[Request for Upload Summary] Operating Procedures for Gas Production Position (Production Plan)

The pressure of semi-water gas at the gas generation station should not exceed 0.05 MPa, while the pressure at the outlet of the gas holder is generally 30 mm of mercury. I. Tasks of this position: The intermittent fixed-bed vaporization method is employed, whereby bituminous coal or coke is used as raw material; under high-temperature conditions, it undergoes vaporization reactions alternately with air and superheated steam, to produce qualified semi-water gas for use in subsequent processing stages. II. Process parameters for this position: 1. Temperature: Temperature of the rising gas: 180°C–250°C; Temperature of the descending gas: 150°C–250°C. Temperature of the hydraulic oil: ≤40°C. Temperature of the gas entering the gas holder: ≤50°C. Temperature of the gas entering the desulfurization unit: ≤40°C. 2. Pressure: Steam pressure after pressure reduction: 0.06–0.08 MPa; Steam pressure before pressure reduction: ≥0.9 MPa. Pressure in the jacketed vessels of each furnace: ≤0.2 MPa. Pressure of the hydraulic oil: 5.0–6.0 MPa. Pressure difference in the gas generation system: ≤0.5 mmHg. Air pressure: 0.015–0.02 MPa. 3. Gas composition: CO2 ≤ 8%, CO ≥ 30.0%, O2 ≤ 0.5%. 4. Liquid level in each drum: between 1/2 and 2/3; height of the gas tank: 1400 m3–4400 m3. III. Safety operating procedures for this position: 1. Follow the start-up and shutdown procedures specific to this position strictly. 2. Strictly control the outlet temperature of the furnace to ensure normal operation of the reaction process. 3. Strictly control the oxygen content level in semi-water gas. 4. Conduct strict routine inspections, and carry out ash and waste discharge at regular intervals. 5. Strictly abide by the safety production regulations for this position to ensure safe production. 6. Identify potential accident hazards in a timely manner, contact the relevant personnel to handle them, and address accidents at their earliest stage. IV. Key operating points for this position: 1. The various data collection points and alarm parameters on the computer must not be deleted arbitrarily. 2. Carefully adjust the liquid level in the jacket steam drums of each furnace to ensure a continuous supply of coal to the coal bin. 3. Control the reaction conditions of each furnace, as well as the height of the carbon layer and the temperatures at the upper and lower levels, to keep the furnaces in good condition. 4. Make sure to check the lifting and lowering status of the valves on each furnace pedestal. 5. Pay attention to the fan bearing temperature and motor current. 6. Scheduled dust cleaning and removal. 7. Ensure that all operating equipment is functioning properly. 8. Adjust the quality of semi-water gas properly, and pay attention to the water supply volume to the scrubber tower. V. Operating Procedures for This Position 1. Starting up 1) Before starting up, conduct a thorough inspection of all equipment first. 2) Start the oil pump and check for any abnormal noises, then adjust the oil pressure. 3) Seal the water seal at the gas holder outlet and the U-shaped connection water seal, and check whether there is water accumulated in the water seal at the gas holder inlet. 4) Check the cycle time of calibration, as well as the operation of various automatic valves and the on/off status of each control valve. 5) Check and verify that all instrument parameters are normal. 6) Check the steam inlet valve and the upper and lower blowing valves, and adjust their opening degrees to appropriate levels. 7) Maintain the level in the jacket and sensible heat boiler at 1/2–2/3, and check whether the vent valve is open. 8) After replacing the air main with steam, start the fan and open the outlet valve. 9) After upward blowing, air is blown in to raise the temperature; then the parameters of the microcomputer are adjusted to start the production of inert gas. Samples are taken from the top of the gas tank for analysis – the oxygen level should be less than 0.5%, and the levels of carbon monoxide and hydrogen should be less than 7%. Once these conditions are met, the water seal at the outlet is removed, and once the gas sent to the processing unit meets the required standards, normal production of coal gas begins, with the gas being supplied to the processing unit as usual. 2. Shutdown 1) First, set the microcomputer to the shutdown position, open the drum vent, and close the steam valves before and after the pressure relief valve. 2) Stop the fan, close the fan’s outlet valve, open the steam for air displacement, seal off the individual furnace, as well as the water seals at the U-shaped bends and at the inlets and outlets of the gas holder, along with the water seals in the U-shaped ducts. 3) Raise the vent valve and stop the oil pump. 4) If hot work is required, or for purging, use 1-2 boilers to set the microcomputer to the inerting program before shutting down the furnace. 5) Adjust the circulation time, start producing inert gas, and purge the system. Sampling analysis for CO+H2

I. Commissioning of the gas system The commissioning of the gas system (including initial commissioning after new construction or major repairs) involves steps such as trial operation and acceptance, ignition and furnace heating, removal of inert gases, and furnace stabilization to produce gas. Points to note for the initial startup of a gas generator system: (1) Refer to the drawings and instructions to thoroughly inspect and verify that all equipment, pipes, valves, analysis sampling points, electrical components, and instruments within the system are in good working condition. ⑵The air blower, furnace strip machine, oil pump station, and microcomputer control system shall each undergo individual trial runs in accordance with the relevant regulations and pass such tests. Among them, the micro-hydraulic control system should drive the hydraulic valves to carry out simulated linkage tests to ensure sensitive and accurate operation. ⑶The purging, cleaning of the system, as well as the airtightness tests and leak checks, shall be carried out in accordance with the relevant procedures to ensure compliance. ⑷Before replacing the gas holder, an air lift test should be conducted to check whether the bell cover of the gas holder can move up and down smoothly across its entire height range. And whether the height indication device, alarm signals, and automatic venting device are sensitive and accurate. ⑸The ignition and heating-up of the gas generator shall be carried out in accordance with the regulations. Rapid temperature increase is strictly prohibited. ⑹System replacement should be thorough, leaving no dead corners. (1) Commissioning and acceptance: After the installation or major repair of each piece of equipment, strict commissioning and acceptance procedures should be carried out separately. This is done to verify that the installation or overhaul meets the required standards; it is crucial for ensuring that production targets can be met properly in the future, and it represents one of the essential steps in the entire commissioning process. The testing scope should include: the trial operation of the transmission equipment as well as tests under light and heavy loads ； Pressure testing and leak testing of stationary equipment and pipelines, as well as joint commissioning of the entire production system. Before conducting a test run, the following preparatory work is generally required. ⑴Organize the personnel from the relevant trial operation and acceptance agencies to divide the tasks among themselves ； ⑵Formulate commissioning procedures and technical quality standards, and organize relevant personnel to conduct training and research in order to achieve unified thinking, unified standards, and unified operations ； ⑶Ensure that all the tools, equipment, materials, instruments, etc. required for the commissioning process are readily available to meet the needs of this work. Review and verify the records of installation or major maintenance to have a clear understanding of the situation ； ⑷Conduct a detailed and thorough inspection of the electrical equipment, instruments, safety measures, etc., on the associated devices. 1. Individual unit testing: Individual unit testing can be divided into testing of transmission equipment, as well as pressure testing and leak testing of stationary equipment. (1) The individual testing of transmission equipment generally requires the following steps: ① The motor must be pre-tested separately. Before starting the motor, its insulation resistance must be checked; it may only be started if the resistance is within acceptable limits. It is required to operate continuously for more than 2 hours, and attention should be paid to checking the temperature, current, vibration, noise, and direction of rotation. ②After the motor passes the tests, before starting up the equipment with mechanical components such as high-pressure water pumps, air blowers, and air compressors, it is necessary to apply lubricant to all lubrication points and manually rotate the equipment several times to check for any issues such as unevenness, friction, or sticking inside the equipment. In the event of such phenomena, they must be eliminated carefully ； Each connecting screw, foundation screw, etc., should also be carefully inspected one by one; only after confirming there are no errors may startup and testing proceed. The first start-up time is very short; stop the machine at any time for inspection. Only if nothing abnormal is found can it be started a second time. During the testing process, it generally starts with no load or light load, and then the load is gradually increased to full load, requiring continuous operation for 8 to 24 hours. After the equipment starts operating, it is necessary to regularly monitor parameters such as temperature, pressure, current, and vibration, and keep proper records of them in a timely manner. (2) Pressure testing and leak testing of stationary equipment: All pressurized vessels with a working pressure of 0.7 kilograms per square centimeter or higher, such as high-pressure water tanks, jacketed boilers and steam drums, waste heat boilers and steam drums, steam buffer cylinders, and other such equipment, must undergo individual pressure tests. Pressure testing can be carried out at a pressure of 1.5 times the operating pressure. When conducting a hydrostatic test, the following points should be noted: ① Before filling the equipment with water for testing, its interior must be cleaned. ②During the process of filling the device with water, it is necessary to ensure that all air inside the device is removed so that the water can fill the entire device. ③During the pressure-raising phase at the start of the test, care must be taken to increase the pressure slowly, without exceeding the specified test pressure. ④During the pressure testing process, it is not allowed to subject the equipment to excessive pressure for long periods of time (i.e., above the operating pressure); generally, a pressure exposure of five minutes is sufficient (no detailed inspection is required at this point), and a detailed inspection should be carried out after the pressure is reduced to the operating level. Generally, it is allowed to use a small hammer weighing 0.5–1.5 kilograms to gently tap along both sides of the joints (about 150 millimeters away from them) in order to conduct a thorough inspection and check for any leaks or deformation at the joints. If there are no such adverse conditions, it is considered qualified. ⑤During the hydrostatic test, the ambient room temperature and water temperature must not be lower than +5°C; otherwise, anti-freezing measures must be taken. When using hot water for the test, its temperature must not exceed 60°C. ⑥For equipment equipped with safety valves, after passing the tests, the safety valves should be adjusted and calibrated. After passing the verification, apply a lead seal. ⑦After the pressure testing and adjustment of the safety valve are completed, care should be taken to drain all water accumulated inside the container to prevent the equipment from rusting or being damaged by freezing. 2. System testing (1) Hydrostatic system testing: Once the individual testing of the drive equipment and the pressure testing of the pressure vessels are completed, system testing can be carried out. The hydrostatic system testing is one of the important components of the overall system testing. ①Turn on the high-pressure water pump to feed clean tap water into the high-pressure tank. Once a sufficient pressure is achieved, remove the flange connections of each high-pressure water pipe at the hydraulic valve, and then wash the high-pressure pipes as well as the main high-pressure pipeline one by one. A small hammer can also be used to strike the pipes in order to dislodge rust from within them, until the water no longer contains any rust, sediment, impurities, or other contaminants. After stopping the high-pressure water pump, reinstall the flange connections on each removed high-pressure water pipe, in preparation for the official trial run. ②Drain all the excess water from the high-pressure tank and the return tank, clean them thoroughly, then add soft water or clean tap water to the return tank, along with a certain amount of water-soluble oil, to create an emulsified liquid. On one hand, the air compressor is started to supply compressed air into the high-pressure water tank ； On the other hand, a high-pressure water pump is used to feed high-pressure water into the high-pressure tank until the liquid level reaches 2/3 of its capacity; once the pressure reaches 9.5 kilograms, this pressure is used to test each high-pressure water pipe individually, checking for any leaks at the joints. Any leaks found must be repaired promptly before further testing, and this process continues until all pipes pass the inspection. ③Automated machine testing a. Adjust the percentages for each stage of the cycle according to the process requirements ； b. Add lubricating oil to each filling station separately. The grade of the lubricating oil used shall meet the following requirements: For rolling bearing parts, use industrial lubricating oil No. 3 ； Other gears, friction parts: Use spindle oil No. 3 or turbine oil No. 22. c. The motor shall be tested in accordance with the requirements for individual testing. After passing the inspection, connect the backrest wheel to prepare for driving the transmission mechanism for a test run. d. Inform the blower and furnace strip machine operators to supply high-pressure water for the automaton testing, and open the control valves for the inlet and outlet water pipes of the hydraulic valve. For the specific testing method, first pull out the start lever, then pull out the hydraulic pressure lever to hold the four pistons in place; thereafter, manually operate each control lever and change direction several times to check whether the gaskets and flanges of the main hydraulic cylinders are properly tight. If not, appropriate adjustments should be made. At the same time, check whether the opening and closing actions of each valve controlled by each joystick meet the production requirements. If the opening and closing speed of each hydraulic valve is too fast, it can easily damage the equipment ； Too slow results in the loss of valuable production time ； If the various hydraulic valves do not work properly together, safety accidents are likely to occur. Generally, the switch speed should be adjusted to 2–3 seconds. e. Before testing the transmission mechanism using an electric motor, manually turn the drive wheel several times to check whether each transmission gear operates smoothly. Once this is confirmed, pull out the air control lever and the hydraulic control lever, then start the electric motor to test the transmission mechanism; it is required to operate continuously for more than 4 hours. Once it is confirmed that there are no issues, plug in the gas generator and turn on the switches for the automatic test control unit and the hydraulic valves. Also, pay attention to checking whether the direction-changing times of each control lever match the indications shown on the dial and the blowing scale ； Are the operating actions of each control lever consistent with those of the corresponding hydraulic valves? ； Are all emergency stop buttons sensitive? ； Whether the direction of each control lever can accurately move to the safe position after the automatic shutdown and emergency stop of the machine. (2) Gas system airtightness test ① Test scope includes gas burners, dust collectors, chimneys, waste heat boilers, gas scrubbing boxes, gas scrubbing towers, pipelines, valves, instrument pipelines, etc. ②Test method: Before the test, water should be added to each water seal device, and water overflow should be maintained ； At the isolation points outside the system, blind flanges or plugs should be installed. Compressed air or an air blower is generally used to introduce air into the system for sectional testing, leak detection in individual sections, or full-system testing. To detect leaks, one can use methods such as listening with the ear, feeling with the hand, and applying soap to each weld, valve, flange joint, screw hole, threaded connection, etc. If any air leaks are found, they should be marked promptly, and then fixed one by one. Then tests are conducted until full compliance is achieved. ③The test requires using compressed air to reach a pressure of 4000 millimeters of water column (or an air blower to achieve the maximum possible pressure), and this condition must be maintained for more than 2 hours, with a permissible air leakage rate of 2%. The formula for calculating the air leakage rate is as follows: a) In the formula, △p represents the air leakage rate, in %; P1 denotes the air pressure at the start (gauge pressure), in millimeters of water column ； P2----Air pressure at termination (gauge pressure), in millimeters of water column ； T1----Initial temperature, absolute temperature ； T2—Temperature at termination, absolute temperature ； B1—Initial barometric reading (ambient air pressure), converted to millimeters of water column ； B2—Barometer reading at termination (ambient pressure), converted to millimeters of water column. (3) Testing of the grate drive machinery ① After the motor passes the tests required for individual testing, it is connected to the reducer ； ②Inspect each lubrication point and apply sufficient lubricant ； ③First, run the reducer (with the ratchet disengaged) continuously for over 4 hours. Check that there are no abnormal noises, the rotation direction is correct, the current does not exceed 2/3 of the value specified on the nameplate, and the temperature is only slightly higher than room temperature – in which case it is considered acceptable. ④After the reducer passes the tests, a ratchet is installed, and the rear wheel is manually turned several times; at the same time, a dedicated person must be sent into the furnace to clean it and check for any metal debris that could cause jamming. Then, it drives the worm, worm gear, pinion gear, and gear to conduct a no-load test. During the testing process, it should start from a low speed and progress to a higher one, with each speed requiring the gray disk to rotate at least one full turn. Finally, a certain amount of ash is added to conduct a load test, requiring continuous operation for 8 hours, with regular checks to ensure that the current and temperature do not exceed the values specified on the nameplate. When the load is too heavy, it is required that the tower spring disengage automatically, causing the ratchet to slip ； When the current is too high, the motor fuse can blow on its own to protect the equipment. (4) Lifting test and airtightness test of the semi-aqueous gas holder ① Lifting test: It can be divided into fast and slow tests. Generally, one starts with a slow speed, and only after that does one try a faster speed; each speed should be tested more than 10 times. The method involves using a blower to inject air in order to raise the top of the gas tank, and then lowering the tank again. This process is repeated until the tank can be raised and lowered smoothly, with the guide wheels and rails fitting well together, and without any issues such as derailment or jamming occurring; at that point, it is considered qualified. The determination of the fast or slow lifting speed for the gas holder can vary from factory to factory. Based on the production capacity of each plant, along with a certain safety factor, the speed at which the gas holder rises or falls is determined; it is advisable that this speed not exceed 1.2 meters per minute. Determine whether it is normal during testing or by inference from the water column manometer. ②For the airtightness test, the gas tank can be filled with air until it reaches nearly its maximum capacity of around 850 cubic meters, at which point filling should be stopped. Water should then be poured into the water seals on the inlet and outlet pipes, and the volume, temperature, pressure, and time at the start and end of the test should be recorded. It is required that after 72 hours, the leakage rate of the gas holder be less than 2%. ③Testing of safety instrumented systems: Gas tanks equipped with acoustic and visual signaling devices are required to emit accurate and timely acoustic and visual signals when they reach their upper and lower limit positions ； When the gas holder is at its lower limit position, the safety cover at the top of its dome can accurately cover the gas vent pipe to prevent the gas holder from collapsing ； When the gas tank reaches its upper limit, it is required that those equipped with automatic venting systems to discharge air automatically promptly, in order to prevent other hazards that may arise from the tank being at too high a level. If it is necessary to drain water inside for inspection, the top vent valve should be opened first before draining the water, to prevent deflation. (II) Ignition and furnace heating: In newly built, overhauled gas systems, or those that have been out of use for a long time, there is a certain amount of moisture present in the refractory bricks and the gaps between them. If the temperature is raised rapidly without baking, the rapid evaporation of moisture can cause cracks in the refractory bricks, and there is even a risk of them collapsing. During the furnace drying process, wood is generally used for heating at a low temperature until the temperature at the outlet at the top of the furnace reaches around 200°C; after that, bituminous coal or coke is used for further drying. It must be noted that if a large amount of wood is used for heating the furnace, resulting in a significant accumulation of ash at the bottom of the furnace, this ash should be removed after heating is complete before the furnace can be filled with material and heated up according to the standard procedures. Otherwise, the entry of air into the furnace can easily lead to uneven distribution, affecting normal operation. The recommended baking time is generally 3 days and nights. If it is an old furnace and the refractory bricks have not been completely replaced but only repaired, the furnace drying time can be appropriately shortened. Before starting the furnace, the following preparatory actions should be taken: 1. For jacketed boilers and waste heat boilers, water should be filled to halfway up the level gauge, and the drum vent valve should be opened to allow exhaust; this valve should then be closed once steam production begins. When the steam pressure is high, the drum outlet valve can be opened to connect with the steam main. 2. Inspect the entire furnace body, including all circular and square doors, the covers of the flame detection holes, and the covers of the feeding cylinders, to check whether the sealing materials in these areas are in good condition ； Check whether each steam purging line is unobstructed and functional; if necessary, conduct tests. Sufficient lubricating oil should be added to all lubrication points. 3. The ash and slag to be loaded into the furnace should be about the size of a fist; the loading height should be around 200 millimeters above the top of the furnace grates (the ash and slag can be leveled in the furnace using a machine or by hand). Spread a layer of coke or brown coal on top of the ash (about 400-600 kilograms) ； Evenly add more wood and wood chips. Then, the lit oil-soaked cotton yarn is inserted from the furnace opening or flame inspection hole to ensure even combustion on the furnace surface. 4. During furnace drying, to adjust the heating rate, one can control the size of the round and square doors to regulate the amount of air entering the furnace. 5. When loading ash, wood, or other fuels, care must be taken to ensure that no hard objects such as metal parts (screws, nails) are brought into the furnace, to prevent the ash tray from getting stuck. (III) What are the key points for starting up a gas generator when it is not in a shut-off state? When starting up a gas generator while it is not shut down, the following steps should be followed: 1. Adjust the liquid levels in the jacket and the waste heat boiler drum to normal levels. 2. Put the microcomputer control system into a normal shutdown state, and ensure the oil pressure control system operates properly. 3. The overflow of the water seal in the scrubber tower is operating normally. 4. Close the furnace lid. 5. Close the jacket and the vent valve of the waste heat boiler drum, and immediately open the steam outlet valve to adjust the steam pressure after depressurization so that it meets the process specifications. 6. Open the steam purging valves for the downward coal gas pipeline and the ash hopper; once the bottom of the furnace has been cleaned, close these steam purging valves. 7. Turn off the microcomputer’s “Power” switch and “Start” switch to begin the gas generation process. 8. Start the furnace rod machine. 9. Once normal operation is achieved, connect the blowair recovery system, close the \"Recover\" switch, and send the blowair to the blowair recovery system. 10. Note: When starting up the system after maintenance, a gas-tightness test of the system should be conducted first; only after leakage checks and purging are successful should the steps from 1 to 9 be followed. (IV) How to carry out the feeding operation? What issues should be noted? Set the \"Process Selection\" switch group of the manual operator to the \"Stop\" position. After the control unit has operated for 10 seconds in blow-dry mode, switch the \"Manual/Automatic\" switch to the \"Manual\" position; at this point, the control unit shuts off all automatic control outputs, and the valves of the gas generation furnace are placed in a safe state. After adding the material, switch the “Manual/Automatic” switch to the “Automatic” position; the control unit will first perform an upward blowing operation for 12 seconds before moving on to the current processing step. The following points should be noted during the feeding operation: 1. Before shutting down the furnace, the person responsible for feeding must know the shutdown time required for the gas generator, and must not get the furnace number wrong. 2. Upon receiving the notification to stop the machine and open the furnace lid, a visual inspection should be carried out on the system’s air and steam flow rates, the pressures indicated by the micromanometers at the top and bottom of the furnace, as well as the displays on the microcomputer panel. Only after confirming that there is no flow or pressure, that all values are at zero, and that the valves shown on the microcomputer panel are in their safe positions, can the furnace lid be opened. 3. If the temperature inside the gas generator is low, ignition should be carried out after opening the lid, allowing air and flames to enter the furnace slowly, so as to burn the remaining gas in the furnace gradually; this prevents explosions that could result from a large amount of air entering suddenly due to rapid opening of the lid. 4. When adding fuel, it should be done slowly to ensure even distribution of the fuel within the furnace; rapid addition of fuel can temporarily extinguish the flames on the furnace surface, which may later lead to explosions at the furnace outlet. The height of the fuel layer varies depending on the properties of the fuel and the operating conditions. The feeding rate should be controlled according to the requirements of the microcomputer operator, in order to prevent significant changes in the height of the carbon layer and avoid large fluctuations in furnace temperature. (5) Production of inert gas and exhaust gas displacement: In new or newly overhauled gas systems, it is necessary to produce inert gas in order to remove the air from within the equipment and pipelines, thereby creating safe conditions for introducing gas into the system later on. The specific operating methods and replacement requirements are described as follows: Inert gas is produced using a generating furnace, and the operation is carried out at low furnace temperatures with a thin carbon layer. At this time, it is required that the fuel be coke in the form of small particles around 40 millimeters in size, with uniformity being essential (the particle size can be slightly larger if brown coal is used as fuel), and it must not contain fine ash. The surface of the carbon layer must be smooth, without any unevenness ； It is appropriate to maintain a fire layer of 30–40 centimeters inside the furnace, with a uniform distribution of the fire layer ； The amount of carbon added each time should not be too much; it should account for about 1/3 to 1/2 of the amount used in normal production (that is, around 200–300 kilograms) ； A test fire should be conducted before closing the furnace lid each time, in order to assess the actual condition of the flame inside the furnace and give the operator a clear idea. Check whether the internal and external conditions of the system meet the requirements of the operating procedures to ensure normal operation. Turn on the computer to perform inert gas generation operations. Open the control unit, close the \"Inerting\" switch, then close the \"Start\" switch; the control unit will initiate full evacuation once it receives a signal from the blow-out queue button allowing the furnace to be started. Wait until the gas composition is satisfactory (O2