Major and minor accidents that have occurred during the operation of space furnaces, Shell furnaces, and Texaco furnaces, as well as the processes for identifying and dealing with such accidents

Problem name: Burner clogging issue. Problem description: After the oxygen supply is stopped during burner startup, the oxygen passage gets blocked by ash, resulting in oxygen corrosion at the burner head. Cause analysis: After coal was fed into the gasification furnace, since the startup burner was about to be shut down and no other fluids were flowing through, the coal powder entered the startup burner. Over time, this led to hardening or even sintering, resulting in blockage. Processing procedure: After starting up and terminating the ignition process, high-pressure carbon dioxide was introduced into this channel to reduce the expansion of the dark zone in the flame, thereby decreasing the radiant heat at the tip of the burner and lowering the oxygen concentration in that area. Several inspections of the channel revealed no signs of blockage.

Repeated breakage of sintered metal internals. Problem description: The sintered metal internals in unit 12 have broken repeatedly, affecting the transportation of pulverized coal. Cause analysis: The high-pressure CO2 contained excessive sulfur; over time, this led to the blockage of the pores in the sintered metal, resulting in a large pressure difference across it and causing the internal components of the sintered metal to break down multiple times. Resolution process: Technical modifications were made to the internal components, and they are now functioning properly.

This post was last edited by wang06120325 on 2015-8-20 at 10:22. Such accidents tend to occur more frequently at the beginning of system operation, and the reasons for this are mainly poor operational procedures and a lack of awareness regarding safety precautions. Here is a report of an accident that occurred in the coal powder preparation section of a pulverized coal furnace, provided for everyone’s reference and learning purposes, to help prevent such tragedies from happening again. Accident name: Explosion of the rupture disc in Gasification S-1103B. Location of the accident: 74 meters on the gasification framework. Time of occurrence: ×××× year × month × day × hour. Course of the accident and handling: At ×××× year × month × day × hour, the weighing coal feeder X-1101B stopped feeding coal suddenly due to the detachment of the lining in V-1101B. Before it stopped, the load on the coal grinding B system was 30 tons per hour, and the oxygen level in the system was within normal limits. As the gasification unit is in the commissioning phase, there are insufficient computers at the central control station; therefore, the two operators responsible for mills in Series A/B share one computer for operation. At that time, Series A was grinding coal, and after the supply of coal to Series B was interrupted, two operators promptly reduced the flow rate by closing valve 11FV-6203 in order to lower the system temperature; they also closed fuel gas valve 11FV-6201. However, they did not have time to close the on-site manual inlet valve K-1103. Within just ten minutes, the oxygen content in the system rose to 17.41%. Additionally, internal leakage in the 11XV-6202 valve allowed fuel gas to leak into the system, resulting in an increase in both the oxygen and fuel gas levels. ××××At ×:× on ×/×/×, there was a muffled noise as the flexible connections at the inlet of the hot air furnace and the four rupture disks of the 74-meter-long bag burst, resulting in the accident. Cause of the accident: 1. Internal leakage in the fuel gas valve 11XV-6202, resulting in an increase in the fuel gas concentration in the system ； 2. The operator did not pay sufficient attention to the issue of high oxygen levels that can occur when coal supply is interrupted, and no appropriate measures were taken ； Preventive measures: 1. Increase the number of computers in the control room’s operation stations ； 2. Resolution of the internal leakage issue in 11XV-6202 (not fully resolved); in the past, when problems occurred, the on-site manual valve was shut down promptly ； 3. Strengthen training for operators to improve their professional skills ； 4. The lining in V-1101B is properly fixed, eliminating the coal breakage issue ；

Bro, you’ve basically been exposed to all these types of stoves. Share more about accidents related to pulverized coal gasification.