Detailed description of the invention
Below against accompanying drawing, by the description to embodiment (5000t/d clinker production line), to the present invention's
Detailed description of the invention is described in further detail, to help those skilled in the art's invention to the present invention
Design, technical scheme have more complete, accurate and deep understanding.
The present invention is applied in novel dry-method cement clinker production.By experimentation and CFD sunykatuib analysis etc.
Technological means, the composition of Study on Coal spoil and combustion characteristics, and for different proportion schemes, carry out cement
Clinker burning is tested;Study on Coal spoil adding mode in novel dry-method cement clinker production process, admixture
The factors such as amount, grinding fineness are on production technology and the impact of Thermal Equipment;The different gangue volume of research, no
With impact on clinker burn-ability under the conditions of gangue fineness;By CFD numerical simulation technology, research
Combustion characteristics in dore furnace of gangue and coal dust intermixture and to calciner temperature field, velocity field, granule
The impact that track, gas componant etc. produce.
By theoretical research and scientific experiments, determine that gangue can be applicable in novel dry-method cement clinker production,
Incorporation is up to about 9%;Find gangue best applications approach in clinker production process, solve
Environmental pollution that Piling of Gangue brings and problem of resource waste, and manufacture of cement cost can be saved, produce huge
Big economic benefit and social environment benefit.
The research method of the present invention is: in the element task consulting amount of literature data, certain for having
The gangue sample of calorific value carries out Basic Experiment Study, to determine optimal adding mode and the fineness control of gangue
System;CFD (Fluid Mechanics Computation) numerical simulation analysis is studied, to determine that the addition of gangue is to dore furnace
System condition affects;Thermodynamic metering is studied, to determine that fuel combination characteristic, firing system heat consumption change and pre-
Hot device outlet temperature changes.
Concrete research contents schematic diagram is as shown in Figure 1 and Figure 2.
The percentage ratio of the composition that present document relates to, is the percentage ratio of quality.
Gangue inventive technique scheme of application in novel dry-method cement clinker produces is discussed below:
One, the selection of gangue adding mode is compared:
1, gangue uses as dispensing:
Limestone, sial material, gangue and irony material samples are carried out XRF (X-ray diffraction analysis side
Method) to analyze, analysis result is as shown in table 1.
Table 1, material chemical component XRF analysis (%)
Material |
Loss |
SiO2 |
Al2O3 |
Fe2O3 |
CaO |
MgO |
SO3 |
K2O |
Na2O |
∑ |
Limestone |
41.77 |
2.07 |
0.45 |
0.19 |
54.44 |
0.90 |
0.02 |
0.05 |
0.01 |
99.90 |
Iron powder |
8.20 |
46.82 |
9.24 |
27.73 |
0.76 |
0.66 |
0.42 |
1.36 |
0.17 |
95.36 |
Gangue |
15.89 |
54.72 |
14.54 |
6.23 |
2.82 |
1.38 |
1.15 |
2.29 |
0.24 |
99.25 |
Clay |
7.08 |
68.14 |
13.49 |
8.79 |
0.10 |
0.54 |
0.00 |
1.24 |
0.00 |
99.41 |
Low silica flour sandstone |
8.24 |
63.19 |
12.64 |
5.33 |
4.25 |
1.67 |
0.02 |
2.81 |
0.84 |
98.99 |
High silica flour sandstone |
4.02 |
79.66 |
8.46 |
3.38 |
0.36 |
0.85 |
0.02 |
2.49 |
0.04 |
99.28 |
By chemical analysis, owing to gangue contains substantial amounts of sa composition, SiO2And Al2O3Content reaches
About 70%, in theory, can use as sa raw material.
According to former, fuel conditions, in conjunction with the concrete feature of new dry process production technology, determine dispensing of the present invention
Rate target value be: KH=0.91 ± 0.02, SM=2.6 ± 0.1, IM=1.6 ± 0.1, to determine bastard coal masonry
Use whether clinker moduli meets target call for dispensing.By calculating, proportion scheme is as shown in table 2.
Wherein: KH lime saturation factor;SM silicon rate;AM [IM] aluminum rate.
Table 2, gangue use proportion scheme
Being analyzed by above, gangue and low silica sand rock use as dispensing, and clinker moduli is in rate target
In the range of value, the Theoretical Calculation program is feasible.
2, gangue mixes with coal dust and sprays into dore furnace:
As shown in table 3 by thermodynamic metering, gangue and coal dust mixing post fuel character.
Table 3, fuel combination character calculated value
From above table 3: fuel combination character calculated value, when coal and gangue mix ratio are
When 90%: 10%, by calculating, the caloric value of fuel combination is 5082kcal/hg, reduces to original coal
91%, the change of coal dust calorific value is less.The combustibility of fuel combination and ash dissolubility can be entered by ash component α value
Row judges:
When all coals, α=(SiO2+Al2O3)/(Fe2O3+ CaO+MgO)=12.4;
When the fuel combination that composite rate is 10%, α=12.1,
So it is essentially identical when α value and pure coal.Melting (tack) that therefore, fuel combination is mellow lime,
The combustibility of fuel combination does not changes significantly.So, gangue enters dore furnace as fuel combination
The program, is the most also feasible.But, the usage amount of gangue in dispensing on year-on-year basis, as mixing combustion
Material gangue usage amount is less, only accounts for less than the 10% of dore furnace coal dust feed quantity, if the highest, can affect
Enter the combustibility of stove fuel.In dispensing, the usage amount of gangue is 0.06867kg/kg.cl, as fuel combination
The gangue usage amount entered in dore furnace is 0.007838kg/kg.cl, the former usage amount be 8 times of the latter with
On.
Consider the factor such as economic benefit of as-fired coal burning property of powder, the usage amount of gangue and generation, power
Weighing apparatus considers, gangue is as the most preferably side of incorporation that dispensing operational version is in novel dry-method cement clinker produces
Formula.
The concrete application technology scheme finally determined is:
The gangue of present invention application process in dry-process cement clinker produces, described dry-process cement clinker
The raw material produced includes calcareous raw material, sa raw material, siliceous correction material, aluminum matter correction material, irony school
Just expecting, described gangue mixes in the raw material that dry-process cement clinker produces in the way of dispensing.
Two, the Basic Experiment Study of the present invention:
On the premise of determining the optimal adding mode of gangue, by Basic Experiment Study, verify gangue
The feasibility that dispensing uses.Main research is that the factors such as gangue addition content, gangue fineness are to grog
The impact of burn-ability.
1, the gangue addition content impact (Fig. 3) on grog burn-ability:
Schematic diagram by Fig. 3 difference gangue incorporation low silicon ingredient scheme free calcium oxide content is permissible
Finding out, gangue incorporation improves, and when same temperature point, the content of free calcium oxide all there occurs brighter
Aobvious reduction.
From the point of view of overall sintering process, when incorporation brings up to the 150% of former volume, when 1350 DEG C all
Basically reach reasonable free calcium oxide content, it is believed that the increase of gangue volume can reduce raw material and burn
Become the temperature of reaction, and improve the infiltration rate of free calcium oxide.
From the point of view of result in conjunction with XRF component analysis, the chemical constituent of gangue is mainly SiO2、Al2O3, and
Fe2O3, sufficient amount of liquid phase can be provided in the stage of burning till, accelerate the C2S transformation to C3S, promote free oxygen
Change the absorption of calcium.Therefore, in the reasonable scope, suitably increasing the proportioning of gangue, one is to improve trip
From degree of absorption and the absorption rate of calcium oxide, clinker is made to obtain raising in stability;Two is permissible
Obtain preferable free calcium oxide content at lower temperature, reduce and burn till reaction temperature, and gangue self also may be used
A part of calorific value is provided, saves coal consumption to a certain extent.
To sum up illustrating, gangue uses as dispensing, and free calcium oxide meets requirement, and burn-ability is preferable;With
Time gangue admixture can reduce raw material and burn till the temperature of reaction, and improve the infiltration rate of free calcium oxide.
2, the gangue fineness impact (Fig. 4, Fig. 5) on grog burn-ability:
Illustrated by Fig. 4 low silica flour sandstone proportion scheme, fineness at 100~120 mesh and 120~during 180 mesh,
Situation of burning till is ideal, and fineness is 120~during 180 mesh, can accelerate free oxidation when lower temperature section
The absorption process of calcium, namely accelerates to burn till reaction.And fineness rises again, the final content of free calcium oxide
Occur raising, say, that the meticulous absorption being unfavorable for free calcium oxide on the contrary of granularity.
So, gangue fineness is controlled the fineness at 100~180 mesh (namely 80~150 μm) suitableeer
Cooperate the dispensing fineness for using during practical operation.
In actual production, gangue, as proportion material, together enters raw mill with other raw materials, and raw material grinds
Mill finish fineness general control tails over < 12% in 80 μm.Control gangue fineness be 80um tail over < 12% with
80um tails over < 5%, and gangue ingredient scheme burn-ability experimental result is as shown in Figure 5.
The signal of different fineness gangue+low silicon ingredient scheme free calcium oxide content is gone out to grind by Fig. 5 raw material
Figure is it can be seen that when gangue fineness controls the granularity about 80 μm, difference tails over fineness to easily burning
Property affect difference inconspicuous, and when the final firing temperature of 1450 DEG C, free calcium oxide (WfCaO)
Content is almost equal.But we still can be seen that, before reaching 1450 DEG C, the gangue tailing over < 12% is easy
Burning property is slightly better than tailing over the gangue of < 5%, and this is consistent with test acquired results trend before.
To sum up illustrating, using gangue as the one of raw materials for production, scheme is reasonable, and fineness controls
At 80um;Tail over < 12%.
The concrete technical scheme finally determined is as follows:
The incorporation of described gangue is the 9% or less than 9% of raw material gross mass.
Described gangue and other raw materials together add raw material grinding mill and carry out grinding, and the raw material that raw material grinds mill are thin
Degree is 80um;Tail over≤12%.
Three, CFD numerical simulation study:
Mix the impact on firing system for understanding gangue by dispensing, first pass through the examination of gangue thermal characteristics
Test, Study on Coal spoil combustion characteristics, and by this technology hands of CFD numerical simulation (Fluid Mechanics Computation)
Section, analyzes coal dust burn-off rate, meal calcining rate change;Change of temperature field in dore furnace.
1, gangue burns experiment (Fig. 6):
Produced coal by differential scanning calorimetry (DSC) observable in thermogravimetric analysis (TG) and differential thermal analysis
Spoil sample varies with temperature the quality of generation and the change of energy.Coal shale in brick making sample is carried out grinding,
And sieve the sample powder body for different fineness, taking sample is: A sample 100~120 mesh, i.e. 120~150um;
B sample 120~180 mesh, i.e. 80~120um;C sample 180~325 mesh, i.e. 45~80um.Gangue TG-DSC
Curve such as Fig. 6 raw material goes out to grind the signal of different fineness gangue+low silicon ingredient scheme free calcium oxide content
Shown in figure.
The mistake rapidly it can be seen that the gangue sample of tri-kinds of different fineness of A, B, C is heated according to thermogravimetric curve
The phenomenon of weight, all occurs mainly between the temperature section of 400~600 DEG C.It is believed that: in this temperature section,
Gangue can be heated generation volatile ingredient, starts to burn, and this section of weight loss rate is very fast, further
Ground is it is believed that gangue happens is that the most violent reaction in this temperature section.
Comparison DSC curve can be seen that, creates obviously exothermic peak, and peak value goes out in this temperature section
Present about 530 DEG C.It is believed that the combustion reaction that primary response is gangue of vigorous reaction herein, its heat release
Effect is much larger than other with reaction, and this temperature is its theoretical temperature combustion.
In the temperature section of 600~800 DEG C, it can be seen that tri-groups of samples of A, B, C are still comparing previous stage
The weightlessness that speed is the slowest, it is believed that only exist the mildest weightless reaction in this temperature section.But comparison DSC
After curve find, without obvious exothermic peak in this temperature section, it is believed that in this stage with occur other
Decalescence reaction counteracts coal gangue combustion liberated heat substantially.
After 800 DEG C, A sample weight is about 86%, and B sample weight is about 85%, and C sample weight is
About 84%, and weight loss rate substantially slows down after this.The Industrial Analysis result of comparison gangue, its ash
About 85%, and in TG curve after 800 DEG C, by the weight of hot residue close to this ash value, it is believed that
Burning is basically completed at 800 DEG C.
To sum up illustrating, the interval that burns of gangue is 400~600 DEG C, and combustion reaction mainly occurs;600~
800 DEG C is phase transformation reaction;800 DEG C of gangues substantially completely burn.
2, can gangue burn in preheater:
By the TG-DSC curve of gangue it can be seen that its main combustion reaction concentrates on 400~600 DEG C, this
Temperature range is mainly distributed on the cyclone cylinder stage (3 grades of cylinders of 2 grades of cylinders), due to the combustion reaction of gangue
Not only need rational temperature, in addition it is also necessary to sufficient O2, the thermogravimetric analysis experiment of gangue is in air atmosphere
In (oxygen content 21%) carry out, but during actual production, in cyclone cylinder, the oxygen content of gas is relatively low, typically
Value is less than 4%, under the conditions of such low oxygen concentration, and with the presence of other non-combustible raw material components substantial amounts of,
Gangue almost cannot be carried out igniting.So, gangue is directly used as raw material when carrying out dispensing, gangue
Together entered by whirlwind pre-heating system top with other raw material components, only come downwards in dore furnace, relatively
At higher temperature and higher oxygen content, heat release of just can igniting.
To sum up illustrating, gangue is difficult to carry out in whirlwind cylinder roasting heat release, will not produce the biggest to preheater
Impact, gangue on the impact of firing system mainly for dore furnace part.Analyzed, clearly by above
The scope of CFD simulation is simulated research mainly for dore furnace.
3, CFD numerical simulation dore furnace operating mode:
Coal dust burn-off rate and meal calcining rate (Fig. 7):
By Fig. 7 " coal dust burn-off rate and meal calcining rate distribution curve " it can be seen that the addition of gangue
Burning to coal dust can produce certain adverse effect, the most in the early stage stage and deflagrate section, this
The burning being primarily due to gangue is the slowest.And after main burning zone, burn-off rate rate of change there is no
Too significantly difference, and final burn-off rate does not produce the biggest change, illustrates that it is to coal dust firing in stove
Particularly apparent impact can't be produced.
The initial stage of coal dust firing and deflagrate stage, meal calcining rate is similarly subjected to a certain degree
Adverse effect, CaCO3Decomposition rate the most relatively add before want slow.But after main burning zone, by
Can burn away heat release with the mildest speed in gangue, before the addition gangue that compares, CaCO3
The degree of deceleration of decomposition reaction speed can be slower, particularly in decline, its resolution ratio is even omited
Before adding gangue.
Temperature Distribution (Fig. 8) in dore furnace:
By Fig. 8 " centre section temperature profile in dore furnace " it can be seen that in an initial condition, should
The central area of dore furnace is the peak region of temperature, and the burning of coal dust and the decomposition of raw material are all had by this
Profit.Fig. 8 b is the profiling temperatures after adding gangue, be can be seen that by figure, and the interpolation of gangue is right
The burning of coal dust can cause certain impact, and owing to coal consumption has made corresponding minimizing, makes in stove
High-temperature slightly reduces, and high-temperature area the most slightly reduces.From the point of view of coal dust burn-off rate before in conjunction with, gangue
Addition somewhat slow down the burn rate of coal dust.But owing to the burn rate of gangue is slow, can make " permanent
Quick burning burns " last much longer, this makes the decomposition reaction of raw material the most fully to carry out.
Considering, the resolution ratio on raw material that adds of gangue does not results in the biggest impact, therewith generally
The result of front meal calcining rate is consistent.
Four, the analysis of implementation result of the present invention:
The produced economical, societal benefits of Theoretical Calculation gangue application in cement produced with the dry method produces, according to front
As a example by stating certain 5000t/d grog line, its benchmark calculated is: gangue calorific value 550kcal/kg, bastard coal masonry
For dispensing addition content 4.58%, it is contemplated that Main Economic technical specification is as follows.
1, gangue ingredient uses mix ratio to control about 4.58%, 5000t/d cement clinker production line coal
Spoil year, usage amount was up to about 112600t.
2,5000t/d cement clinker production line can save heat consumption 36kcal/kg.cl, and year saves coal consumption 10560t,
Be sparing in the use of coal in year cost 6,800,000 yuan.
3, kiln tail gas pipe temperature rises about 10 DEG C, can promote kiln tail cogeneration amount 1.2kwh/t.cl,
Annual electricity generating capacity about increases 1800000kwh.
Illustrate: as system heat balance after dispensing admixture, as shown in Figure 9, general preheater exports gangue
Temperature design value is about 320 DEG C, and after adding 4.58% gangue in dispensing, temperature is promoted to about 330 DEG C,
EGT increases by 10 DEG C.
Five, the concrete application example of the present invention:
The present invention is applied to 5000t/d cement production line project.
1, gangue adding mode: four groups of the most same limestone of gangue, sandstone, irony correction material
Divide and carry out grinding according to certain proportioning such as raw material grinding mill.Raw material butt match ratio is as shown in table 4.
Table 4, raw material butt coordinate when theoretical material consumption
2, gangue fineness controls: according to going out to grind raw material fineness guarantee value 80um;Tail over≤12%.
3, gangue addition content: gangue addition content general control is below 9%, when actual operation runs,
Originally the mix ratio of gangue should control about 3.0%, and can be gradually increased, prevent C2 cylinder, C5 cylinder,
Dore furnace cone and kiln tail smoke-box skinning occur.
Concrete anti-skinning measure mainly has:
(1), the strict C1 cylinder outlet temperature that controls is below 330 DEG C;
(2), strict control C2 cylinder outlet temperature less than 540 DEG C
(3), strict control decomposition furnace outlet temperature less than 900 DEG C.
(4) grope the adjustment with actual operating mode, along with calcining system, be gradually increased gangue admixture
Amount, but upper limit suggestion controls below 9%.
4, final guarantee firing system stable operation, grog 28d predicted intensity >=60MPa.Concrete mineral group
Become and rate value is as shown in table 5.
Table 5, clinker moduli and mineral composition
Above in conjunction with accompanying drawing, the present invention is exemplarily described, it is clear that the present invention implements not by upper
State the restriction of mode, if the various unsubstantialities that the method design that have employed the present invention is carried out with technical scheme
Improvement, or the most improved design by the present invention and technical scheme directly apply to other occasion, all exists
Within protection scope of the present invention.