How does everyone detect air leaks in the system when producing acid from zinc concentrate?
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Our factory uses zinc concentrate as raw material; it undergoes roasting in a fluidized bed furnace, with waste heat boilers generating steam as well as sand for use in zinc smelting in downstream workshops. There are also processes involving electrostatic dust collection, purification, dry absorption, and conversion. It’s two rotations and two suction cycles. All new systems are computer-monitored, displaying data such as temperature and pressure. Information such as the start and stop of the equipment. Typically, systems have many areas where air leakage occurs, which affects the system; for example, ash accumulation on the tubes inside the waste heat boiler. What methods does everyone use to check for air leaks? Of course, it can be determined that there is air leakage based on the negative pressure displayed by the computer. But it’s still quite difficult to find the exact location. Are there any good methods?
There is air leakage; smoke emerges when positive pressure is applied, and this phenomenon can be detected through inspections. It is not easy to detect it when negative pressure is present； Regular inspections focus mainly on the welding areas; a change in the color of the insulation and anti-corrosion materials after a leak can also serve as an indication ； Verify on-site based on what was shown on the instrument system display panel
To check for system leaks, one must go to the site based on pressure changes, and use listening, touching, looking, and smelling.
Experienced inspectors are able to detect leakage points in negative-pressure pipes and equipment; for example, by creating fog on-site and observing the direction in which the fog moves, it is possible to locate the leakage points in the pipes and equipment.
From the roasting stage to the fan, negative pressure exists; by measuring the sulfur dioxide concentration at the roasting outlet and the fan inlet, it is possible to determine the amount of leakage. If the leakage is significant, an on-site inspection is required. In cases where there are sounds associated with the leakage, the source of the leak can be identified, while in areas with positive pressure, the leak can be detected by the presence of smoke. If it is a leak inspection of the heat exchange unit, it is necessary to determine this by checking the amount of flue gas in the tube side and the shell side.
Negative pressure leak detection: 1) One can listen for the sound of air leakage; if such a sound is heard, peel back the insulation layer； 2) By touch, the area with air leakage is generally cooler to the touch than other areas ； 3) The probability of air leakage at the welds of channel steel, supports, and steel plates is relatively high ； 4) In the event of a sudden power outage, smoke will emanate from the leak site ； As for detecting leaks under positive pressure, it’s easy – there is usually smoke under such conditions