ventilation should be carried out first to prevent poisoning and explosions. 12. For any hot work or maintenance activities within this area, a hot work permit must be obtained in advance, and safety measures must be properly implemented. 13. Before the electrostatic precipitator is put into use for the first time, its structure must pass a gas-tightness test before it can be utilized. 14. If the electrical equipment does not start successfully on the first attempt, it is necessary to inform professional maintenance personnel to carry out repairs before power can be supplied again. Motors with a capacity of over 50 KW must not be started three times in a row. 15. The insulation box of the electrostatic tar catcher is protected by nitrogen; in case of any abnormality with the nitrogen supply, power should be cut off immediately. 16. When an alarm is triggered by the oxygen analyzer in the gas of the electrostatic tar precipitator, and the interlock causes an automatic trip, it is necessary to identify the cause and carry out effective treatment before the equipment can be put back into service. 17. There should be no exposed wires in equipment such as control rooms and control panels; if any electric leakage is detected, it is necessary to inform the electrician promptly so that the issue can be resolved and potential hazards eliminated. 18. If any signs of leakage, escaping fluid, dripping, or seepage are detected, notify the relevant personnel promptly to handle it. 19. Ensure the motor operates smoothly, with all parameters meeting the required standards; any abnormalities should be addressed promptly. 20. Operation is prohibited if the couplings of various operating equipment lack protective covers. 7. Equipment maintenance, production and maintenance procedures: (1) Equipment overview: 1. Non-standard equipment: ⑴ .Primary cooler A, B, C: 3 units length × width × height: 4484×3300×～32866 F total=5144㎡ Upper section: F=3026㎡ shell side: Coke oven gas ~-0.001MPa (meter) pipe side: Circulating water 0.4MPa (table) 30~40℃ Heat exchange tube: 57×3×4500 n=3800 lower section: F=2118㎡ shell side: Coke oven gas ~-0.002MPa (meter) pipe side: Refrigeration water 0.4MPa (table) 16～23℃ Heat exchange tube: 57×3×4500 n=2660 ⑵.Gas-liquid separator: 1 unit2400×7315 V total=24m3 medium: Coke oven gas, ammonia, tar temperature: ~80℃ pressure: ~-0.001MPa (table) ⑶. Mechanized ammonia clarification tank: 2 models: 71.067 length×width×height: 24616×4590×～5686 V full=340m3 medium: Temperature of tar, ammonia and tar residue: ~80℃ pressure: Normal pressure attached transmission device: Motor direct-coupled three-stage horizontal planetary cycloidal pinwheel reducer model: XWSD2.2-1174-1/16555 motor: Voltage: 380V power: N=2.2KW speed: 1430r/min total reduction ratio: i=16555×2.5238=41781.5 scraper conveyor: work ability: ~400kg/h tar residue working speed: 3.7555m/h ⑷. Circulating ammonia water tank: 2 units8000×5100 V total=256m3 vertical temperature: ~80℃ pressure: Normal pressure ⑸.Remaining ammonia water tank: 2 units8250×8600 V full=460m3 vertical media: Ammonia, water vapor and condensate temperatures: ~80℃ pressure: Atmospheric pressure additional heat device: Heating coil: 57×3.5 F=40.8㎡ Pipe temperature: ~158℃ pressure inside the pipe: ~0.5MPa ⑹.Tar intermediate tank: 1 unit5200×4500 V total=95.6m3 vertical medium: Tar, water vapor and condensate temperatures: ~80℃ pressure: Atmospheric pressure additional heat device: Heating coil: 57×3.5 F=～12㎡ Pipe temperature: ~158℃ pressure inside the pipe: ~0.5MPa ⑺.Tar tank: 2 units8800×8200 V total=500m3 vertical medium: Tar, water vapor and condensate temperatures: ~75℃ pressure: Atmospheric pressure additional heat device: Heating coil: 57×3.5 F=48㎡ Pipe temperature: ~158℃ pressure inside the pipe: ~0.5MPa ⑻. Water seal tank of primary cooler: 6 units800×3000 V total=1.5m3 vertical flat top medium: gas condensate temperature: 20～45℃ pressure: Normal pressure ⑼. Blower water seal tank: 1 unit length × width × height = 2600 × 1000 × 4000 V full = 10.4m3 vertical flat top medium: gas condensate temperature: ~35℃ pressure: Normal pressure ⑽. Blower water seal tank: 1 unit length × width × height = 2600 × 1000 × 4000 V medium: gas condensate temperature: ~35℃ pressure: Normal pressure ⑾.Electric water capture and sealing tank: 1 unit length × width × height = 2600 × 1000 × 4000 V medium: Electrocapture liquid temperature: ~35℃ pressure: Normal pressure ⑿. Condensation tank: 1 unit3000×2500 V total=18m3 medium: Steam condensate temperature: ~90℃ pressure: Normal pressure ⒀.Waste liquid collection tank: 1 unit4000×4000 V total=50m3 medium: Tar and ammonia temperature: ~75℃ pressure: Normal pressure 3 Full = 10.4m3 Full = 10.4m Vertical cone top Vertical flat top Vertical flat top Vertical flat top ⒁. Upper condensate circulation tank: 1 set2200 L=6000 V full=21.3m3 horizontal medium: gas condensate temperature: ~45℃ pressure: Normal pressure ⒂. Lower section condensate circulation tank: 1 set2200 L=6000 V full=21.3m3 horizontal medium: gas condensate temperature: ~45℃ pressure: Normal pressure ⒃. Exhaust gas liquid sealing tank: 1 unit400×600 V total=0.075m3 vertical flat top medium: Tar and ammonia temperature: Normal temperature and pressure: Normal pressure ⒄. Exhaust cleaning tower: 1 unit1500×～17720 V total=23.6m3 vertical flat top medium: Tank area exhaust gas and circulating water temperature: ~40℃ pressure: Normal pressure polypropylene garland filler 25×9 random pile 2. Standard equipment ⑴. Centrifugal blower: 2 models: D1450-1.11/0.81 Q=1450m3/h △P=30000Pa conveying medium: Coke oven gas medium weight: ~0.45㎏/m3 inlet pressure: ~-3500~-5000Pa inlet temperature: 22～25℃ rotation speed: 4340r/min shaft power: 936KW attached: Motor power: 1000KW voltage: 10KV 2 units attached: Explosion-proof speed-regulating hydraulic coupling (matched with plate cooler) 2 units: Lubricating oil system (including explosion-proof oil station, high-level oil tank, etc.) 2 units attached: 2 transmissions ⑵. Exhaust fan: 2 models: 9-19NO.4A2 Right 90 Q=970m3/h △P=3665Pa conveying medium: Ammonia-containing exhaust gas with motor power: 2.2KW voltage: 380V model: YB90L-2W ⑶. Circulating ammonia water pump: 2 models: 350S-75B Q=828～1225m3/h H=59～47.5m Single-stage, double-suction split-type centrifugal pump transports media: Ammonia medium weight: ~1000㎏/m3 temperature: ~75℃ rotation speed: 1470r/min with motor power: 250KW voltage: 10KV model: Y450-4C 2 sets ⑷.Remaining ammonia water pump: 2 models: IS65-40-250 Q=15～30m3/h H=82～78m Single-stage, single-suction centrifugal pump transports medium: Ammonia temperature: ~75℃ rotation speed: 2900r/min with motor power: 15KW voltage: 380KV model: Y132S2-2 2 sets ⑸. Tar pump: 2 models: 80AY-60 Q=50m3/h H=60m single-stage, single-suction centrifugal pump transports media: Tar temperature: ~80℃ rotation speed: 2950r/min with motor power: 18.5KW voltage: 380KV model: Y160L-2 2 sets ⑹. Upper condensate circulation pump: 2 models: IS100-65-200 Q=60～120m3/h H=54～47m single-stage, single-suction centrifugal pump medium: gas condensate temperature: ~45℃ rotation speed: 2900r/min with motor power: 22KW voltage: 380KV model: YB180M-2W 2 sets ⑺. Lower section condensate circulation pump: 2 models: IS150-125-315 Q=120～240m3/h H=34～29m single-stage, single-suction centrifugal pump medium: gas condensate temperature: ~30℃ rotation speed: 1450r/min with motor power: 30KW voltage: 380KV model: YB200L-4W 2 sets ⑻. Condensate pump: 2 models: ISR50-32-200 Q=7.5～15m3/h H=48～52.5m single-stage, single-suction centrifugal pump medium: Ammonia temperature: ~75℃ rotation speed: 2900r/min with motor power: 5.5KW voltage: 380KV model: Y132S1-2 2 sets ⑼. Blower water seal tank submersible pump: 2 models: LYA40-160 Q=28m3/h H=28m single-stage, single-suction corrosion-resistant submersible pump medium: Gas condensate, tar, ammonia temperature: ~30℃ rotation speed: 2960r/min Page 30 / 34 Insertion depth: L=3800㎜ with motor power: 7.5KW voltage: 380KV model: YB132S2-2W 2 sets of ⑽. Waste liquid collection tank submersible pump: 2 models: LYA40-160 Q=28m3/h H=28m single-stage, single-suction corrosion-resistant submersible pump medium: gas condensate temperature: ~50℃ rotation speed: 2960r/min insertion depth: L=3800㎜ with motor power: 7.5KW voltage: 380KV model: YB132S2-2 2 sets ⑾. Electric water trapping and sealing tank submersible pump: 1 model: LYA40-160 Q=28m3/h H=28m single-stage, single-suction corrosion-resistant submersible pump medium: gas condensate temperature: ~30℃ rotation speed: 2960r/min insertion depth: L=3800㎜ with motor power: 7.5KW voltage: 380KV model: YB132S2-2W 1 set ⑿. Exhaust cleaning pump: 2 models: IS50-32-200 Q=7.5～15m3/h H=52.5～48m Single-stage, single-suction centrifugal pump transports medium: Ammonia temperature: ~75℃ rotation speed: 2900r/min with motor power: 5.5KW voltage: 380KV model: Y132S1-2 2 sets ⒀. High pressure ammonia water pump: 2 models: D46-50×7 Q=30～55m3/h H=388.5～322m Multi-stage, single-suction centrifugal pump transports medium: Ammonia Page 31 / 34 Temperature: ~75℃ rotation speed: 2950r/min with motor power: 75KW voltage: 380KV model: Y280S-2 2 units⒁. Manual single beam crane: 1 model: SDQ-10 lifting capacity: 10 tons LK = 13 meters lifting height: 6 meters track width: 70㎜ attached: Lifting capacity of hand chain hoist: 10 tons lifting height: 10m model: HS10 1 unit ⒂. Manual monorail trolley: 1 model: SDX-5 lifting capacity: 5 tons lifting height: 5 meters attached: Hand chain hoist: Lifting weight: 5 tons lifting height: 5 meter model: HS5 1⒃. Trolley with bucket: 3 sets of ⒄. oil filters: 1 model: LY150 equipped with motor: power: 3KW voltage: 380V ⒅.Electric tar trap: 2 models: FD248-II-A(D) working medium: Coke oven gas treatment gas volume containing tar and naphthalene mist droplets: 48000～58000m3/h gas temperature: 22～25℃ gas pressure: ~-3~-5KPa insulation box jacket steam pressure: 0.4～0.5 MPa steam heating tube pressure: 0.4～0.5 MPa top cleaning fluid pressure: ﹥0.3 MPa sedimentation pole: Structural type: Honeycomb single tube specifications: Inscribed circle of regular hexagon: 250×4500 units Page 32 / 34 Effective cross-sectional area: 13.4㎡ attached: High-voltage constant current power supply (indoor type) 1.0A/60KV 2 sets (ii. Equipment maintenance): 1. Operators must have “four understandings and four skills””: Understand the structure, principles, performance, usage, know how to use, know how to maintain, know how to troubleshoot, and know how to make minor repairs. 2. Operators must operate the equipment carefully and correctly, and strictly follow the operating procedures. 3. Strictly control the process technical conditions to ensure no overheating, no overpressure, and no overload. 4. Regularly inspect the lubrication systems of all operating equipment to ensure that the oil level is within the required range. 5. All valves should be lubricated regularly to ensure smooth operation. 6. The standby operating equipment should be rotated once per shift, while the standby fans should be rotated 1/4 of a turn per shift. 7. Before starting any operating equipment, it must first be rotated, and the auxiliary equipment as well as the lubrication conditions in various areas should be checked; equipment with defects must not be put into operation. 8. Regularly take samples of the lubricating oil in the wind turbine’s oil tank for analysis; address any changes in the oil quality promptly. Filter the oil once a month and clean the filter elements on a regular basis. 9. Regularly test the quality of the oil in the hydraulic coupling tank; it must be replaced promptly if it does not meet the standards. 10. The backup electric blower should undergo an air-drop test once a month, and the electrician shall check its insulation condition twice, with the electrician required to make proper records in the shift handover book. 11. The fan operates for a period of 3 months; upon expiration, maintenance personnel must conduct a thorough inspection and testing to determine whether it can continue to operate, and they should also inspect and maintain the backup fan. 12. The ammonia spray nozzles of the electrostatic tar catcher should be cleaned once a year, and any clogged nozzles should be replaced. 13. Have electrical personnel regularly check the insulation performance of the electrostatic precipitator system. 14. Under normal circumstances, the ammonia water pump 3 should be replaced every three months for a thorough inspection. Pages 33/34: Motors with a power of 15.50 KW or more must not be started continuously more than three times. 16. All equipment and the working environment must be kept clean, with no leaks or spills, to ensure civilized production practices. 17. The equipment should be painted regularly to prevent corrosion, and measures should be taken in advance to cool it down in summer and protect it from freezing in winter. 18. Regularly check and adjust the temperature and pressure of the equipment cooling water as well as the cooler cooling water, to prevent excessive water temperatures from damaging the equipment and from water entering the oil. 19. Strictly implement the routine inspection system, adhere to the five-step approach of \"listening, feeling, checking, observing, and smelling\", and address any abnormalities promptly

Exam Questions for the Cold Drum Section I. Fill in the blanks: 1. In the lower section of the primary cooler, chilled water flows, while in the upper section, circulating water flows; gas flows through the shell side, and cooling water flows through the tube side. 2. The critical speed of the blower is 3708 r/min, which corresponds to a coupling speed of 2037 r/min. 3. Closely monitor the oxygen content in the gas to ensure the safe operation of the electrostatic tar catcher. Alarm value: 1.0%, trip value: 1.8%. 4. The temperature of the gas after the electrostatic tar catcher is <30°C, the secondary current is >300mA, and the secondary voltage is <45KV. 5. Rotate the drum once every 15-20 minutes within two hours after the blower is stopped. 6. The blower unit must not operate in the surge zone; if it is found to be operating in this zone, the return control valve should be manually opened promptly or the speed should be adjusted to help the unit exit the surge zone as soon as possible. 7. The explosion range of gas is 5.6–30.4%, and its auto-ignition temperature is 648°C. 8. The maximum allowable concentration of ammonia in the air is 30 mg/m3. 9. Purpose of initial cooling of gas: First, to cool the gas; second, to separate tar and ammonia water, and to remove tar residues. 10. The temperature of the gas before entering the primary cooler is 80–85°C; after the primary cooler, it is 23–25°C in winter and 21–23°C in summer. The upper section of the primary cooler is generally sprayed with circulating ammonia water to remove tar adhering to the pipe walls, while the lower section is sprayed with light tar to remove naphthalene from the gas. The gas exiting the initial cooler passes through an electrostatic tar catcher to further remove any tar mist from it, before being sent to the next processing stage. 11. Closely monitor the oxygen content in the gas to ensure the safe operation of the electric tar catcher. 12. The outlet pressure of the high-pressure pump is ≥4.5 MPa, and the outlet pressure of the circulation pump is ≤0.6 MPa. 13. The temperature of the tar storage tank is 80–90°C; the moisture content of the tar is <4%, and its density is 1.15–1.21 g/ml. 14. The separation time of tar and ammonia water in the mechanized ammonia water clarifier is over 20 minutes. 15. Regularly check the liquid levels in all oil tanks and water tanks to ensure that there is no overflow or depletion of fluid. 16. In the event of a sudden power outage, the outlet valves of each pump should be closed, and the power supply should be cut off immediately. 17. Regularly check whether the opening degree, temperature, pressure, and flow rate of the pump’s outlet valve meet the requirements. 18. Before starting the pump, carefully check that all components are in good condition: the packing is in good order, the compression ring is in good condition, there is sufficient lubricating oil, and all valves function properly. 19. Gas suction before the primary cooler < 4 KPa; temperature: 80–85°C. 20. Gas temperature after the electrostatic tar precipitator < 30°C. 21. Gas pressure after the blower ﹤20 Kpa. 22. The bearing temperature of the blower motor is <100°C, and the shaft displacement is ±0.7um. 23. Hydraulic coupling oil pressure: 0.15–0.3 Mpa. 24. The critical speed range of the blower is 3500–3900 r/min. 25. Oil pressure at pump outlet > 0.18 Mpa. 26. The pressure of the high-pressure ammonia pump is ≥4.5 MPa. 27. Regularly clean the oil filter at the fuel station to remove accumulated impurities. 28. The moisture content of tar should be <4%. 29. The clarification time in the mechanized ammonia water clarifier shall be no less than 20 minutes. 30. The speed of the scraper conveyor is 1.8 m/h. 31. Tar is a black viscous liquid with a density of 1.15–1.21 g/ml. It has a characteristic unpleasant odor, and its viscosity is ≤4. E: Toluene insolubles 3.5–7.0%, ash content ≤0.13%, moisture content ≤4%. 32. The viscosity of tar decreases as the temperature rises. 33. If the temperature of the gas at the outlet of the primary cooler is high, the resistance of the electrostatic tar catcher tends to increase. 34. The temperature of the tar in the storage tank should be maintained at 80–90°C to reduce its viscosity, thereby facilitating dehydration through settling. The tar must remain in the tank for more than 36 hours, and water should be removed from it regularly. 35. The pressure in the gas collection pipe is generally maintained between 80–120 Pa, in order to reduce the entrainment of coal powder and coke powder along with the gas. 36. 30 process technical indicators for the cold drum section. 37. Quality standards for coal tar. II. Short Answers 1. Post safety regulations 1. The relevant provisions of the gas safety regulations must be strictly followed. 2. Open flames are strictly prohibited; it is also forbidden to strike fans, gas equipment, and pipelines with metal objects. 3. Flammable and explosive materials are strictly prohibited from being stored in the fan room; be careful to avoid burns caused by hot tar and ammonia water during operation. 4. During mechanical operation, it is prohibited to repair, wipe, or touch the rotating parts. 5. The startup and shutdown of the blower must be carried out in strict accordance with the operating procedures. 6. When there is a sudden change in the pressure before and after the fan, inspections and adjustments should be carried out until the abnormal condition is resolved. 7. If abnormal phenomena such as knocking sounds are detected in the fan, it should be reported to the supervisor promptly. 8. The water seal for the furnace gas must always remain unobstructed. 9. When it is detected that the oxygen content in the gas is greater than 1.0%, power supply to the electrostatic precipitator should be stopped. Identify the cause, address it so that everything is normal, and then restore power supply. 10. When performing maintenance at the top of the electrostatic precipitator due to a power outage, work can only be carried out after discharge. Entry to the high-voltage rectifier room is strictly prohibited unless it is for work-related purposes. 11. Pedestrians are not allowed to stay within 50 meters in front of the area at 30° angles on either side of the center line of the explosion-proof membrane opening of the electrostatic tar catcher. 12. During thunderstorm weather, be sure to reduce the voltage of the electric tar catcher to below 30 KV. 13. Work at heights is prohibited during thunderstorms. It is prohibited to use mobile phones and walkie-talkies at heights. 14. Some platforms are lacking kickboards; all employees should be cautious to avoid slipping and falling from the platforms. 15. The drum cooling operator should be familiar with the properties of coal gas and ammonia water, and keep in mind the following: The explosion range of coke oven gas is 5.6–30.4%, with a auto-ignition temperature of 648°C. The explosion range of ammonia gas is 15.7–27.4%, with an auto-ignition temperature of 651°C. The maximum allowable concentration of ammonia in air is 30 mg/m3. 2. Job responsibilities: 1. Responsible for the transportation of coke oven gas and ammonia water, as well as the separation of tar and ammonia water; also responsible for the initial cooling of raw coal gas, to ensure stable pressure in the coke oven collection pipes. 2. Responsible for removing naphthalene and tar mist from gas. 3. Responsible for collecting tar, dehydrating it, and storing it. 4. Responsible for delivering recycled ammonia water and high-pressure ammonia water to the coke oven. 5. Responsible for delivering the remaining ammonia water to the ammonia vaporization unit. 6. Complete temporary tasks assigned by supervisors on time. 3. Causes of sudden increase in suction pressure in front of the blower and corrective measures. Cause: The air collection duct adjustment flap is closed, with poor adjustment ； High fan speed ； The drain pipe of the main gas pipeline before the primary cooler was blocked, resulting in a liquid seal forming at the main gas pipeline ； Measure: Contact the coke oven to adjust the flap ； Adjust the fan speed appropriately ； The liquid return pipeline should be purged in a timely manner ； Conduct regular inspections to ensure there are no gaps in the system ； Pay attention to changes in system resistance behind the machine ； 4. Handling of sudden power outages in the fan room: 1. Immediately cut off the power supply to the blower, reduce the speed of the hydraulic coupler to its lowest level, quickly close the gas outlet valve of the blower, and shut down the electric precipitator in use. 2. Contact the coke oven control room to inform them that the blower has lost power and stopped operating, ask them to take emergency measures, and contact electricians, instrument technicians, and maintenance staff to arrive at the site. 3. Contact the dispatch and power distribution room to inquire about the cause of the power outage and the time when power will be restored. 4. On-site, pay attention to monitoring the liquid level in the condensate circulation tank and ensure that the level does not overflow onto the site. 5. Check that all equipment is functioning properly and ensure it is in a standby state. 6. Be prepared to drive upon receiving a call, and maintain smooth communication with the relevant departments. 5. Steps for reversing the fan: 1. Start the main motor of the new unit when the oil pressure at the oil station outlet reaches 0.15 Mpa; if the rated current is not restored within the specified time (about 1 minute), stop attempting to start it. Three consecutive attempts to start are prohibited. 2. During the startup process of the unit, it is necessary to listen to the sounds coming from within various components, and pay attention to the engagement of the bearing gears as well as the operation of the oil pump and oil seals. If any abnormal noises are heard, immediate action should be taken or the unit should be stopped for inspection. 3. After the new machine starts up, wait until the current drops to normal levels, then adjust the blower’s speed to around 2800–3000 rpm. After waiting until the pressure reaches 6.5–7 kPa or higher, open the gas outlet valve of the new unit by one notch; opening the outlet will result in a decrease in the suction force in front of the device. Then increase the speed of the new unit to around 3400 revolutions per minute. Once the speed is stable, observe any changes in the suction force. If the suction force is too high, reduce the speed of the original unit accordingly – this will lower the suction force, and at the same time increase the speed of the new unit. Adjust the outlet valve of the original unit to half-open status based on the pressure levels, increase the speed of the new unit and also open its outlet valve to half-open, then monitor the suction force again. Once the speed of the new unit is at the appropriate level, fully open its gas outlet valve until the pressure returns to normal levels. Set the original blower’s speed to zero and close the gas outlet valve of the original unit. (When opening and closing the inlet and outlet valves, try to use a small range of movement to ensure that the suction pressure in front of the device is not lower than -1000 Pa and not higher than -3000 Pa.) ) 6. Steps for starting and stopping the high-pressure ammonia water pump: Starting the pump 1. Before starting the pump, inspect all pipelines and valves, check the high-pressure pump for any issues, and address any leakage points promptly. 2. Before starting the pump, turn it over manually and open the inlet valve of the high-pressure ammonia water pump as well as the pressure gauge valve to discharge any gas present inside the pump. 3. Supply power to start the pump and adjust its speed using the frequency converter; once the outlet pressure reaches 1 Mpa, slowly open the pump’s outlet valve, keeping the pressure at ≥4 Mpa. 4. The pump must not be operated without water to prevent damage to the impeller and seal rings. 5. The bearing temperature should not exceed 100°C. Stop the pump: 1. Notify the workshop, dispatch team, and coke oven. 2. Reduce the speed to the lowest level using the frequency converter and then cut off the power supply. 3. Close the inlet and outlet valves of the pump. 7. Steps for starting and stopping the circulating ammonia water pump: Starting the pump 1. Before starting, contact the coke oven unit and the dispatch team, and have the maintenance and electrical staff confirm that everything is in order before preparing to start the pump. 2. Before starting the pump, turn it over manually and open the inlet valve as well as the pump’s exhaust valve to remove all air from inside the pump. 3. Power on the pump and slowly open the outlet valve; pay attention to the pressure, motor current, and vibration of the pump, and adjust the pump’s outlet valve according to the required flow rate. 4. After normal operation, carefully check for any abnormal phenomena in various parts of the system, and pay attention to the motor temperature rise and bearing temperatures. Shutting down the pump: 1. Upon receiving the notification to shut down the pump, contact the relevant departments and get ready to do so. 2. Gradually close the pump’s outlet valve; once the current reaches its minimum value, cut off the power supply, and then close both the outlet valve and the inlet valve. 3. Notify the electrician to cut off the power supply and drain all liquid from the pump. 8. Purging operation of the electrostatic tar precipitator
1. Notify the electrician to come to the site; inform the condensation operators to adjust the valve for the electrostatic condensate on the main ship, and close the valve allowing the electrostatic condensate to flow into the condensate circulation tank of the primary cooler. 2. Remove the file and shut down Electric Deodorizer No. 1. The electrician cuts off the power supply to Electric Deodorizer No. 1, performs grounding discharge, and maintains the electrical components. 3. Close the inlet valve and outlet valve for gas at 1# electrostatic precipitator; open the top gas release valve and the small release valve of the insulation box. Open the small gas bypass valve, and slowly open the steam purge valve on the apparatus body to purge the electrostatic precipitator. Adjust the opening degree of the steam valve based on the amount of gas vented from the top. Blow out and vent the gas inlet pipeline through the drain pipe. 4. After allowing steam to vent from the top for about half an hour, close the steam valve, the top vent valve, and the small vent valve of the insulation box. Then, close the steam purging valve on the liquid drain pipe of the inlet pipeline and open the liquid drain valve. 5. Slowly open the gas inlet valve until it is fully open, and slightly open the gas outlet valve to cool down the gas. Pay attention to the temperature of the gas after electrostatic precipitation, the temperature of the gas before the blower, and the oxygen content in the gas. Based on these temperature readings, gradually open the gas outlet valve. Close the small gas bypass valve. 6. Employees inspect the No. 1 electrical explosion-proof plate, and compare the manually measured oxygen content with the computer-generated oxygen level. 7. Contact the electrician to supply power to #1 electrostatic precipitator. After passing the self-check, start #1 electrostatic precipitator when the oxygen level is low due to no coal being loaded. Increase the setting to the appropriate level and check whether the voltage and current are normal; generally, the setting is increased to level 9 when the electrostatic precipitator is started up right after purging. Pay attention to inspecting the operating status during routine checks. 9. Cold drum process flow: 1. Raw coke oven gas enters the gas-liquid separator, where the gas is separated from tar, ammonia water, etc. The separated raw gas is cooled in a primary cooler. The separated tar-ammonia water and tar residue together enter a mechanized ammonia water clarifier for separation. 2. The primary cooler is divided into upper and lower sections. In the upper section of the primary cooler, circulating ammonia water is used to exchange heat with the coal gas. Here, the coal gas is cooled from 80°C to 45°C, while the temperature of the circulating water rises from 32°C to 40°C. Then, the gas enters the lower section of the primary cooler, where it exchanges heat with the chilled water in the cooling tubes, cooling from 45°C to 22°C. Meanwhile, the temperature of the chilled water rises from 16°C to 23°C. The cooled gas enters the electrostatic tar catcher in parallel to remove as much tar droplets and naphthalene as possible from the gas. After passing through the electrostatic tar catcher, the gas goes into a negative-pressure desulfurization tower to have hydrogen sulfide removed, after which it is pressurized using a centrifugal blower. The pressurized gas is then sent to the anhydrous ammonia section. 3. The tar, ammonia water, and tar residue separated from the gas-liquid separator converge and flow by gravity to the mechanical ammonia water tar clarification tank. After clarification, it separates into three layers: the upper layer is ammonia water, the middle layer is tar, and the lower layer is tar residue. The separated ammonia water is combined and overflows into the circulating ammonia water tank, after which it is pressurized by a circulating ammonia water pump and sent to the coke oven to cool the raw gas. When the primary cooler and electrostatic tar catcher in this section need to be cleaned, a portion of water is drawn from the circulating ammonia water pipe for regular cleaning. The excess ammonia, that is, the residual ammonia, is drawn from the circulating ammonia pipeline; a portion of it is sent to the residual ammonia tank. After settling and separation, the ammonia enters an air flotation unit to remove some of the floating oil, and then it goes into the residual ammonia transfer tank. From there, it is pumped using a residual ammonia transfer pump to the ammonia vaporization process. Another portion of this ammonia is pumped via a high-pressure ammonia pump into the bridge tubes of the coke oven to help reduce smoke and dust during coal loading. The separated tar is sent to the tar intermediate tank; once a certain liquid level is reached, it is pumped to the tar dehydration tank using a tar pump to allow dehydration. Once the moisture content in the tar meets the required standards, it is pumped to the storage area using a tar pump. The separated tar residue is placed in a tar residue container and then sent to the coal yard for mixing in coke production. 10. Spraying operation of the primary cooler: 1. Inform the water pump room to stop the spraying at the primary cooler, and pay attention to monitoring the levels of the cooling water and circulating water. 2. Adjust the control valve for the condensate flow to the maximum position on the large vessel in order to reduce the liquid level in the condensate circulation tank; inform the staff responsible for condensate handling to stop adding light tar to the condensate circulation tank, and adjust the opening degree of the valve that controls the flow of condensate to the large vessel according to the actual conditions. 3. Close the gas valve at the outlet of the 1# primary cooler, as well as the water supply valve for cooling water and the water supply/return valve for circulating water in the 1# primary cooler. 4. Close the spray valves in the middle and lower sections of coolers 2#, 3#, 4#, and 5#. Stop pumps 1# and 2# for condensate and close their outlet valves; close the valves leading from pumps 3# and 4# to the main spray pipeline in the middle section, and open the bypass valves for pumps 4# and 5#. 5. Based on the liquid level in the condensate circulation tank, open the ammonia spray valve at the upper section of #1 primary cooler and carry out spraying for about 1 hour; after that, close the ammonia valve. Then open the ammonia spray valve at the lower section of #1 primary cooler to continue spraying, and once the temperature at the back of #1 cooler rises to 50°C (with spraying at the lower section continuing for no less than 1 hour), close the ammonia valve. 6. Perform ammonia replacement in the water seal tank of the primary cooler and the condensate circulation tank one by one; after the replacement is complete, maintain a stable liquid level in the condensate circulation tank. 7. Notify the pump room to start feeding water to the No. 1 primary cooler, and slowly open the valves for circulating water inlet and return flow, as well as the valve for refrigerant water inlet. 8. Open the valves of the intermediate spray headers for the 3# and 4# condensate pumps; open the spray valves for the upper and lower sections of the 2#, 3#, 4#, and 5# primary coolers; start the 1# and 2# condensate pumps and open their outlet valves. 9. Wait until the temperature of the gas after passing through the No. 1 primary cooler drops to 30°C; then slowly open the gas outlet valve based on the suction force, and adjust the temperature thereafter. Open the spray valve at the lower section of the 1# primary cooler. 10. Adjust the liquid level in the condensate circulation tank as appropriate, and inform the staff responsible for condensation to operate the large valves in order to add light tar to the tank, while ensuring that the required ratio is maintained.

Is it enough? If it’s not enough, there’s more

Are there any photos from the scene? It would be great if there are pictures of large ships

Currently, the 5 large vessels are placed side by side in operation, and with insulation in place it’s not possible to see much; in the future, when they are taken out for maintenance, photos can be taken of the internal scrapers and chains

The process flow is detailed enough; photos are not very useful.

3.1.5.1 Condensation and Blowing Section a) Process Flow: The raw gas coming from the coke oven at -82°C, along with tar and ammonia water, flows through the coal suction pipeline to the gas-liquid separator. After separation, the raw gas exits from the upper part and enters 5 horizontally arranged primary coolers that operate in parallel (two in use and one as a spare), where it is cooled in two stages. The upper section uses 32°C circulating water, while the lower section uses 16°C cold water to cool the gas to 2122°C. The gas discharged from the lower part of the horizontal tube initial cooler enters 3 electric tar capturers operating in parallel (2 in Phase 1), where the tar contained in the gas is removed. The gas is then pumped to the desulfurization section by gas blowers (3 in total, 2 in Phase 1). To ensure the cooling efficiency of the primary cooler, a mixture of tar and ammonia water is sprayed continuously in the upper and lower sections, while the top part is periodically rinsed with hot ammonia water to remove impurities such as tar and naphthalene from the pipe walls. The primary cooler is equipped with break plates that divide it into upper and lower sections. The condensate discharged from the upper section flows into the upper condensate tank through a water seal groove, and is then pumped to be sprayed in the middle of the upper section of the primary cooler; any excess amount is sent to the mechanical ammonia clarification tank. The condensate discharged from the lower section of the primary cooler flows into the lower condensate tank through the water seal groove; after adding a certain amount of tar, it is pumped to the top of the lower section of the primary cooler for spraying, while the excess amount flows into the upper condensate tank. Hot ammonia water is periodically introduced into the upper and lower condensate tanks to heat and dissolve impurities such as tar and naphthalene at the bottom of the tanks. The tar and ammonia water separated by the gas-liquid separator first enter a mechanical ammonia water clarification tank, where separation of ammonia water, tar, and tar residue takes place. The ammonia water from the upper part flows into the circulating ammonia water intermediate tank, and is then pumped by the circulating ammonia water pump to the coke oven gas collection pipe to spray cooling water on the coal gas; the remaining ammonia water is sent to the remaining ammonia water intermediate tank. The tar at the bottom of the clarification tank flows into the tar separator under the action of static pressure, where further sedimentation and separation of tar from tar residues take place. The tar is then sent to the tar storage tank in the oil storage area using a tar pump. The tar residue that settles at the bottom of the mechanized ammonia clarification tank and the tar separator is scraped onto tar residue trucks and sent to the coal yard on a regular basis to be mixed into coking coal. The residual ammonia water that enters the residual ammonia water intermediate tank is pumped by the residual ammonia water intermediate pump to the tar remover; after the tar is removed, it flows back to the residual ammonia water tank, from where it is then pumped by the residual ammonia water pump to the residual ammonia water distillation unit in the ammonium sulfate production section. The tar removed by the tar remover flows back to the underground vent tank.

b) Process characteristics: 1) A high-efficiency cross-tube cooler is used as the primary cooler to cool the gas to 2122°C, thereby removing most of the naphthalene from the gas through primary cooling. This achieves the goals of cooling the gas, removing oil, and eliminating naphthalene, prevents blockages in subsequent equipment, and significantly reduces operating costs and capital investment. 2) The horizontal tube cooler features a two-stage structure with a break tower disk in between, which reduces the amount of low-temperature water required and lowers operating costs. 3) A new type of high-efficiency honeycomb electrostatic tar catcher is used, which allows the tar content in the gas after treatment to be kept below 50 mg/m3, thereby facilitating the proper operation of subsequent equipment. Ceramic insulators are filled with nitrogen for protection, which reduces the need for maintenance and extends their lifespan. 4) The gas blower is a high-efficiency and low-consumption centrifugal electric gas blower equipped with a hydraulic coupling, which allows the blower to adjust its speed according to the amount of gas required. This feature is suitable for the periodic fluctuations in gas volume in coking plants, and it also enables automatic adjustment of the pressure in the gas pipeline leading up to the blower. It also features flexible operation control, as well as high efficiency and energy savings. 5) The tar content in the remaining ammonia water is **reduced** after passing through the tar remover, which reduces the polymerization of tar on the trays of the ammonia evaporation tower, ensures stable operation of the tower, maintains a consistent quality of the ammonia evaporation wastewater, and contributes to environmental protection.