Process Design Package: P170 Manual

P&P Industrietechnik GmbH – www.pp-group.at Dr.
Auner Strasse 21/6, 8074 Raaba, AUSTRIA
PROCESS DESIGN PACKAGE
PROJECT NR: 1612475
CONTRACT NR: 16UMXH/FJ022
CONTRACT DATE: DEZEMBER 13RD 2016
PLANT DESIGNATOR: 8
DOCUMENT NUMBER: 485633202.DOCX
SPENT ACID REGENERATION PLANT (SAR)
P170 MANUAL
INCINERATOR & BURNER

燃烧室和燃烧器
/conversion/tmp/scratch/485633202.docx
485633202.DOCX
Document revision history
Rev. Issue Date Comment Revised by / Date

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0 GOR 20171220 1st Issue JOK / 20180316 (update)
This information is property of P&P Industrietechnik and may not be copied or forwarded without written approval. Page 2 of 32
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INDEX
1. GENERAL SYSTEM DESCRIPTION 4

2. GENERAL PREPARATION: 基本准备 5
3. SYSTEM OPERATION MODES 6
4. GENERAL INTRODUCTION 概述 8
5. MAIN PARTS OF THE BURNER SYSTEM 燃烧系统的主要组成 11
6. AIR RATIO CONTROL 空气比率的控制 12
7. SECONDARY AIR CONTROL 助燃风的控制 13
8. START-UP PROCEDURE OF BURNER SYSTEM 燃烧器的开车步骤 14
9. HEATING: 升温原则 15
10. BURNER 燃烧器 16
11. OPERATING INSTRUCTIONS 操作指南 21
11.1. Burner cooling 燃烧器的冷却 21
11.2. Starting preparations / Burner settings 开车准备/燃烧器的设定 21
11.3. Fuel gas operation 燃料气的运行 22
11.4. Fuel gas Stop 燃料气停止 22
11.5. Acid gas start / if applicable 24
11.6. Acid gas stop/ if applicable 25
12. INCINERATOR 燃烧室 26
13. CHECKLIST 28
14. REFERENCE DOCUMENTS 29
15. EQUIPMENT LIST 30
16. DISCLAIMER 30
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1. General System Description

The Spent Acid Regeneration Plant (SAR) is an advanced process to treat waste gases and
liquids containing sulphuric and organic components. The process of inlet gases in the presence
of water vapour; makes it a wet oxidation process.
The Process Flow Diagram (PFD), Piping Instrumentation Diagrams (P&IDs) and corresponding
stream tables show the process in following Sections. (See more details at the PID lead sheet)
Table 1 – P&ID Sections
Section P&ID Description
100 810 Combustion System
200 820 Reactor 1
300 830 Condenser 1
400 840 Reactor 2
500 850 Condenser 2
590 855 Carbon Reactor (Tail gas treatment)
600 860 Heat transfer Salt (HTS) System
700 870 Acid Cooling and Transfer
800 880 Steam System
Using a three-stage process, reaches a maximum efficiency to convert sulphuric components into
H2SO4.
In the first reaction stage, thermal energy (mainly the reaction from H 2S and CS2 to SO2) oxidises
all sulphuric components into SO2.
In the second stage (the reaction from SO 2 to SO3), the produced SO3 inhibits conversion rates
above 98 %. In the three hurdles, conversion takes place by different types of catalysts.
In the third stage, P&P applies LTCC (low temperature carbon catalyst) for tail gas treatment
where the remaining SO2 directly converts into weak acid with a conversion rate of more than
95%.
This achieves a total conversion of SO2 into H2SO4 of >99.9 %
FOR A BETTER UNDERSTANDING OF THE FOLLOWING PAGES PLEASE READ THE
CORRESPONDING DOCUMENTS IN PARALLEL!
PLEASE NOTE SOME OF THE EQUIPMENT MIGHT NOT BE PART OF THE SUPPLY OR NOT
INSTALLED IN YOUR PLANT. NEGLECT SUCH PARAGRAPHS. THE VALID SCOPE OF
SUPPLY IS INDICATED AT THE END OF THIS DOCUMENT IN THE EQUIPMENT LIST!
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2. General preparation: 基本准备

1. Power supply and DCS must be ready 供电和 DCS 都已经准备妥当
2. All equipment must be off and in manual mode, 所有的设备都必须置于手动模式
all valves must be in safety position, 所有的阀门都置于安全位置
and all controllers must be in manual mode. 所有的控制器都要置于手动模式
3. Supply on compressed air to all equipment 给所有的设备通压缩空气
4. Assure all manholes are closed 确认所有的人孔都已经关闭
5. For start-up, first all the utilities for the plant must be ready and switched on by the operator.
开车前，首先操作员应该确认所有系统的共用工程已经准备妥当，并开起来。
Spent Acid [SA]
Sulphur (liquid) [LIS]
Fuel gas [FG]
Instrument air [IA]
Plant (compressed) Air, [PA]
Nitrogen system [LN]
Ammonia Water Solution [AMW]
Cooling Water supply [CWS]
Boiler feed water(deaerated) [BFW]
Demineralized Water [DW]
Low Pressure Steam - IN [LS]
Medium Pressure Steam - IN [MS]
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3. SYSTEM OPERATION MODES

For the SAR 3 automatic modes are selectable: 对 SAR 系统本身，将有三个模式可选：
1 Stop Mode (STM) In this mode, no gas flow passes the main equipment like,
condensers, electrostatic filters, reactors, and burning
停车模式 (STM)
chamber.
该模式下，系统主要设备中，如高温过滤器，冷凝器，静电除
雾器，反应器和燃烧室等无气流通过。
The main gas valve for combustion air must be closed as well
as the stack valve, the process gas blowers and the
combustion air blower must be stopped. There should be no
process gases containing sulphuric components in the
equipment to avoid corrosion.
助燃风主风阀必须关闭，烟囱阀门也必须关闭，工艺气风机
以及助燃风机都必须停止。系统中不应该有含有硫化物的工艺
气流以避免设备腐蚀。
2 Fresh Air Mode In this mode, the plant is fully in operation and only ambient air
(FAM)新风模式 is going through the equipment, the burner is on, but no waste
gases flow and no acid is produced. MIN 48HRS before STOP
该模式下，装置在运行状态，但只有新风通过系统设备。燃烧
器在工作，但不允许切入废气，系统不会产生硫酸
3 Acid Gas Mode In this mode acid is produced by burning the waste gas
(AGM) containing sulphuric components, the process gas contains
SO2 and SO3 for acid production ，all the temperatures in the
酸性气模式 (AGM)
steel parts must be over the dew point to avoid serious
corrosion.
该模式下含有硫化物的废气被燃烧，装置生产硫酸。所有的金
属设备表面温度都要高于酸的露点，避免过度腐蚀
Therefore the sequence to START SAR must always be: STM  FAM  AGM
and to STOP SAR switch from: AGM  FAM  STM
所以，SAR 装置开车的顺序总是应该由 STOP 停车模式到新风模式而后到酸模式。
将装置停车，总是要将酸性气模式切换到新风模式，而后最终到停车模式。
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STOP MODE
WARM UP RUN DOWN
FRESH AIR
MODE
ON LINE OFF LINE
ACID GAS
MODE
DCS program must follow this procedure, in case of problems DCS will switch back from AGM to
FAM, ONLY IN EXTRAORDINARY SITUATIONS to stop the plant is allowed because of the risk
of corrosion to the equipment because SO3 and H2SO4 is present in the whole plant
DCS 编程必须遵守该步骤。如果有问题，DCS 将会从酸性气模式切到新风模式。因为整个系统中
有 SO3 和硫酸，为避免腐蚀风险，只有在极端情况下才允许中途停止装置的运行。
The plant must run in FAM for 48h before you might even think of turning the SAR into warming or
totally off. TURNING OFF THE SAR BEFORE 48 HOURS FAM OPERATION IS A SEVERE AND
BRUTE OFFENCE AGAIN P&P MANUAL! WE REFUSE ALL WARRANTY CLAIMS FOLLOWING
SUCH OPERATION!
After any emergency shut down of the plant, first the plant has to run in Ambient Air Mode with
temperatures in the first reactor between 510 and 540°C. The catalyst will release SO 3 resulting in
a small amount of acid. After min. 48 hours and when with no further acid produced the plant is
ready for shut down.
装置紧急停车后，首先装置会运行在新风模式下内的温度在 510°C 到 540°C。催化剂内剩余的 SO2
将会以 SO3 释放出来并且产生少量的酸。48 小时候当不再有酸生成时，装置才可以停车。
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4. General Introduction 概述
The combustion system (Burner, Combustion chamber with internal bare tube heat exchangers) is
designed for an efficient oxidation of all waste gases, spent acid and sulphur (if applicable) by
minimized external fuel input and minimized total volume throughput.
燃烧系统（燃烧器，带光管换热器和翅片管换热器的燃烧室）被设计成使用最少燃料来高效氧
化所有的废气，并且维持最少体积的总工艺风量。
The incinerator is the central equipment of SAR for the thermal oxidation of the waste gases, all
Carbon containing components are oxidized to CO 2 and all Sulphur containing components to
SO2.
燃烧室是 SAR 工厂用于废气氧化的中心设备，所有碳的元素都将氧化成 CO2，所有硫元素都将氧化
成为 SO2.
Oxidation temperature range between 850°C to 950°C to guarantee a complete oxidation.
需要在 850°C 度到 950°C 度的温度范围内进行氧化以保证废气得到彻底氧化。
The minimum temperature of 850°C guarantees a complete and high reaction speed with more
than 99.9% efficiency of oxidation of organic components to CO 2 and sulphuric components to
SO2. The maximum temperature by the design of the inner brick lining of the incinerator is 1400°C.
High temperatures will also cause production of NOx. In case the temperature in the incinerator
exceeds 1100°C, the secondary air is increased to have lower temperatures at outlet of the
incinerator; the lambda factor should be decreased to generate lower temperatures at the burner
outlet. P&P specialists will do the correct adjustment of the burner system.
850 度的最低温度可以保证完全快速的氧化过程，将有机元素氧化成 CO2,硫元素氧化成 SO2,效率超
过 99.9%。设计最高温度 1400 度是燃烧室耐火砖的设计温度。更高的温度会产生氮氧化物。一旦
温度超过 1100 度，就需要增加助燃风的量以便降低燃烧室的出口温度，同时需要调节兰姆达值以
便降低燃烧器的喷口温度。P&P 的专家将对燃烧器系统做最后的调整。
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A standard-fuel pilot burner ignites; while

special P&P burners for acidic components
is used to bring in the waste gases (e.g. acid
gases containing H2S and CS2). External
lances incinerate the spent acid.
Fuel gas and combustion air (ambient air,
preheated up to max. 250°C, secondary air)
are supplied with constant pressure, the fuel
gas pressure is controlled by pressure
control valves. The combustion air pressure
by controlling the speed of combustion air
blowers.
Leaf dampers in ratio to the fuel gas and
acid gas flow rates adjust the combustion air
quantity, while a leaf damper to control the
outlet temperature of the incinerator at 850 -
900 ° C. controls the secondary airflow rate.
燃烧风的补风量按燃料气和酸性气的量按比
例通过翻板阀门来调节。助燃风的流量通过
燃烧室的出口温度 850---900 度来调节翻板阀
门来控制。
The combustion chamber is operated in a
slight vacuum of 1-2 hPa, depending on the
flow rate of acidic components.
See the mass balance for typical quantities
and the media spec for the relevant
components.
Both of the acidic gases are individually
passing a knock down drum to avoid liquid is
sent to the burner.
两股富气分别通过液体分离器以防止将液体
带到燃烧器中。
See the burner manual for more information.
In case of low flow rates there is a risk of
destroying the burner, as the velocity of the
gases out of the burner head is getting too low to avoid flash-backs for rich gas resulting in a shut-
down of these burners.
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As long as the incinerator outlet temperature is at its setpoint, no waste streams are used for
combustion, only the pilot burner with a low power might be on all the time. In case not enough
energy is supplied from the acidic lines, fuel gas is added to keep the temperature at its setpoint.
只要燃烧室的出口温度在其设定值，则燃烧时就不需要不燃料，只是点火器会总需要很低的能量。
一旦酸性气的能量不够，则将会通过补充一定量的燃料以便维持温度设定值。
For the acidic wastes and gases and fuel gas lines an individual control line is designed, because
for the oxidation process an accurate measurement of the waste gas streams is mandatory.
对酸性气管线和燃料气管线的控制是分别设计的。因为氧化工艺过程对废气的流量需要准确的计量，
这是强制的标准。
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5. Main parts of the burner system 燃烧系统的主要组成

The fuel gas burner essentially consists of: 燃料燃烧器主要由以下部件组成：
 Burner body 燃烧器本体
 Pilot burner .1 with individual combustion air supply from instrument air
and individual fuel gas supply (in exceptions a 2 nd pilot is installed)
 Combustion air line including flow meter and control damper to control the combustion air
flow in ratio to the fuel gas
燃烧风包括流量计和控制阀来控制燃烧风和燃料气的配比
A minimum flow of combustion air can be adjusted by a bypass valve
通过旁通阀门来调节燃烧风的最小流量。
Fuel gas line including flow meter, fuel gas control valve, and fuel gas shut off valves,
equipped with pressure sensor for tightness control
 Acid gas lances with special ceramic nozzle ( can be individually changed ), if applicable
 Sight glass 视镜
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6. Air ratio control 空气比率的控制

The quantity of combustion air is controlled by a combustion air valve driven by the burner control
system in that way, that all the time there is enough Oxygen for the oxidation process in the
incinerator and in the tail gas, where the Oxygen content is indicated by an Oxygen analyser to
ensure correct control of combustion air.
The ratio of air to each individual waste and fuel gas streams (burners) varies by nature and is
subject to the control system, basic information is indicated in the data sheets of the media and
the mass balance.
For the pilot burner instrument or plant air is used as combustion air. The air and fuel are adjusted
by a pressure control valve.
For the main burner, the combustion chamber temperature that is controlling the temperature in
the incinerator, is acting on the fuel gas valve or giving the setpoint to the fuel gas controller. Ratio
controller, acting on the combustion air valve, controls the combustion air to the main burner. The
ratio depends on the waste composition.
In case using lambda factor (Flambda) and air factor (Fair) instead of ratio air/fuel (RAF) following
formula is suggested to use:
如果使用兰姆达系数(Flambda)和空气系数(Fair)取代风/燃料气比例(RAF)，建议使用以下公式：
RAF = Fair x Flambda = 10 x 1.1 = 11 Nm3/Nm3 = 18,81 x 1,1 = 20,69 kg/kg
Fuel gas parameters (e.g. Methane):
Density 密度 0,72 kg/Nm3
Heat value 热值 50.000 kJ/kg = 36.000 kJ/Nm3
13,88 kW/kg = 10 kW/Nm3
The minimum air flow to the burner should be 500 Nm3/h or 635 kg/h, even without fuel gas.
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7. Secondary air control 助燃风的控制

Secondary air is used to cool down the process gases from the burner system, but mainly
necessary to guarantee a complete oxidation from SO 2 to SO3 in the reactor and further to H2SO4.
助燃风的作用是用来冷却燃烧系统的工艺气的，但主要作用还是保证将 SO2 完全氧化成 SO3 进而
结合成硫酸。
To have a complete conversion from SO2 to H2SO4 the O2 content in the tail gas must be around
10%, because the carbon catalyst needs this high amount of Oxygen.
为得到完全的 SO2 到硫酸的转化，尾气中的氧含量必须在 10%左右，因为炭催化剂需要这个氧含量。
Therefore the DCS System must calculate the demand of Oxygen or secondary air.
所以，需要的氧或需要多少助燃风需要通过 DCS 系统计算而给出。
During the first start-up, the control of secondary air to the incinerator is fixed. The setpoint of the
controller should be around 1900 kg/h or 1500 Nm3/h.
在开车期间，向燃烧室补的助燃风的控制是给定的控制器的设定值必须是 1900kg/h 或
1500Nm3/h.
The correct values and settings are found during commissioning but will always vary according the
waste line amounts and composition. Additional combustion air (min flow) is going through the
burner, minimum 500 Nm3/h or 635 kg/h.
If necessary, during initial start-up the air ratio of air/fuel gas may be increased, to heat up the
incinerator slowly.
All waste lines (spent acid and sulphur lines) are equipped with flow meter indicating the flow rate,
and we prefer to use kg/h for all the streams (combustion air, secondary air, fuel gas, rich gas etc)
for easy use.
Beside the secondary air, there are further air streams, along and in the burner and the lances.
These air streams shall prevent a) corrosion by backflow of acid and b) overheating of the nozzle.
Make sure that if there is no mass flow through any inlet equipment that the purge medium is
always on in both AGM and FAM! In the corrosive atmosphere and with the temperatures near the
burner it is a question of hours rather than days before the lance parts would fail.
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8. Start-up procedure of burner system 燃烧器的开车步骤

Before the start-up of the burner system, purge the incinerator with ambient air.
燃烧器系统开启之前需要对燃烧室用新风进行吹扫。
Reactor temperature control must be active and there must be an open way for the process gases
at the outlet of the incinerator.
Further the way for the tail gases to the stack must be open, either the carbon reactor has been
started up or the gases may go over the bypass.
去烟囱的尾气通道也必须是畅通的，炭反应器或是已经开起来，或工艺风先从炭反应器旁通。
Process gas blower must operate and control an under-pressure in the condensers, and
combustion air blower must be active, providing combustion air with an overpressure of 5 kPa to
the burner system.
工艺风机 V-350 需要开起来，以控制冷凝器的负压，燃烧风风机也必须启动，以提供给燃烧室 5kPa
的正压。
The DCS system has to purge the incinerator with five times the volume of the incinerator with
combustion air.
通过 DCS 系统对燃烧室进行吹扫，吹扫量应该是五倍于燃烧室总体积的吹扫风。
First, the pilot burner is switched on after activating the pilot burner, then the operator can activate
the main burner, and DCS has to execute the tightness test of the shut off valves, bring fuel gas
valve and combustion air valve in start position and start the burner by opening the shut off valves.
首先，点着点火器，之后操作员可以开启主燃烧器。 DCS 需要完成截止阀的气密测试，将燃气阀
门和燃烧风阀门达到开车位置。通过打开截止阀以点燃主燃烧器。
The controllers are controlling the correct ratio of fuels and air.
控制器会自动控制燃料器和燃烧风的比例。
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9. Heating: 升温原则
The temperature in the combustion chamber is controlled by the quantity of fuel gas and the
setpoint of the temperature controller is adjusted to 850°C.
燃烧室内温度通过控制燃料气的量来实现。控制器的温度设定为 850 度。
In AGM, if the heating value of the rich gas burner is high enough to keep the temperature above
850°C, no more fuel gas is going through the fuel gas line.
在 AGM 酸性气模式，如果富气燃烧的热值足够高，可以维持炉膛温度高于 850 度，这无需补充燃
料气。
Once the temperature of the incinerator outlet has reached 900°C, the secondary air controller is
adding additional combustion air to the incinerator, also when there is enough Oxygen inside the
incinerator according the formulas before.
一旦燃烧室出口温度达到 900 度，将补入助燃风到燃烧室内，如果按上节公式计算发现燃烧室内氧
气含量不够时，也补入助燃风。
In case of incorrect temperatures at the incinerator outlet:
一旦燃烧室的出口温度不对：
1) Below 850°C fuel gas is added to keep the temperature in the incinerator.
如果低于 850 度，则需要增加燃料气以便维持炉内温度高于 850 度
2) At 900°C: The secondary air controller is adding more secondary air to the incinerator. Risk:
Damage of the combustion chamber 2nd bare heat exchanger
3) At 1200°C: All burners must be switched off
到了 1200 度：燃烧器将都被关闭。
The lambda controllers control the ratio between the combustion air and the burnable media. In
case the ratio is going out of range, the burner is locked. The lower limit for lambda 0,8.
通过兰姆达控制器来控制燃烧风和可燃介质的比例。一旦该比例出了许可范围，燃烧器将被锁死。
如果兰姆达值低于 0.8，燃烧器也会被锁死。
The combustion air itself is preheated up to 220°C in the condensers by cooling the process
gases. If the temperature is higher than 300°C, then the combustion air fan is locked.
燃烧风是在冷凝器当作冷却风而被预热到的新风。如果燃烧风温度高于度，燃烧风机也将被锁死。
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10. Burner 燃烧器

The pilot burner is used to ignite the burner safe and under all circumstances
The pilot burner is equipped with an ignition rod for igniting the burner, and an ionisation rod for
the flame detection of the pilot burner.
点火器会配置点火棒以引燃点火器，同时配有电离火焰检测棒以检测点火器是否点燃。
Instrument air is used as combustion air for the pilot burner, and fuel gas is arriving from the main
fuel gas line. Both lines are equipped with pressure regulators, to adjust the necessary pressure
for the pilot burner. Once the correct pressures for combustion air and pilot gas are adjusted,
ignition is very easy and safe. Pilot air is recommended to be on all the time to purge and cool the
pilot burner. The pilot gas is switched on and off by redundant shut off valves for fuel gas.
点火器的燃烧风使用仪表风，燃料来源于主燃料供应线。两股来源都配有压力调节器，以便调节到
点火器的需要的压力。一旦燃烧风和燃料气的压力调配得当，点火器会很容易也很安全地点燃。点
火燃烧风建议一直通着，以便对主燃烧器进行吹扫和冷却。点火器的燃料气通过燃烧气供应阀的开
关控制。
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Before any burner is allowed to be ignited, either the temperature in the combustion chamber must
be more than 750°C (high temperature mode), or the incinerator needs to be purged before
ignition with combustion air. All the necessary safety regulations for burners and burner control
system have to follow the local rules. Normally the volume of the incinerator has to be purged 5
times before ignition.
在点燃燃烧器前，或是燃烧室温度已经超过 750 度（高温模式），或燃烧室需要在点火前通过燃烧
风进行吹扫。所有的当地对燃烧器以及燃烧器控制系统的安全规程都需要遵守。一般，点火前，要
对燃烧室进行五倍容量的燃烧风吹扫。
Once the pilot burner is on, the incinerator can be heated up regarding the specifications of the
supplier of the incinerator. For the heating up the fuel gas lance is used. The mixture of fuel gas
and combustion air is controlled by the burner control system.
一旦点火器点燃，可以遵照燃烧室的供应商的规定对燃烧室增温。在升温过程，只使用燃料燃烧器。
燃料和燃烧风的配比通过燃烧器的控制系统来控制。
Before using one of the fuel gas lines, the safety shut off valves in the fuel gas lines need to be
checked by the valve tightness test, integrated in the control system. Therefore a pressure
transmitter is foreseen in between the shut off valves.
在使用燃料气管线前，通过控制系统的内置程序，需要对管线上的安全截止阀进行气密检测。为此，
在截止阀间需要设置压力传感器。详细的设置需要参照燃烧器系统供应商和当地规定执行。
Once the tightness test for the shut off valves has passed successfully, the fuel gas burner can be
started. The control system has to bring the control valve for fuel gas in the start position and also
to adjust the combustion air flow to starting flow rate. Then the control system can open the shut
off valves and latest 5 seconds after opening the shut off valves the flame detector has to indicate
the flame is ignited, otherwise the shut off valves need to be closed and the starting procedure has
to be restarted after acknowledging by the operator. Only in high temperature mode (temperature
inside the combustion chamber is > 750°C) no flame detection is necessary.
在截止阀气密检测通过后，就可点燃主燃料气燃烧器。控制系统需要将燃气阀置于开启位置，同时
将燃烧风调至开启流量。之后，控制系统可以开启燃气阀门，在阀门开启后五秒钟，火焰检测器需
要检测到已经有火焰，否则燃气阀需要被关闭。在操作员将报警复位后，点火程序需要重新开始。
只有在高温模式（燃烧室内温度超过 750 度）时才不需要火焰检测。
After a certain time (stabilizing time of about 20 seconds) of running the main fuel gas burner in
starting load, the temperature controller is heating up the incinerator according the suppliers
characteristic by a ramp (make sure that a supplier provides the initial and the regular heat-
up and cool-down curve for the combustion chamber), acting on the control valve of fuel gas.
在主燃气燃烧器稳定后（开启后大约 20 秒），温度控制器将根据燃烧室供应商的升温曲线来控制燃
料气的阀门以便控制升温过程。
请一定要从燃烧炉厂家索要燃烧炉的初次升温和正常升温以及冷却降温的曲线！！
Each fuel gas or waste line is equipped with a filter unit, to avoid interferences on the following
control or shut off valves. Once the pressure difference between the both pressure transmitter in
front and after the filter has reached its limit, the filter needs to get cleaned.
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The combustion air has to be controlled according the ratio and lambda factors of the gases, see
chapter before. The combustion air blower is controlled by a frequency converter, and the outlet
pressure of the combustion air fan is controlled by pressure controller. In case the pressure in the
incinerator is changing, it is better to have a constant overpressure to the incinerator. The quantity
of combustion air is controlled by ratio controller, acting on combustion air valve. The set point is
given by adding the fuel gases, multiplied by the air/fuel ratio, and finally multiplied by the lambda
factor.
燃烧风需要根据燃料和风配比以及兰姆达值进行控制，详见前章。燃烧风风机通过变频控制，风机
出口压力通过压力控制器来控制。一旦燃烧室内压力会变化，所以最好控制给燃烧室一个恒定正压。
燃烧风流量通过比例控制器来控制燃烧风的阀门。设定值根据加入的燃料气，乘以气/燃料之比，最
后乘以兰姆达系数来确定。
After the incinerator has reached its final operating temperature, and the plant is ready for acid
production, line by line can be switched on. The procedure is similar to the fuel gas, a tightness
test is necessary to check the shut off valves of each line, and the control valve has to be put in
start position. After the ratio of fuel gas and combustion air has been reached, each waste gas line
is controlled by a pressure loop, keeping the pressure in each supply line constant.
在燃烧室达到器最后的工作温度后，工厂可以开始生产酸了。可以一条一条切入富气。过程类似于
切入燃料气，每条线上的截止阀气密性检测是必须的，之后控制阀置于开启位置。当燃气和燃烧风
配比达到后，每条废气线将通过压力回路控制，保证每条供应线的压力恒定。
Typical start-up procedure: 标准的开启过程：
- Plant is ready for process gas flow
工厂可以接受工艺气气流
- The combustion air blower must be started and purging the incinerator with 5 times the
volume of the incinerator with combustion air, this step is not necessary once the
temperature inside the combustion chamber is more than 750°C
燃烧风风机必须已经开启，对燃烧室进行五倍燃烧室体积的燃烧风的吹扫。一旦燃烧室内温
度超过 750 度，这个吹扫步骤就没有必要了。
- Igniting the pilot burner
点燃点火器
- Tightness control of the fuel gas valves
对燃料气阀门进行气密检测。
- Switch on of main fuel gas burner, flame detection must be within 5 seconds
点燃主燃烧器，必须在 5 秒内检测到火焰
- Control the temperature in the incinerator according the heat up procedure,
take care, the salt is switched on before the outlet temperature of the reactor is less than
250°C, otherwise heating up the incinerator must be stopped
按升温步骤来控制燃烧室内升温速度，一定注意，在反应器出口温度达到稍低于 250 度时，
必须开启盐系统，否则需要停止升温过程。
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- Heat up the incinerator to final set point of 850°C

将燃烧室温度最终升到设定的 850 度。
- When the plant is ready for acid gas, all other lines can be started
当工厂可以接受酸性气后，可以切入富气。
- Beside the secondary air, there are further air streams, along and in the burner and the
lances. These air streams shall prevent a) corrosion by backflow of acid and b) overheating
of the nozzle. Make sure that if there is no mass flow through any inlet equipment that the
purge medium is always on in both AGM and FAM! In the corrosive atmosphere and with
the temperatures near the burner it is a question of hours rather than days before the lance
parts would fail.
- Normal operation (as an extension to fuel gas operation)

正常运行（如同燃料气运行的延续）
o Acid gas operation 酸性气运行
IMPORTANT: For run down, we recommend to stop SAR plant after running the plant minimum
48 hours with ambient air, so no sulphuric components should be remaining in the reactors.
重要：停车时，建议新风吹扫至少 48 小时候再停车，以保证反应器内没有硫化物
The burners can be stopped immediately, also the process gas flow through the plant, and the
incinerator is cooling down by itself.
之后可以立即停止燃气燃烧器和通过工厂的气流，让燃烧室自己冷却下来。
IMPORTANT: During rundown the plant may still produce liquid acid. Therefore run the plant with
between 350-520°C as long as no sulphuric acid is rinsing in the acid tank.
重要：在停车过程中，系统还会有酸产生。所以工厂应该在 350 度到 520 度运行，直到再没有酸
流入到酸罐中。
If the combustion chamber temperature is above 200° C and the burner is not in operation, it is
necessary to provide sufficient cooling of the system:
- The combustion air and cooling air supply (also the instrument air pressure and flow) must
be ensured.
如果燃烧室内温度高于 200 度，燃烧器没有工作时，需要保证给系统提供足够的冷却风：
- 燃烧风和冷却风必须保证开着，同时仪表风需要维持其风压和流量。
Only in case of urgent maintenance works, the incinerator should be cooled down as quick as
possible. The ramp down rate is given by the supplier of the incinerator.
只有在特殊紧急情况下，需要尽快冷却燃烧室时，也需要参照厂家建议的冷却速度降温。
Make sure the supplier provides the initial/regular heat-up and cool-down ramps
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请一定要从燃烧炉厂家索要燃烧炉的初次升温和正常升温以及冷却降温的曲线！！
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11. Operating instructions 操作指南

11.1. Burner cooling 燃烧器的冷却
If the combustion chamber temperature is above 200° C and the burner is not in operation, it is
necessary to provide sufficient cooling of the system:
如果燃烧器内温度超过 200 度，燃烧器如果不工作，则需要给系统提供足够的冷却
- The combustion air and cooling air supply must be ensured.
必须确保燃烧风和冷却风的供应
If the cooling is not provided (e.g. vessel which provides the plant air is empty etc.), the
lances must be removed within a short time otherwise it can be seriously damaged.
如果没有足够的冷却（比如提供工厂风的罐空了），则需要把燃烧枪临时拉出来，否则会造
成严重损坏。
11.2. Starting preparations / Burner settings 开车准备/燃烧器的设定
The following procedures and descriptions are general information. Some of them may not fit to
the specific plant.
以下为一般描述，有些可能不适合特定工厂.
- The emergency stop button is released. 松开急停开关
- All insulation valves for pressure transmitters and gauges are to be open. 把全部的压力变送
器和压力表的隔离阀门都打开
- The purge/venting/drain connections and the by-pass valve of the fuel lines are closed. 吹扫，
通风或排放的接口以及燃料管线旁通阀都需要关闭
- The ball valves in the fuel feed lines are open. 打开燃料管线上的球阀
- The ball valve in the ignition gas line and the adjusting valves on the pilot burner are open.
点火器供气管线的球阀，点火器的调节阀都要打开。
- The fuel gas pressure at the pressure gauge and/or at the transmitter is in accordance with
the design conditions and lies within the defined shut-off points.
燃料气压力表或压力变送器显示压力符合设计要求，并符合设定的关闭压力。
- The ignition gas pressure at the pressure gauge and/or at the transmitter is in accordance
with the design conditions and lies within the defined shut-off points. 点火燃料气压力表或压
力变送器显示压力符合设计要求，并符合设定的关闭压力。
- The purge/venting/drain connections in the acid gas line are closed.
吹扫，通风或排放的接口以及酸性气气管线旁通阀都需要关闭
- All ball valves in the acid gas line are open.
打开酸性气气管线上的球阀
- The acid gas pressure at the pressure gauge and/or at the transmitter is in accordance with
the design conditions and lies within the defined shut-off points. .
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酸性气气压力表或压力变送器显示压力符合设计要求，并符合设定的关闭压力。
- All manual valves in the cooling air supply are open. 冷却风管线手阀打开
- The cooling air pressure at the pressure transmitter is in accordance with the design
conditions and lies within the defined shut-off points. 冷却风气压力表或压力变送器显示压力
符合设计要求，并符合设定的关闭压力。
- The adjusting valves in the cooling air supply must be adjusted in such a way that each
sight glass and flame detector is cooled with about 5 - 10 Nm³/h air (inspection of
rotameter if applicable). 冷却风供给调节需要达到每个视镜和火焰检测器都同冷却风 5-
10Nm3/h(如果有，观察转子流量计)
- The adjusting valve at the pilot burner must be adjusted in such a way that the ignition air
volume flow is same as indicated before.
点火器的调节阀必须按前节叙述进行调节以便保证点火空气流量。
- All ball valves and the manual valves in the purging supply must be open. The combustion
air pressure at the pressure gauge and/or at the transmitter is in accordance with the
design conditions and lies within the defined shutoff points.
用于吹扫的所有的球阀和手阀都必须开。燃烧风气压力表或压力变送器显示压力符合设计要
求，并符合设定的关闭压力。
11.3. Fuel gas operation 燃料气的运行
For the Fuel Gas Operation please refer to the start-up procedure.
对于燃料气的操作，请参照开车步骤。
11.4. Fuel gas Stop 燃料气停止
This procedure is a typical description, only, and can also be executed in a similar way.
以下为基本步骤，可以按类似方式运行
- The fuel gas operation can be stopped via DCS.
燃料气运行可以在 DCS 上停下来
- The status "Stop fuel gas" is signalled in the DCS.
“燃料气停车”状态显示在 DCS 上
- The fuel gas flow control valve is closed until reaching the start-position.
燃料气控制阀门将关闭，直到开始位置。
- The safety shut-off valves in the fuel gas line are closed.
燃料气管线安全截止阀关闭
- The fuel gas flow control valve is closed and set to manual mode.
燃料气控制阀控制阀关闭，置于手动模式
- The status "Fuel gas in operation" is reset.
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燃料气运行状态确定
- The status "Flame On" is reset.
“点火”状态重置
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11.5. Acid gas start / if applicable

The description of acid gas operation is based on the assumption that the fuel gas is in operation
and the release temperature for acid gas is reached. This procedure is a typical description, only;
the operation concept can also be executed in a similar way.
酸性气运行基于燃料气已经运行，并且已经达到可以运行酸性气的运行温度。以下叙述只是典型状
况，可以按类似方式运行。
- The acid gas operation can be started via DCS. (Release temperature is reached and fuel
gas is in operation)
酸性气运行通过 DCS 系统开启（燃料气在运行中，达到了运行温度）
- The message "Start acid gas" is signalled in the DCS.
在 DCS 系统上给出“酸性气开”的信号.
o The signal "Start acid gas" automatically starts the step sequence for Leak tightness
check procedure
该酸性气开信号会自动开启测漏步骤
- The acid gas control valve is set to the start position.
酸性气控制阀置于开始位置
- Automatic burner control is set to manual operation.
燃烧器控制置于手动运行
- The volume flow on the combustion air is increased.
燃烧风风量增加
- After the safety shut-off valves have opened in the acid gas line there are 15 seconds time
for stabilizing the flame.
在酸性气管线上安全截止阀打开后，有大约 15 秒的火焰稳定期
- After this time automatic operation is release.
之后，会切到自动运行
- The status "Acid gas in operation" is signalled in the DCS.
“酸性气运行”状态将显示在 DCS 上。
- The status "Start acid gas" is reset.
“酸性气开动”状态重置
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11.6. Acid gas stop/ if applicable

- The acid gas operation can be stopped through the DCS.
酸性气运行可以在 DCS 上停下来
- The status "Stop acid gas" is signalled in the DCS.
“酸性气停车”状态显示在 DCS 上
- The acid gas flow control valve is closed until reaching the start-position.
酸性气控制阀门将关闭，直到开始位置。
- The safety shut-off valves are closed in the acid gas line.
酸性气管线安全截止阀关闭
- Combustion air flow has to be reduced by equivalent acid gas / combustion air ratio.
燃烧风按酸性气/燃烧风比例减小
- The status "Acid gas in operation" is reset.
酸性气运行状态确定
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12. Incinerator 燃烧室

The incinerator is designed for temperatures less than 1400°C for continuous operation.
燃烧室的设计温度为 1400 度下可以连续运行
The shell of the incinerator is made out of steel, the design pressure is +/- 5 kPa.
燃烧室外壳为钢制，设计压力位正负 5kPa
The incinerator is equipped with an inner brick lining incl. the checker walls according the
supplier’s specification. The outer insulation is designed in the way to hold the temperature of the
steel body between 250°C and 400°C.
燃烧室内砌筑耐火砖，包括挡火墙，按厂家规格配置，外做外保温，保证钢制外壳温度在 250 度到
400 度间。
IMPORTANT: The minimum temperature of 250°C is important to avoid corrosion from the inner
side, the dew point is about 230°C, and corrosion occurs quickly.
A perfect outer insulation, mainly the rain protection is necessary, to keep the wall of the
incinerator above the dew point.
重要：钢制外壳的最低温度不低于 250 度非常重要，可以避免内部腐蚀。其露点大约为 230 度，可

以产生快速腐蚀。完好的外部保温，主要防雨，保证燃烧室外壳温度不低于露点温度。
The checker walls are responsible to guarantee a homogeneous temperature distribution by
internal mixing enhancements to avoid hot gas streams inside the process gas.
挡火墙作用是保证很好的气流温度均衡，避免工艺气中有高温气流。
IMPORTANT: For long life time, the incinerator should not be heated up or cooled down quickly.
Follow the combustion Chamber supplier’s instructions
The slower, the better. Especially the initial start-up has to be made according the
recommendation of the supplier, this is essential for the inner brick lining.
重要：为燃烧室有个长的使用寿命，避免过快升温或降温。越慢越好。特别是第一次开车一定按厂
家建议的升温过程进行，这对内保温耐火材料尤其重要。
The sight glasses on each side of the incinerator are foreseen to have an excellent observation of
the burner and the flame, so visually the quality of the flame gives a feedback for correct mixture
of gas and combustion air.
燃烧室每侧的视镜是用来很好地观察火焰和燃烧器的，可以通过目测火焰质量来判断燃料和燃烧风
配比是否正确。
One sight glass can be used to mount the flame eye of the main burner, in case there is not
enough place at the back side of the burner housing or the back side of the incinerator. Provide
flow indicators (e.g. rotameter) if to make sure the sight glasses are cooled efficient, otherwise the
glass may be dirty within a short time.
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如果一旦燃烧器壳体上或燃烧器端头没有安装火眼的位置，可以使用其中一个视镜用来安装观测主
燃烧器的火眼。建议安装流量计以便确定有足够的视镜冷却风保证视镜得到很好的吹扫冷却。否则
视镜会很快变污无法使用。
The process gases are cooled down by the two heat exchangers.
工艺气将通过两台换热器冷却。
Both heat exchangers are using liquid heat transfer salt as a cooling media, and the maximum
operating temperature of the heat transfer salt (HTS) is 500°C.
两个换热器都使用液体换热盐作为冷却介质，换热盐的最高运行温度为 500 度。
The bare tube heat exchangers are cooling the process gas down to 550°C, a temperature
controller is controlling the outlet temperature of the HTS to avoid overheating. For redundancy
reason the control valves for HTS are working in parallel. In case of no flow of HTS, the heat
exchanger will get damaged and leakages of HTS needs to be replaced.
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13. Checklist
Weekly:每周
Check for leakages 检查是否有泄露
Check for corrosion on the burner and incinerator housing 检查燃烧器和燃烧室外壳是否有腐蚀
Check for proper insulation 检查保温是否完好
Check the flame shape 检查火焰形状
Check the pressure drop over the burner 检查燃烧器压力损失
Check the control valve lines 检查管线上的控制阀门
Check the combustion air blower 检查燃烧风风机
Clean the sight glasses if necessary 如果需要，对视镜进行清理
Check and clean the flame eye 检查并清理火眼
A yearly inspection needs to be done 之后需要做年度检查
Clean the sight glasses if necessary 如果需要，清理视镜
Check the HTS system for leakages 查看是否盐系统有泄漏
Check all burner and lance nozzles for wear and free flow
Monthly Inspection list:
Check the long term trends for abnormal operation 检查长期运行趋势是否有不正常的运行
Report abnormalities to P&P 将不正常的情况报告给 P&P
Check for impurities 检查杂质
Check the pilot burner 检查点火器
Check the fuel gas lances 检查燃料气燃烧器
Check the condition housing and insulation 检查外壳和保温
Check the inlet gas filters 检查管线上的过滤器
Check all the instruments in the burner system 加查燃烧器的控制系统
Replace all not proper working items as soon as possible 尽量更换不正常工作的项目
Check the wall thickness of heat exchangers 检查和的壁厚
A yearly inspection needs to be done 之后，需要做年度检查
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14. Reference documents
Process Flow Diagram In P110

Mass Balance In P120
Equipment guidance drawings In P132
Overview drawings In M241
Piping & Instrumentation In P111
Media in and out In P124
Media Specification In P125
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15. Equipment List
For this project, the equipment has the following tags in all relevant documents:
H-810 COMBUSTION CHAMBER

A-811 BURNER
A-812 ATOMISER
E-810 HEAT EXCHANGER
F-814 HOT GAS FILTER
C-820 PROCESS GAS BLOWER
R-820 REACTOR
B-820 CATALYTIC BED
B-821 CATALYTIC BED
H-822 CATALYTIC BED
V-830 CONDENSER
F-830 ELECTROSTATIC FILTER
C-830 PROCESS GAS FAN
C-831 COOLING FAN
C-832 COOLING FAN
F-831 COOLING FAN FILTER
R-840 REACTOR
B-840 CATALYTIC BED
V-850 CONDENSER
F-850 ELECTROSTATIC FILTER
C-850 PROCESS GAS FAN
C-851 COOLING FAN
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C-852 COOLING FAN

C-853 COMBUSTION AIR FAN
F-859 AIR INTAKE FILTER
V-860 SALT TANK
P-860 A SALT PUMP
P-860 B SALT PUMP
V-870 ACID TANK
E-870 A ACID COOLER
E-870 B ACID COOLER
P-870 A ACID CIRCULATION PUMP
P-870 B ACID CIRCULATION PUMP
P-871 A ACID PRODUCT PUMP
P-871 B ACID PRODUCT PUMP
C-875 COOLING TOWER FAN
P-875 A COOLING WATER PUMP
P-875 B COOLING WATER PUMP
E-875 COOLING TOWER
E-880 STEAM BOILER
V-880 BLOW DOWN VESSEL
R-855 ACTIVATED CARBON REACTOR
V-855 WEAK ACID TANK
P-855 A WEAK ACID CIRCULATION PUMP
P-855 B WEAK ACID CIRCULATION PUMP
P-856 A WEAK ACID PUMP
P-856 B WEAK ACID PUMP
Y-855 STACK
P-807 30W% AMMONIA SOLUTION DOSING PUMP
485633202.DOCX
16. Disclaimer
The operating instructions correspond to the state at the time of printing, subject to technical
changes. We have checked the contents of this document to ensure consistency with the
hardware and software. The information in this documentation is up to date at the saving date and
any necessary corrections are included in subsequent editions.
Errors and omissions expected.
For reasons of simplification, this manual cannot contain all detailed information about all the
individual parts of the system. More detailed information can be found in the operating instructions
of the component manufacturer.
为了简单明了，本手册无法详述系统的每个细部。详细的知道请参见单独的厂家说明书。

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P&P Industrietechnik GmbH – www.pp-group.at Dr.

Auner Strasse 21/6, 8074 Raaba, AUSTRIA

PROCESS DESIGN PACKAGE

PROJECT NR: 1612475

CONTRACT NR: 16UMXH/FJ022

CONTRACT DATE: DEZEMBER 13RD 2016

DOCUMENT NUMBER: 485633202.DOCX

SPENT ACID REGENERATION PLANT (SAR)

INCINERATOR & BURNER

Document revision history

Rev. Issue Date Comment Revised by / Date

0 GOR 20171220 1st Issue JOK / 20180316 (update)

1. GENERAL SYSTEM DESCRIPTION 4

1. General System Description

2. General preparation: 基本准备

Spent Acid [SA]

Sulphur (liquid) [LIS]

Fuel gas [FG]

Instrument air [IA]

Plant (compressed) Air, [PA]

Nitrogen system [LN]

Ammonia Water Solution [AMW]

Cooling Water supply [CWS]

Boiler feed water(deaerated) [BFW]

Demineralized Water [DW]

Low Pressure Steam - IN [LS]

Medium Pressure Steam - IN [MS]

3. SYSTEM OPERATION MODES

WARM UP RUN DOWN

ON LINE OFF LINE

A standard-fuel pilot burner ignites; while

5. Main parts of the burner system 燃烧系统的主要组成

6. Air ratio control 空气比率的控制

7. Secondary air control 助燃风的控制

8. Start-up procedure of burner system 燃烧器的开车步骤

10. Burner 燃烧器

- Heat up the incinerator to final set point of 850°C

- Normal operation (as an extension to fuel gas operation)

11. Operating instructions 操作指南

11.5. Acid gas start / if applicable

11.6. Acid gas stop/ if applicable

12. Incinerator 燃烧室

重要：钢制外壳的最低温度不低于 250 度非常重要，可以避免内部腐蚀。其露点大约为 230 度，可

14. Reference documents

Process Flow Diagram In P110

Overview drawings In M241

Piping & Instrumentation In P111

Media in and out In P124

Media Specification In P125

15. Equipment List

H-810 COMBUSTION CHAMBER

C-852 COOLING FAN

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