How to formulate a production operation plan for a gasification furnace with two in service and one standby unit?
Thread Content
This post was last edited by xuqinger on 2009-10-31 at 19:55. For a gasification furnace with two units in operation and one as backup, how can long-term stable operation of the system be ensured? How to minimize the impact on subsequent processes when switching gasifiers? How should the work schedule be arranged between the standby furnace and the operating furnace?
1. Based on the service life of key components such as cylinder bricks, conical bottom bricks, arch top bricks, and burners, as well as the operating cycles of various mechanical devices, an annual production plan for the gasification furnace is formulated. This plan must detail the specific time of shutdown, the reasons for the shutdown, and the main tasks to be carried out during the shutdown. To avoid overlapping maintenance of multiple furnaces, the operation cycle of the gasification furnace can be adjusted accordingly. 2. Check the oxygen production capacity; if it is only sufficient to meet the 100% load of two furnaces, then when the third furnace is started, the operating furnaces must reduce their load in order to supply oxygen for its operation. When merging gases in the third furnace, make sure the system pressure is slightly higher than that of the furnace being shut down, to prevent gas backflow and resulting fluctuations. Be careful during operation, and try to avoid having all three furnaces online at the same time. 3. How should the work schedule be arranged between the standby furnace and the operating furnace?
Plan the schedule carefully; the key is to reduce unexpected stops, especially system-wide stops. Once such situations occur, it becomes difficult to stagger the operation cycles. Often, plans can’t keep up with changes. My approach is to plan for shorter time intervals, make frequent adjustments, and strive to ensure three units in operation with two as backups, even if it means sacrificing part of the operating cycle for a single unit. Furthermore, the quality of furnace maintenance work must be ensured.
It depends on the usage conditions of the slurry pump and the furnace bricks, as well as the degree of scaling in the quench water system and the performance of the slag locking valve. Generally, it is reasonable to perform maintenance on the furnace after about three months of operation. Theoretically, the cone-bottom bricks can last for 3,000 hours, the arch-top bricks for 6,000 hours, and the straight-tube bricks for 12,000 hours; however, if the furnace temperature is well controlled, this time period can be extended. Domestic-made slag locking valves can operate for 4,000 hours, while imported ones can last much longer. The coal used in our company’s gasification process requires a solvent, with the amount reaching up to 3.5% of the weight of the coal itself. The ash water system suffers from severe scaling, and the melting point of the coal ash is extremely unstable. Yet our gasification unit has been able to operate for up to 30 days without any need for furnace maintenance, thanks to measures taken in the following areas.