The following is a detailed instructions on the usage process of organic halogen combustion furnaces, covering the complete steps and precautions from preliminary preparation to operation completion:

1、 Preparation and inspection before use

1. Equipment status confirmation

-Appearance inspection: Observe whether there are any deformations, cracks, or corrosion marks on the entire combustion furnace, especially focusing on high-temperature areas such as the combustion chamber, nozzles, and pipeline interfaces. If any abnormalities are found, the use should be stopped immediately and professional personnel should be contacted for repair.

-Component function testing: Confirm whether the ignition device (such as spark plug), fuel delivery system (gas/fuel pipeline), and fan are operating normally. Check the flexibility of each valve opening and closing to prevent uncontrolled feeding due to jamming.

-Safety protection facilities: Verify the effectiveness of safety devices such as emergency stop buttons, explosion-proof valves, and flame monitors. Ensure that there is no accumulation of flammable materials around the furnace and that fire-fighting equipment (fire extinguishers, sandboxes) is in a usable state.

2. Preparation of raw materials and auxiliary materials

-Fuel compatibility verification: Select the matching fuel type (natural gas, liquefied gas, or light oil) based on the design parameters of the combustion furnace. Mixing fuels of different properties is prohibited to avoid causing explosions.

-Combustion enhancer configuration: Adjust the air intake ratio to the theoretical air-fuel ratio (usually 10:1~15:1), which can be precisely controlled by a flow meter. Excessive air can cause heat loss, while insufficient air can easily produce black smoke or unburned particles.

-Sample pretreatment: The organic matter to be processed needs to be crushed to a uniform particle size (recommended ≤ 5cm), and metal impurities should be removed. Waste containing high concentrations of halogens (Cl/Br/I) should be classified separately to prevent side reactions with other substances.

3. Optimization of environmental conditions

-Ventilation system activation: Start the exhaust device in advance to maintain a negative pressure environment in the workshop and prevent harmful gases from escaping. Install combustible gas detectors to monitor the concentration of volatile organic compounds (VOCs) in the air in real-time.

-Temperature and humidity control: The ambient temperature should be maintained at 5-40 ℃, and the relative humidity should be less than 80%. Low temperature may lead to poor fuel atomization, while high temperature can accelerate equipment aging.

2、 Startup and Running Phase Operations

1. Cold start program

-Pre blowing process: Start the induced draft fan and blow the furnace at a wind speed of ≥ 0.5m/s for 5-10 minutes to replace residual gas inside. This step can eliminate the risk of explosion during ignition.

-Gradual ignition method: First ignite the auxiliary small flame (constant light), and then gradually turn on the main burner. It is strictly prohibited to directly impact with a large fire to prevent local overheating and damage to the refractory lining.

-Gradual heating mode: Slowly increase the pressure according to the following curve: ① Room temperature → 150 ℃ (hold for 1 hour for dehydration); ② 150-300 ℃ (heating up ≤ 50 ℃ per hour); ③ After exceeding 300 ℃, enter the continuous working range. Rapid temperature rise can easily cause cracking of the furnace body.

2. Dynamic operation regulation

-Accurate temperature management: Automatically adjust fuel supply through thermocouple feedback. Under typical operating conditions, the temperature of the primary combustion chamber is set at 850~1200 ℃, and the temperature of the secondary catalytic section is maintained at 600~800 ℃. Trigger sound and light alarm and cut off fuel source when overheating occurs.

-Pressure balance control: Use a differential pressure transmitter to monitor the pressure difference inside and outside the furnace, and maintain it within the range of -50~+100Pa. Excessive positive pressure can cause smoke leakage, while excessive negative pressure can suck in cold air and reduce efficiency.

-Collaborative treatment of pollutants: Simultaneously activate the rapid cooling tower (cooling rate>200 ℃/s to suppress dioxin regeneration), bag filter (filtering accuracy up to PM2.5 level), and alkali spray tower (neutralizing acidic gases such as HCl/HF) to ensure emissions meet standards.

3. Emergency response plan

-Shutdown protection mechanism: In case of sudden shutdown, immediately close the fuel valve, perform the purge procedure again, and then try ignition again. The reason for three consecutive failures needs to be investigated, and forced restarts are prohibited.

-Leakage response measures: When smelling a pungent odor, quickly wear a gas mask, turn off the main power, and use a portable detector to locate the leakage point. Minor leaks can be checked by applying soapy water, while severe leaks require evacuation of personnel.

-Fire extinguishing plan: In the initial stage, small fires can be suppressed with carbon dioxide fire extinguishers, and in large-scale fires, the nitrogen fire extinguishing system can be activated. It is strictly prohibited to direct water column directly onto the high-temperature furnace body to prevent sudden cooling and cracking.

3、 Shutdown and aftermath handling

1. Orderly shutdown steps

-Principle of load reduction: Gradually reduce the feed rate and synchronously decrease the fuel input. When the load drops below 30%, switch to low flame and maintain combustion for 15 minutes to fully release residual heat.

-Forced cooling restriction: Water spray rapid cooling should not be used unless in emergency situations to avoid damaging the furnace. The maintenance door can only be opened after natural cooling to below 100 ℃.

-Residual cleaning: Remove salt crystals (mainly NaCl/KCl mixture) from the ash hopper and unclog clogged nozzles. Disassemble the filter screen for high-pressure steam flushing to restore permeability.

2. Key points of maintenance and upkeep

-Periodic inspection: Daily recording of operating parameters (temperature/pressure/flow), monthly detection of flue gas composition (O ₂/CO/NOx content). Verify sensor accuracy comprehensively every quarter.

-Replacement cycle of vulnerable parts: The service life of refractory bricks is about 3 years, and replacement is required when the erosion depth is greater than 1/3 of the thickness; Polish the contact points of the electrode rod every six months; The sealing gasket is updated annually.

-Anti corrosion and rust treatment: During the shutdown period, dry nitrogen gas is filled into the furnace to isolate moisture. The shell is coated with high-temperature resistant and rust proof paint, and the moving parts are coated with lithium based grease.

3. Document archiving requirements

-Detailed records of operation logs: including start stop time, fault symptoms, maintenance content, consumables requisition, etc., with a retention period of not less than 3 years.

-Preparation of energy efficiency analysis report: Compare historical data to calculate the energy consumption per unit mass of waste treatment and identify energy-saving potential.