Gas external heating activated carbon rotary kiln

Technical solutions
Introduction: At present, the common types of wooden activated carbon on the
market generally include coconut shell, apricot shell, walnut shell, hawthorn shell,
peach shell, macadamia nut shell, palm shell, charcoal and other materials that
can produce activated carbon. This equipment adopts an automatic control
system, which can meet the two processes of carbonization and activation, and
belongs to a multi-function type. The equipment is widely used in environmental
protection and chemical industries;

A. The main technical parameters

1. Application: activated carbon carbonization/activation
2. Material parameters: nuts, specific parameters provided by the customer
3. Production method: continuous
4. Processing capacity: adjustable according to tool technology
5. Material Calcined process: temperature 500-900℃
6. Heating cylinder size: Φ2×22m
7. Heating cylinder material: heat-resistant 310S stainless steel, wall thickness
18mm
8. Heating method: self-control gas (natural gas) external heating
9. Temperature control method: touch screen + PID intelligent instrument
automatic temperature control, 6 zone temperature control
10. Temperature control accuracy: ±5°
11. Furnace layout: horizontally
12. Number of supporting files: 2 files
13. Roller speed: 0.5-1.5r/min, (usually 1r/min)
14. Cylinder sealing method: carbon fiber packing and packing compression type
combined sealing structure.
15. Feeding method: gate valve + diagonal flow pipe
16. Discharge sealing method: radial discharge.
17. Pressure in the cylinder: slightly positive pressure state
18. Flue gas utilization; the flue gas outlet is 350-500°C, passes through the heat
exchanger, and exchanges hot air to supply the burner combustion-supporting air
and the high-temperature activated air supply in the cylinder.
19. Steam supply; steam generation equipment is provided by the buyer, and the
rotary kiln reserves steam inlet and outlet to meet the activation supply.
20. Auxiliary operation measures: The transmission motor adopts an extended
shaft, which can be shaken manually in case of a sudden power failure to avoid
deformation of the cylinder due to excessive temperature.

B. Brief introduction of kiln system

The gas-fired external heating rotary furnace adopts indirect heating, which is
composed of drum, transmission and support mechanism, feeding mechanism,
discharge end cover, dynamic and static sealing, external heating furnace body,
measurement and control system, safety measures and other parts.
1. Feeding system; slide pipe feeding, adjustable speed (butterfly gate valve
control)
2. Cylinder: The cylinder has a diameter of 2 meters and a total length of 22
meters. The cylinder is made of heat-resistant 310S stainless steel (thickness
18mm), which can operate stably at a high temperature of 900°C for a long time.
Intermittent spiral baffle plates are installed at the position of the roller inlet,
and the discontinuous spiral baffle plates are made and shaped according to the
production process requirements, so as to more accurately realize the product
processing process requirements.
The heating furnace adopts a frame structure, and the bottom is made of
standard channel steel. The inner lining of the heating furnace adopts a full-fiber
structure, the inner lining is made of high-quality high-aluminum fiber modules,
and the top cover is a split combined structure. The furnace is easy to open and
repair. The outer metal frame structure is strong and durable. It has good
insulation effect and the appearance is resistant to spraying. The
high-temperature lacquer is beautiful, durable and durable. The external surface
temperature of the kiln is lower than 50℃.
3. Sealing of inlet and outlet end cover:
The inlet and outlet adopt a narrowing structure, and the end covers are
respectively arranged with ventilation and oxidation ports, steam inlets,
inspection holes, etc., and the dynamic and static sealing between the inlet and
outlet ends and the drum adopts multiple packing compression seals, a total of 2
sets. Each set of sealing mechanism includes: moving ring, static ring, packing
compression ring, sealing packing, fasteners, etc.
Pack multiple packings on the sealing surface between the moving ring and the
static ring, and use bolts/spring fasteners to compress the packing between the
compression ring and the static ring.
4. Transmission; rolling rings and supporting wheels are all solid materials,
processed with ZG310-570 materials, and normalized. The construction and
material specifications shall not be lower than the requirements of the
HGT20566-2011 chemical rotary kiln design standard.
The cylinder body is supported by two gear supporting rollers, and the
positioning supporting wheel also functions as a blocking wheel, which not only
supports the cylinder body but also limits the front and rear displacement of the
cylinder body; the extension supporting wheel allows the cylinder body to
expand and elong freely. The transmission motor adopts frequency converter to
adjust the speed, and the barrel speed can be adjusted between 0.5 and 2.5r/min
according to the output. The transmission gear and wheel belt are made of 45#
wear-resistant steel to ensure long-term operation and reduce wear.
5. Gas heating system
The natural gas heating system consists of a gas system, a combustion air system,
a combustion system, and a control system.
Natural gas pipeline: Natural gas pipeline includes safety shut-off valve, air-fuel
proportional valve, hand valve, flame arrester, pipeline steel structure, etc.
Combustion air pipeline: combustion air pipeline pressure switch, pressure
gauge, manual butterfly valve, electric actuator, pipeline steel structure, etc.
Burner: select customized gas high-speed burner, use air-fuel ratio to burn, the
air-to-air regulation ratio is 1:15, the regulation ratio is large, it can ensure full
combustion, and the thermal efficiency is >96%. The burner is equipped with a
fire hole, UV detection interface, high-energy igniter interface, etc., and the
service life is not less than 10 years.
Control System
Using dual-language Kunlun Tongtai large-format color touch screen and
Siemens PLC as the centralized core control, the upper computer can dynamically
and intuitively display the operation of the kiln equipment. Including data
collection, setting, modification, and storage. In the event of a fault, the host
computer can directly reflect the alarm point and send out sound and light
reminders.
Chain control instructions:
1) Ignition control: The ignition adopts a high-energy igniter, which is built into
the burner. When igniting, the system will automatically purge. After purging, the
gas valve will be automatically opened for ignition, and fire detection and
flameout instructions will be output.
2) Temperature control: 12 burners are divided into 6 zones to control the
temperature, in the furnace: 6 K-type thermocouples; exhaust pipe: 1 K-type
thermocouple; exhaust gas pipe: 1 E-type thermocouple; combustion-supporting
Hot air duct: 1 bimetal thermometer, on-site display; temperature setting, display,
and storage are all operated on the touch screen.
3) Control system: The control cabinet is equipped with a 10-inch color touch
screen, the frequency converter adopts Siemens PLC software, the output of the
control system is compatible with the factory-level control system (can
communicate with the factory DCS system to upload data), and the operating
system panel will go through the corresponding process Variables monitor the
operation of the rotary kiln.
3) Kiln head and tail pressure detection: The pressure sensor and the induced
draft fan form a closed-loop control. Through PLC intelligent PID calculation, the
frequency of the fan frequency converter is controlled to make the fan run
automatically and control the pressure at the head and tail of the kiln.
4) Transmission: The transmission motor adopts frequency conversion control
(Siemens), and the frequency is displayed and operated intuitively on the touch
screen.
5) Gas leakage detection: Four gas detection probes are set in the operating area
in front of the furnace, which are arranged on both sides of the furnace body.
They mainly detect whether there is gas leakage in the furnace operating area.
After detecting the leakage, it will automatically cut off the gas main valve and
give an alarm.
6) Flameout alarm: When the ignition is unsuccessful or the burner is
extinguished during operation, the system will automatically cut off the gas
solenoid valve in front of the burner and give an alarm.
7) System failure alarm: alarm for super high and low gas pressure, low fan
pressure alarm, over temperature alarm, gas leak alarm, etc.
All data and alarms are visually displayed on the touch screen and saved, and the
data can be directly exported and saved with a U disk.
This kiln control system strictly interlocks the start and stop operations of all
electromechanical equipment on the kiln in accordance with the operating
specifications, including protection if the single machine starts/stops if it does
not comply with the safety regulations. The system requires that the exhaust fan
be started first, then the combustion-supporting fan, and finally the gas main
solenoid valve. The safety protection of the combustion system is that each
burner adopts a flame monitoring/ignition controller, which can be automatically
ignited by the control system according to a pre-set procedure, and immediately
shuts off the protection of the gas solenoid valve in front of the burner, providing
reliable safety guarantee.