CN110953877A - Method and device for calculating power of rotary kiln - Google Patents
Method and device for calculating power of rotary kiln Download PDFInfo
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- CN110953877A CN110953877A CN201811130655.5A CN201811130655A CN110953877A CN 110953877 A CN110953877 A CN 110953877A CN 201811130655 A CN201811130655 A CN 201811130655A CN 110953877 A CN110953877 A CN 110953877A
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B7/00—Rotary-drum furnaces, i.e. horizontal or slightly inclined
- F27B7/20—Details, accessories, or equipment peculiar to rotary-drum furnaces
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Abstract
The invention discloses a method and a device for calculating the power of a rotary kiln, which relate to the technical field of rotary kiln design calculation, wherein a structure diagram of the rotary kiln is obtained, and a material flow in the rotary kiln is divided into n sections according to the material flow information of the rotary kiln; calculating the volume flow of each of the 1 st section to the nth section; determining the material flow rate of each of the 1 st section to the nth section of the rotary kiln; determining the material flow sectional area of each of the 1 st to the nth sections; determining the material flow filling rate of each of the 1 st section to the nth section; determining the material volume of the materials in the 1 st section to the m section; calculating the length of the eccentric moment arm of the material from the 1 st section to the m-th section; calculating the material eccentric moment and the material eccentric resultant moment of the 1 st section to the m-th section respectively; and calculating the required power of the rotary kiln. The technical effects that the calculation is intuitive and simple, and the calcination time and the rotary kiln power can be accurately calculated are achieved.
Description
Technical Field
The invention relates to the technical field of design calculation of rotary kilns, in particular to a method and a device for calculating power of a rotary kiln.
Background
At present, the rotary kiln refers to a rotary calcining kiln, and belongs to the field of building materials and metallurgical equipment. Rotary kilns can be divided into cement kilns, metallurgical chemical kilns and lime kilns according to the different materials to be treated. The rotary kiln is widely applied to the production of cement, alumina, ferronickel, lithium carbonate, titanium dioxide, metal vanadium and the like at home and abroad. According to the physicochemical properties of different materials, the required calcination time is different, and the calcination time of the materials is controlled by adopting measures such as necking, material blocking rings and the like for the design of the kiln.
However, in the process of implementing the technical solution in the embodiment of the present application, the inventor of the present application finds that the above prior art has at least the following technical problems:
the rotary kiln with the necking and the material blocking ring in the prior art has the technical problem that the calculation of the power and the calcination time of the rotary kiln is complicated and even can not be calculated.
Disclosure of Invention
The invention provides a method and a device for calculating the power of a rotary kiln, which are used for solving the technical problems that the calculation of the power and the calcination time of the rotary kiln is complicated and even can not be calculated in the rotary kiln with a necking and a stop ring in the prior art, and achieve the technical effects that the calculation method is visual and simple and can accurately calculate the calcination time and the power of the rotary kiln.
In a first aspect, the present invention provides a method for calculating power of a rotary kiln, the method comprising: obtaining a structural diagram of the rotary kiln according to structural information of the rotary kiln, and dividing material flow in the rotary kiln into n sections according to the material flow information of the rotary kiln; respectively obtaining the mass flow and the volume density of the 1 st section to the nth section of the rotary kiln, and calculating the volume flow of the 1 st section to the nth section according to the mass flow and the volume density; determining the material flow rate of each of the 1 st section to the nth section of the rotary kiln; determining the material flow sectional area of each of the 1 st section to the nth section according to the volume flow and the material flow velocity of each of the 1 st section to the nth section of the rotary kiln; determining the material flow filling rate of each of the 1 st section to the nth section according to the material flow cross section of each of the 1 st section to the nth section and the effective radius of the rotary kiln of each section; dividing the rotary kiln into m sections according to every two adjacent sections of the n sections, determining the material volume of the material in each section from the 1 st section to the m section, and obtaining the total material volume according to the material volume of each section from the 1 st section to the m section, wherein n-m is 1; calculating the length of the eccentric moment arm of the material from the 1 st section to the m-th section; calculating the material eccentric moment and the material eccentric resultant moment of the 1 st section to the m th section, calculating the power for overcoming the material eccentric resultant moment, and calculating the friction power consumption according to the total weight of the rotary kiln rotating part and the motion information; and calculating the required power of the rotary kiln according to the power for overcoming the eccentric resultant torque of the material and the friction power consumption.
Preferably, before obtaining the total volume of the materials according to the material volume of each of the 1 st section to the m th section, the method further comprises: dividing the lengths of the 1 st section to the m th section according to the structural diagram of the rotary kiln and the material flow sections from 1 st to n th.
Preferably, after obtaining the total volume of the materials according to the material volume of each of the 1 st section to the m th section, the method further comprises: calculating the residence time of the materials in the 1 st section to the m th section, and obtaining the total residence time of the materials in the kiln according to the residence time of the materials in the 1 st section to the m th section.
Preferably, before calculating the length of the material eccentric moment arm of each of the 1 st section to the m th section, the method further includes: and calculating the mass of the materials from the 1 st section to the m-th section, and obtaining the total mass of the materials in the kiln according to the mass of the materials from the 1 st section to the m-th section.
Preferably, the method further comprises: and calculating the mass of the material in each of the 1 st section to the m th section according to the average value of the volume and the volume density of the material in each of the 1 st section to the m th section, wherein the average value of the volume density is the average value of the volume density at two end points of the corresponding section.
Preferably, the volume flow rate is a ratio of the corresponding mass flow rate and the volume density.
Preferably, the stream fill ratio is from 0.05 to 0.2.
Preferably, the method further comprises: and calculating the length of the eccentric moment arm of the material in each of the 1 st to m-th sections by adopting a material flow section gravity center estimation mode.
Preferably, the method further comprises: the included angle between the interface of the material with the ith section and the gas in the kiln and the horizontal plane is thetaiAnd the section takes the ith cross-section inner diameter circle of the rotary kiln as an arch of an arc, wherein i is a natural number of 1-n.
In a second aspect, the present invention provides an apparatus for calculating power of a rotary kiln, the apparatus comprising:
the first dividing unit is used for obtaining a structural diagram of the rotary kiln according to structural information of the rotary kiln and dividing a material flow in the rotary kiln into n sections according to information of the material flow in the rotary kiln;
the first obtaining unit is used for respectively obtaining the mass flow and the volume density of the 1 st section to the nth section of the rotary kiln and calculating the volume flow of the 1 st section to the nth section according to the mass flow and the volume density;
a first determination unit for determining the material flow rate of each of the 1 st section to the nth section of the rotary kiln;
a second determination unit for determining the material flow sectional area of each of the 1 st to the nth sections according to the volume flow and the material flow velocity of each of the 1 st to the nth sections of the rotary kiln;
a third determination unit for determining the material flow filling rate of each of the 1 st to nth sections from the material flow cross section of each of the 1 st to nth sections and the effective radius of the rotary kiln of each section;
a second obtaining unit, configured to divide the rotary kiln into m sections according to each two adjacent sections of the n sections, determine respective material volumes of materials in a 1 st section to the m th section, and obtain total material volumes according to the respective material volumes of the 1 st section to the m th section, where n-m is 1;
the first calculating unit is used for calculating the length of the eccentric force arm of the material from the 1 st section to the m-th section;
the second calculation unit is used for calculating material eccentric torque and material eccentric resultant torque of the 1 st section to the m-th section, calculating power for overcoming the material eccentric resultant torque, and calculating friction power consumption according to the total weight of the rotary part of the rotary kiln and motion information;
and the third calculating unit is used for calculating the required power of the rotary kiln according to the power for overcoming the eccentric resultant torque of the materials and the friction power consumption.
Preferably, the apparatus further comprises:
and the second dividing unit is used for dividing the lengths of the 1 st section to the m th section according to the structural diagram of the rotary kiln and the material flow sections from 1 st to the n th.
Preferably, the apparatus further comprises:
a fourth calculating unit, configured to calculate respective residence times of the material in the 1 st section to the m-th section, and obtain a total residence time of the material in the kiln according to the respective residence times of the material in the 1 st section to the m-th section.
Preferably, the apparatus further comprises:
and the fifth calculating unit is used for calculating the mass of the materials from the 1 st section to the m-th section and obtaining the total mass of the materials in the kiln according to the mass of the materials from the 1 st section to the m-th section.
Preferably, the apparatus further comprises:
a sixth calculating unit, configured to calculate the mass of the material in each of the 1 st section to the m th section according to the average value of the volume and the bulk density of the material in each of the 1 st section to the m th section, where the average value of the bulk density is an average value of the bulk density at two end points of the corresponding section.
Preferably, the apparatus further comprises: the volume flow is the ratio of the corresponding mass flow to the volume density.
Preferably, the apparatus further comprises: the stream fill ratio is from 0.05 to 0.2.
Preferably, the apparatus further comprises:
a seventh calculating unit, configured to calculate lengths of material eccentric moment arms of the 1 st to m-th sections by using a material flow cross section gravity center estimation method;
the included angle between the interface of the material with the ith section and the gas in the kiln and the horizontal plane is thetaiAnd the section takes the ith cross-section inner diameter circle of the rotary kiln as an arch of an arc, wherein i is a natural number of 1-n.
In a third aspect, the present invention provides a device for calculating power of a rotary kiln, comprising a memory, a processor and a computer program stored in the memory and running on the processor, wherein the processor executes the computer program to implement the following steps: obtaining a structural diagram of the rotary kiln according to structural information of the rotary kiln, and dividing material flow in the rotary kiln into n sections according to the material flow information of the rotary kiln; respectively obtaining the mass flow and the volume density of the 1 st section to the nth section of the rotary kiln, and calculating the volume flow of the 1 st section to the nth section according to the mass flow and the volume density; determining the material flow rate of each of the 1 st section to the nth section of the rotary kiln; determining the material flow sectional area of each of the 1 st section to the nth section according to the volume flow and the material flow velocity of each of the 1 st section to the nth section of the rotary kiln; determining the material flow filling rate of each of the 1 st section to the nth section according to the material flow cross section of each of the 1 st section to the nth section and the effective radius of the rotary kiln of each section; dividing the rotary kiln into m sections according to every two adjacent sections of the n sections, determining the material volume of the material in each section from the 1 st section to the m section, and obtaining the total material volume according to the material volume of each section from the 1 st section to the m section, wherein n-m is 1; calculating the length of the eccentric moment arm of the material from the 1 st section to the m-th section; calculating the material eccentric moment and the material eccentric resultant moment of the 1 st section to the m th section, calculating the power for overcoming the material eccentric resultant moment, and calculating the friction power consumption according to the total weight of the rotary kiln rotating part and the motion information; and calculating the required power of the rotary kiln according to the power for overcoming the eccentric resultant torque of the material and the friction power consumption.
One or more technical solutions in the embodiments of the present invention at least have one or more of the following technical effects:
1. according to the method and the device for calculating the power of the rotary kiln, provided by the embodiment of the invention, the structure diagram of the rotary kiln is obtained according to the structural information of the rotary kiln, and the material flow in the rotary kiln is divided into n sections according to the material flow information of the rotary kiln; respectively obtaining the mass flow and the volume density of the 1 st section to the nth section of the rotary kiln, and calculating the volume flow of the 1 st section to the nth section according to the mass flow and the volume density; determining the material flow rate of each of the 1 st section to the nth section of the rotary kiln; determining the material flow sectional area of each of the 1 st section to the nth section according to the volume flow and the material flow velocity of each of the 1 st section to the nth section of the rotary kiln; determining the material flow filling rate of each of the 1 st section to the nth section according to the material flow cross section of each of the 1 st section to the nth section and the effective radius of the rotary kiln of each section; dividing the rotary kiln into m sections according to every two adjacent sections of the n sections, determining the material volume of the material in each section from the 1 st section to the m section, and obtaining the total material volume according to the material volume of each section from the 1 st section to the m section, wherein n-m is 1; calculating the length of the eccentric moment arm of the material from the 1 st section to the m-th section; calculating the material eccentric moment and the material eccentric resultant moment of the 1 st section to the m th section respectively, and calculating the power for overcoming the material eccentric resultant moment; calculating friction power consumption according to the total weight of the rotary part of the rotary kiln and the motion information; and calculating the required power of the rotary kiln according to the power for overcoming the eccentric resultant torque of the material and the friction power consumption. The method solves the technical problems that the calculation of the power and the calcining time of the rotary kiln with the necking and the material blocking ring in the prior art is complicated and even can not be calculated, and achieves the technical effects that the calculation method is visual and simple and the calcining time and the power of the rotary kiln can be accurately calculated.
2. The material flow filling rate of the embodiment of the invention is 0.05-0.2. The filling rate is further prevented from being too low, the heat dissipation loss of the kiln body is large, and the filling rate can be improved by reducing the rotating speed of the kiln; the filling rate is too high, the material is possibly calcined and is not thorough, and the technical effect that the filling rate can be reduced by improving the kiln speed is achieved.
The foregoing description is only an overview of the technical solutions of the present invention, and the embodiments of the present invention are described below in order to make the technical means of the present invention more clearly understood and to make the above and other objects, features, and advantages of the present invention more clearly understandable.
Drawings
FIG. 1 is a schematic flow chart of a method for calculating power of a rotary kiln according to an embodiment of the present invention;
FIG. 2 is a schematic view of the construction of a rotary kiln according to an embodiment of the present invention;
FIG. 3 is a schematic structural diagram of a device for calculating power of a rotary kiln according to an embodiment of the present invention;
fig. 4 is a schematic structural diagram of another device for calculating the power of the rotary kiln in the embodiment of the invention.
The reference numbers illustrate: a bus 300, a receiver 301, a processor 302, a transmitter 303, a memory 304, a bus interface 306.
Detailed Description
The embodiment of the invention provides a method and a device for calculating power of a rotary kiln, which are used for solving the technical problems that the calculation of the power and the calcination time of the rotary kiln is complicated and even can not be calculated in the rotary kiln with a necking and a material blocking ring in the prior art.
The technical scheme in the embodiment of the invention has the following overall structure:
the invention provides a method and a device for calculating the power of a rotary kiln, which are characterized in that a structural diagram of the rotary kiln is obtained according to the structural information of the rotary kiln, and a material flow in the rotary kiln is divided into n sections according to the material flow information of the rotary kiln; respectively obtaining the mass flow and the volume density of the 1 st section to the nth section of the rotary kiln, and calculating the volume flow of the 1 st section to the nth section according to the mass flow and the volume density; determining the material flow rate of each of the 1 st section to the nth section of the rotary kiln; determining the material flow sectional area of each of the 1 st section to the nth section according to the volume flow and the material flow velocity of each of the 1 st section to the nth section of the rotary kiln; determining the material flow filling rate of each of the 1 st section to the nth section according to the material flow cross section of each of the 1 st section to the nth section and the effective radius of the rotary kiln of each section; dividing the rotary kiln into m sections according to every two adjacent sections of the n sections, determining the material volume of the material in each section from the 1 st section to the m section, and obtaining the total material volume according to the material volume of each section from the 1 st section to the m section, wherein n-m is 1; calculating the length of the eccentric moment arm of the material from the 1 st section to the m-th section; calculating the material eccentric moment and the material eccentric resultant moment of the 1 st section to the m th section, calculating the power for overcoming the material eccentric resultant moment, and calculating the friction power consumption according to the total weight of the rotary kiln rotating part and the motion information; and calculating the required power of the rotary kiln according to the power for overcoming the eccentric resultant torque of the material and the friction power consumption. The technical effects that the calculation method is visual and simple and convenient, and the calcination time and the rotary kiln power can be accurately calculated are achieved.
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example one
The embodiment of the present invention provides a method for calculating power of a rotary kiln, please refer to fig. 1, where the method includes:
step 110: obtaining a structural diagram of the rotary kiln according to structural information of the rotary kiln, and dividing material flow in the rotary kiln into n sections according to the material flow information of the rotary kiln;
specifically, according to the determined specifications of the rotary kiln and the internal structure of the rotary kiln, wherein the specifications of the rotary kiln comprise an effective inner diameter and a length, the internal structure of the rotary kiln comprises a material stop ring, a reducing ring, a necking and a material lifting plate, a structural diagram of the rotary kiln is drawn, and the rotary kiln is divided into n sections according to the material flow property of the rotary kiln, as shown in fig. 2.
Step 120: respectively obtaining the mass flow and the volume density of the 1 st section to the nth section of the rotary kiln, and calculating the volume flow of the 1 st section to the nth section according to the mass flow and the volume density;
further, the volume flow rate is a ratio of the mass flow rate and the volume density of the corresponding section.
Specifically, the rotary kiln comprises n different sections, and mass flow, material density and volume flow of the different sections of the kiln are determined according to the capacity of the rotary kiln, the physicochemical reaction property of materials in the rotary kiln and the wind speed in the kiln, wherein the calcining kiln is subjected to burning reduction, and the specific gravity and the volume of the materials are changed; the change of the material proportion and the volume of the cooler is not large, the air speed in the dry-method cement kiln is high, and more fine materials are carried by the air; the air speed in the garbage incineration kiln is slow, and the amount of fine materials taken away is small. Therefore, when calculating, the mass flow and the volume density of each section are respectively obtained, and then the volume flow is calculated according to the mass flow and the volume density, wherein the volume flow is the ratio of the mass flow to the volume density, that is, the mass flow and the volume density of the 1 st to the nth sections of the rotary kiln are respectively obtained, and the volume flow of each section is calculated according to the mass flow and the volume density of the 1 st to the nth sections.
Step 130: determining the material flow rate of each of the 1 st section to the nth section of the rotary kiln;
step 140: determining the material flow sectional area of each of the 1 st section to the nth section according to the volume flow and the material flow velocity of each of the 1 st section to the nth section of the rotary kiln;
specifically, according to a formula of HG-T20566-2011 chemical rotary kiln design regulation, wherein the residence time and the flow rate of the material in different sections of the rotary kiln are determined according to a residence time of the material in the rotary kiln, wherein the formula is L (theta +24)/(324Dio n sin α), L is a section length and is m, theta is an angle of repose of the material in the section in the kiln, Dio is an effective inner diameter of the section in the kiln and is m, n is a kiln rotation speed and is rpm, sin α is a mounting inclination of the kiln, namely, the residence time and the flow rate of the material in the corresponding section are respectively obtained according to the n sections and the m sections of the material flow of the rotary kiln, the cross-sectional area of the material flow of the corresponding section is further determined according to the material flow volume flow rate of the section and the passing (residence) time, namely, the cross-sectional area of the material flow from the 1 st to the nth section is respectively obtained, wherein the reciprocal of the time of the material flow passing through the section of the section per unit length is the flow rate, and the ratio of the flow rate of the material flow rate, namely, the volume flow rate/flow.
Step 150: determining the material flow filling rate of each of the 1 st section to the nth section according to the material flow cross section of each of the 1 st section to the nth section and the effective radius of the rotary kiln of each section;
further, the material flow filling ratio is preferably 0.05 to 0.2.
Specifically, the filling ratio corresponding to the section is determined by the ratio of the material flow section area of different sections to the effective section area of the kiln determined by the inner effective radius r of the rotary kiln in the section, and is preferably between 0.05 and 0.2. Wherein, the filling rate is the ratio of the sectional area of material flow to the internal sectional area of the rotary kiln determined by the effective radius. Thereby avoiding the over-small filling rate and the large heat dissipation loss of the kiln body, and reducing the rotating speed of the kiln can improve the filling rate; the filling rate is too high, the material is possibly calcined and cannot be completely calcined, and the filling rate can be reduced by increasing the kiln speed.
Step 160: dividing the rotary kiln into m sections according to every two adjacent sections of the n sections, determining the material volume of the material in each section from the 1 st section to the m section, and obtaining the total material volume according to the material volume of each section from the 1 st section to the m section, wherein n-m is 1;
specifically, when the section of the rotary kiln is divided into n sections, the n sections form m sections, and the material volumes of the m sections are summed up to obtain the total material volume of the rotary kiln. The volume of each section of material in the rotary kiln can be calculated by a volume formula of a cylinder and a volume formula of a frustum body, wherein the volume formula of the cylinder is used for calculating the sections without reducing diameter, a material blocking ring and obvious volume flow change, and the volume formula of the frustum body is used for calculating the sections with reducing diameter, a material blocking ring and obvious volume flow change. Calculating the material volume requires first obtaining the material volume of each section, and then obtaining the total material volume of the rotary kiln according to the value of the material volume of each section.
Step 170: calculating the length of the eccentric moment arm of the material from the 1 st section to the m-th section;
further, the length of the eccentric moment arm of the material in each of the 1 st to m-th sections is calculated by adopting a material flow section gravity center estimation mode.
Particularly, by adopting a gravity center or mass center method, in consideration of reaction and ignition loss in the rotary kiln, no matter the material flow is in a cylindrical section or a table-shaped section, the gravity center or mass center of the sectional material along the axial direction of the kiln needs to be calculated firstly, then, the face center calculation is carried out on the arch section of the gravity center, for the calculation accuracy, the arch face is divided into four equal parts, the arch heights of three arches of the total arch areas 1/4, 1/2 and 3/4 are respectively calculated, the average value of the three arch heights is taken, i.e., the more subdivided, the closer to true values, the effective radius of the kiln for that segment is subtracted by the calculated average value, multiplied by the sine of the angle of repose, the length of the force arm of the gravity of the material in the section to the rotary central line of the kiln is obtained, so that the length of the eccentric force arm of each section can be calculated one by one, namely, the lengths of the eccentric moment arms of the materials from the 1 st section to the m-th section are calculated.
Step 180: and calculating the material eccentric moment and the material eccentric resultant moment of the 1 st section to the m-th section respectively, calculating the power for overcoming the material eccentric resultant moment, and calculating the friction power consumption according to the total weight of the rotary kiln rotating part and the motion information.
Step 190: calculating the required power of the rotary kiln according to the power for overcoming the eccentric resultant torque of the materials and the friction power consumption;
specifically, in the calculation process, the partial moments of different sections are calculated firstly, then the total moment (resultant moment) is obtained, that is, the material eccentric moment of the 1 st section is calculated, the respective material eccentric moments of the 2 nd to m th sections are calculated in sequence, the respective eccentric moments of the 1 st to m th sections are added, and finally the total eccentric moment (resultant moment) of the material in the kiln is obtained. Wherein, the power for overcoming (inverse) total torque (resultant torque) is calculated, and the formula is P1Pi × T × n/30, wherein P is1In order to overcome the counter torque power, the unit is kw, T is the total torque, the unit is k.Nm, n is the rotation speed of the kiln, and the unit is rpm. Further adopting a calculation formula same as HG-T20566-2011 chemical rotary kiln design regulation, and obtaining friction consumed power according to the total weight of the rotary part (including the lining and the material) of the rotary kiln and the motion information thereof, wherein: the total weight W is equal to the total weight of the cylinder body, the rolling ring, the gear ring, the refractory material and the material. P2W × Dr × d × n × f × 0.06016/Dt, wherein P is2The power consumption is the frictional resistance, and the unit is kw; w is the total weight in kN; d is the diameter of the collar, and the unit is m; d is the diameter of the supporting wheel shaft, and the unit is m; n is the kiln rotation speed, and the unit is rpm; f is friction coefficient, and the sliding bearing is 0.03; dt is the diameter of the riding wheel in m.
Further, before obtaining the total volume of the materials according to the material volume of each of the 1 st section to the m th section, the method further includes: dividing the lengths of the 1 st section to the m th section according to the structural diagram of the rotary kiln and the material flow sections from 1 st to n th.
Specifically, dividing the length of each section in the kiln according to the structural diagram in the rotary kiln and the change situation of the sectional area of the material, namely, dividing the length of each section in the rotary kiln respectively to obtain the area of a representative section of each section, namely obtaining the sectional area of the material flow of the 1 st to the nth sections of the rotary kiln respectively; and according to the length and the cross section area of each section, wherein the average area of the material flow which is not changed much is taken, the area of both ends of the material flow which is changed much is taken, the volume of the material flow in each section is obtained, and the total volume of the material flow in the rotary kiln is obtained from the volume of the material flow in each section.
Further, after obtaining the total volume of the materials according to the material volume of each of the section 1 to the section m, the method further includes: calculating the residence time of the materials in the 1 st section to the m th section, and obtaining the total residence time of the materials in the kiln according to the residence time of the materials in the 1 st section to the m th section.
Specifically, the residence time and the total residence time of the materials in each section are calculated according to the material volume of each section, the total volume of the materials in the kiln and the flow rate, wherein the residence time is the key point of the process design of various calcining or reaction kilns, and is related to whether the calcining and reaction time meets the design requirement or not.
Further, the method further comprises: the included angle between the interface of the material with the ith section and the gas in the kiln and the horizontal plane is thetaiAnd the section takes the ith cross-section inner diameter circle of the rotary kiln as an arch of an arc, wherein i is a natural number of 1-n.
Specifically, due to the continuous rotation of the rotary kiln and the determination of the material repose angle theta, the section of material flow in any section in the rotary kiln is in an arch shape, the included angle between the section and the horizontal plane is theta, and the effective inner diameter circle of the rotary kiln is an arc. The 1 st to i th section material flow and the interface of the smoke in the kiln respectively form an included angle theta with the horizontal1To thetaiWhere i ∈ [1, n ]]And the cross sections of the material flows are respectively arched with the effective inner diameter circle of the cross section of the rotary kiln as an arc. Taking the 1 st section and the 2 nd section as examples, the sections of the 1 st section and the 2 nd section respectively form an included angle theta with the horizontal1、θ2And the No. 1 section inner diameter circle of the rotary kiln is respectively used as an arch of an arc, and the No. 2 section inner diameter circle is used as an arch of an arc. Wherein, the effective inner diameter of the kiln, the sectional area of material flow and the sin theta value determine the arm length of the material core moment.
Further, before calculating the length of the material eccentric moment arm of each of the 1 st section to the m th section, the method further includes: and calculating the mass of the materials from the 1 st section to the m-th section, and obtaining the total mass of the materials in the kiln according to the mass of the materials from the 1 st section to the m-th section.
Further, the method further comprises: and calculating the mass of the material in each of the 1 st section to the m th section according to the average value of the volume and the volume density of the material in each of the 1 st section to the m th section, wherein the average value of the volume density is the average value of the volume density at two end faces of the corresponding section.
Specifically, calculating the mass of the segmented materials and the total mass according to the segmented volume of the materials in the rotary kiln and the average value of the segmented volume density, specifically, calculating the mass of the materials in the 1 st segment and the mass of the materials in the 2 nd segment respectively until the mass of the materials in the m-th segment is calculated, and adding the masses of the materials in the 1 st segment to the m-th segment to finally obtain the total mass of the materials in the rotary kiln.
Example two
The following describes in detail a method for calculating power of a rotary kiln according to an embodiment of the present invention, specifically as follows:
firstly, taking a phi 4.85 x 100m ferronickel reduction kiln as an example, obtaining a structural diagram of the rotary kiln as shown in fig. 2;
next, the volume flow for each section is calculated, for example at the throat of the kiln head, with a mass flow of 56458.5kg/h, which is equal to the kiln output. Volume density 1000kg/m3The value is provided by the owner or a commission inspection department or is found by an associated design manual. Volume flow rate/volume density 56458.5kg/h/1000kg/m3＝56.45m3/h＝0.94m3/min；
Then, the residence time t of the material in different sections in the rotary kiln is calculated in units of min, wherein L is the section length in units of m, theta is the angle of repose of the material in the section in the kiln, Dio is the effective inner diameter of the section in the kiln in units of m, n is the kiln rotation speed in units of rpm, sin α is the installation slope of the kiln, for example, the time t of the material passing through a 1 m-length section in the throat section of the kiln head is 1 (theta +24)/(324Dio n sin α), theta is the angle of repose of the material in the section in the kiln, theta is 40 degrees, Dio is the effective inner diameter of the section in the kiln, namely the actual diameter of the barrel inner diameter of the kiln minus 2 times the thickness of the refractory lining, Dio is 2.85m, n is the rotation speed, n is 1.2 min, and n is 1.2.035 (7.8.8.8) according to the formula, and the installation slope of the kiln is calculated according to the formula of t + L (theta +24)/(324, 8).
Further, the cross-sectional area of the material flow is determined according to the volume flow and the residence time, wherein the reciprocal of the time for the material to pass through the belt per unit length is the flow rate, and the flow rate is 1/1.65 or 0.61m/min, and the cross-sectional area of the material flow is the volume flow/flow rate.
Furthermore, because the rotary kiln rotates continuously and the angle of repose theta of the material is determined, the section of the material flow in any section in the kiln is in an arch shape, the included angle between the section and the horizontal plane is theta, and the effective inner diameter circle of the kiln is an arc. If θ is 40 °, sin40 ° is 0.66, the effective radius of the kiln and sin θnThe value determines the arm length of the material core moment. The calculation formula of the arch area is as follows: 0.5 ═ r (l-c) + ch](2)、
Wherein, the expressions (2) to (5) are respectively calculation formulas of the area, the arc length, the arch height and the chord length of the arch. In the formula: s is the arch area in m2(ii) a l is the arc length of the arch, and the unit is m; h is the arch height, and the unit is m; c is the chord length of the arch, and the unit is m; r is the arc radius of the arch in m. During calculation, the arch height, namely the maximum thickness of the material, is assumed, and then the chord length, the arc length and the area of the arch are calculatedAnd comparing the calculated area with the area determined according to the process in the step 140, wherein after several comparisons, the corresponding arch height when the areas are equal is the maximum thickness of the material.
After the power for overcoming the (reverse) total torque is calculated, a calculation formula which is the same as HG-T20566-2011 chemical rotary kiln design regulation is further adopted to obtain the friction power consumption. When the total weight is calculated, if the total weight W is 20498.95kN, the frictional resistance consumes power P2W Dr d n f 0.06016/Dt 20498.95 5.9 0.6 1.2 0.03 0.06016/1.8 87.31kw, P in the formula2The power consumption is the frictional resistance, and the unit is kw; w is the total weight in kN; d is the diameter of the collar, and the unit is m; d is the diameter of the supporting wheel shaft, and the unit is m; n is the kiln rotation speed, and the unit is rpm; f is friction coefficient, and the sliding bearing is 0.03; dt is the diameter of the riding wheel in m.
The values of the starting coefficient and the standby power coefficient of the rotary kiln are unchanged, the two coefficients are both 1.3, and the calculated total power is 637.51kw and is closer to the actual value of the industrial kiln.
Example 3
Based on the same inventive concept as the method for calculating the power of the rotary kiln in the foregoing embodiment, the present invention further provides a device for calculating the power of the rotary kiln, as shown in fig. 3, including:
the first dividing unit 11 is used for obtaining a structural diagram of the rotary kiln according to structural information of the rotary kiln, and dividing a material flow in the rotary kiln into n sections according to information of the material flow of the rotary kiln;
a first obtaining unit 12, where the first obtaining unit 12 is configured to obtain a mass flow rate and a volume density of each of the 1 st cross section to the nth cross section of the rotary kiln, and calculate a volume flow rate of each of the 1 st cross section to the nth cross section according to the mass flow rate and the volume density;
a first determination unit 13, wherein the first determination unit 13 is used for determining the material flow rate of each of the 1 st section to the nth section of the rotary kiln;
a second determination unit 14, wherein the second determination unit 14 is used for determining the material flow cross section area of each of the 1 st section to the nth section according to the volume flow and the material flow velocity of each of the 1 st section to the nth section of the rotary kiln;
a third determination unit 15, wherein the third determination unit 15 is configured to determine the material flow filling rate of each of the 1 st to nth sections according to the material flow cross section of each of the 1 st to nth sections and the effective radius of the rotary kiln of each section;
a second obtaining unit 16, configured to divide the rotary kiln into m sections according to each two adjacent sections of the n sections, determine material volumes of materials in the 1 st section to the m th section, and obtain total material volumes according to the material volumes of the 1 st section to the m th section, where n-m is 1;
a first calculating unit 17, wherein the first calculating unit 17 is used for calculating the length of the eccentric moment arm of the material from the 1 st section to the m-th section;
the second calculating unit 18 is used for calculating the material eccentric moment and the material eccentric resultant moment of each of the 1 st section to the m-th section, calculating the power for overcoming the material eccentric resultant moment, and calculating the friction power consumption according to the total weight of the rotary part of the rotary kiln and the motion information;
and the third calculating unit 19 is used for calculating the required power of the rotary kiln according to the power for overcoming the eccentric resultant torque of the materials and the friction consumed power.
Further, the apparatus further comprises: and the second dividing unit is used for dividing the lengths of the 1 st section to the m th section according to the structural diagram of the rotary kiln and the material flow sections from 1 st to the n th.
Further, the apparatus further comprises: a fourth calculating unit, configured to calculate respective residence times of the material in the 1 st section to the m-th section, and obtain a total residence time of the material in the kiln according to the respective residence times of the material in the 1 st section to the m-th section.
Further, the apparatus further comprises: and the fifth calculating unit is used for calculating the mass of the materials from the 1 st section to the m-th section and obtaining the total mass of the materials in the kiln according to the mass of the materials from the 1 st section to the m-th section.
Further, the apparatus further comprises: a sixth calculating unit, configured to calculate the mass of the material in each of the 1 st section to the m th section according to the average value of the volume and the bulk density of the material in each of the 1 st section to the m th section, where the average value of the bulk density is an average value of the bulk density at two end points of the corresponding section.
Further, the apparatus further comprises: the volume flow is the ratio of the corresponding mass flow to the volume density.
Further, the apparatus further comprises: the stream fill ratio is from 0.05 to 0.2.
Further, the apparatus further comprises: a seventh calculating unit, configured to calculate lengths of material eccentric moment arms of the 1 st to m-th sections by using a material flow cross section gravity center estimation method; the included angle between the interface of the material with the ith section and the gas in the kiln and the horizontal plane is thetaiAnd the section takes the ith cross-section inner diameter circle of the rotary kiln as an arch of an arc, wherein i is a natural number of 1-n.
Example 4
Based on the same inventive concept as the method for calculating the power of the rotary kiln in the previous embodiment, the invention further provides a device for calculating the power of the rotary kiln, which comprises a memory, a processor and a computer program stored on the memory and capable of running on the processor, wherein when the program is executed by the processor, the steps of any one of the methods for calculating the power of the rotary kiln are realized.
Where in fig. 3 a bus architecture (represented by bus 300), bus 300 may include any number of interconnected buses and bridges, bus 300 linking together various circuits including one or more processors, represented by processor 302, and memory, represented by memory 304. The bus 300 may also link together various other circuits such as peripherals, voltage regulators, power management circuits, and the like, which are well known in the art, and therefore, will not be described any further herein. A bus interface 306 provides an interface between the bus 300 and the receiver 301 and transmitter 303. The receiver 301 and the transmitter 303 may be the same element, i.e., a transceiver, providing a means for communicating with various other apparatus over a transmission medium.
The processor 302 is responsible for managing the bus 300 and general processing, and the memory 304 may be used for storing information used by the processor 302 in performing operations.
One or more technical solutions in the embodiments of the present invention at least have one or more of the following technical effects:
1. according to the method and the device for calculating the power of the rotary kiln, provided by the embodiment of the invention, the structure diagram of the rotary kiln is obtained according to the structural information of the rotary kiln, and the material flow in the rotary kiln is divided into n sections according to the material flow information of the rotary kiln; respectively obtaining the mass flow and the volume density of the 1 st section to the nth section of the rotary kiln, and calculating the volume flow of the 1 st section to the nth section according to the mass flow and the volume density; determining the material flow rate of each of the 1 st section to the nth section of the rotary kiln; determining the material flow sectional area of each of the 1 st section to the nth section according to the volume flow and the material flow velocity of each of the 1 st section to the nth section of the rotary kiln; determining the material flow filling rate of each of the 1 st section to the nth section according to the material flow cross section of each of the 1 st section to the nth section and the effective radius of the rotary kiln of each section; dividing the rotary kiln into m sections according to every two adjacent sections of the n sections, determining the material volume of the material in each section from the 1 st section to the m section, and obtaining the total material volume according to the material volume of each section from the 1 st section to the m section, wherein n-m is 1; calculating the length of the eccentric moment arm of the material from the 1 st section to the m-th section; calculating the material eccentric moment and the material eccentric resultant moment of the 1 st section to the m th section, calculating the power for overcoming the material eccentric resultant moment, and calculating the friction power consumption according to the total weight of the rotary kiln rotating part and the motion information; and calculating the required power of the rotary kiln according to the power for overcoming the eccentric resultant torque of the material and the friction power consumption. The technical problems that in the prior art, the rotary kiln with the necking and the stop ring has complicated and even incountable calculation of the power and the calcining time of the rotary kiln are solved, and the technical effects that the calculation method is visual and simple and can accurately calculate the calcining time and the power of the rotary kiln are achieved.
2. The material flow filling rate of the embodiment of the invention is 0.05-0.2. The filling rate is further prevented from being too low, the heat dissipation loss of the kiln body is large, and the filling rate can be improved by reducing the rotating speed of the kiln; the filling rate is too high, the material is possibly calcined and is not thorough, and the technical effect that the filling rate can be reduced by improving the kiln speed is achieved.
While preferred embodiments of the present invention have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. Therefore, it is intended that the appended claims be interpreted as including preferred embodiments and all such alterations and modifications as fall within the scope of the invention.
It will be apparent to those skilled in the art that various modifications and variations can be made in the embodiments of the present invention without departing from the spirit or scope of the embodiments of the invention. Thus, if such modifications and variations of the embodiments of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to encompass such modifications and variations.
Claims (10)
1. A method for calculating power of a rotary kiln, the method comprising:
obtaining a structural diagram of the rotary kiln according to structural information of the rotary kiln, and dividing material flow in the rotary kiln into n sections according to the material flow information of the rotary kiln;
respectively obtaining the mass flow and the volume density of the 1 st section to the nth section of the rotary kiln, and calculating the volume flow of the 1 st section to the nth section according to the mass flow and the volume density;
determining the material flow rate of each of the 1 st section to the nth section of the rotary kiln;
determining the material flow sectional area of each of the 1 st section to the nth section according to the volume flow and the material flow velocity of each of the 1 st section to the nth section of the rotary kiln;
determining the material flow filling rate of each of the 1 st section to the nth section according to the material flow cross section of each of the 1 st section to the nth section and the effective radius of the rotary kiln of each section;
dividing the rotary kiln into m sections according to every two adjacent sections of the n sections, determining the material volume of the material in each section from the 1 st section to the m section, and obtaining the total material volume according to the material volume of each section from the 1 st section to the m section, wherein n-m is 1;
calculating the length of the eccentric moment arm of the material from the 1 st section to the m-th section;
calculating the material eccentric moment and the material eccentric resultant moment of the 1 st section to the m th section, calculating the power for overcoming the material eccentric resultant moment, and calculating the friction power consumption according to the total weight of the rotary kiln rotating part and the motion information;
and calculating the required power of the rotary kiln according to the power for overcoming the eccentric resultant torque of the material and the friction power consumption.
2. The method of claim 1, wherein before obtaining the total volume of material based on the volume of material in each of the 1 st to m-th sections, further comprising:
dividing the lengths of the 1 st section to the m th section according to the structural diagram of the rotary kiln and the material flow sections from 1 st to n th.
3. The method of claim 1, wherein after obtaining the total volume of the materials from the volume of the materials in each of the 1 st to m-th sections, further comprising:
calculating the residence time of the materials in the 1 st section to the m th section, and obtaining the total residence time of the materials in the kiln according to the residence time of the materials in the 1 st section to the m th section.
4. The method of claim 1, wherein prior to calculating the length of the material eccentric moment arm for each of the 1 st segment through the m-th segment, further comprising:
and calculating the mass of the materials from the 1 st section to the m-th section, and obtaining the total mass of the materials in the kiln according to the mass of the materials from the 1 st section to the m-th section.
5. The method of claim 4, wherein the method further comprises:
and calculating the mass of the material in each of the 1 st section to the m th section according to the average value of the volume and the volume density of the material in each of the 1 st section to the m th section, wherein the average value of the volume density is the average value of the volume density at two end points of the corresponding section.
6. The method of claim 1, wherein the volumetric flow rate is a ratio of the corresponding mass flow rate and the corresponding bulk density.
7. The method of claim 1, wherein the stream fill ratio is from 0.05 to 0.2.
8. The method of claim 1, wherein the method further comprises:
calculating the length of the eccentric force arm of the material in each of the 1 st section to the m th section by adopting a material flow section gravity center estimation mode;
the included angle between the interface of the material with the ith section and the gas in the kiln and the horizontal plane is thetaiAnd the section takes the ith cross-section inner diameter circle of the rotary kiln as an arch of an arc, wherein i is a natural number of 1-n.
9. An apparatus for calculating power of a rotary kiln, the apparatus comprising:
the first dividing unit is used for obtaining a structural diagram of the rotary kiln according to structural information of the rotary kiln and dividing a material flow in the rotary kiln into n sections according to information of the material flow in the rotary kiln;
the first obtaining unit is used for respectively obtaining the mass flow and the volume density of the 1 st section to the nth section of the rotary kiln and calculating the volume flow of the 1 st section to the nth section according to the mass flow and the volume density;
a first determination unit for determining the material flow rate of each of the 1 st section to the nth section of the rotary kiln;
a second determination unit for determining the material flow sectional area of each of the 1 st to the nth sections according to the volume flow and the material flow velocity of each of the 1 st to the nth sections of the rotary kiln;
a third determination unit for determining the material flow filling rate of each of the 1 st to nth sections from the material flow cross section of each of the 1 st to nth sections and the effective radius of the rotary kiln of each section;
a second obtaining unit, configured to divide the rotary kiln into m sections according to each two adjacent sections of the n sections, determine respective material volumes of materials in a 1 st section to the m th section, and obtain total material volumes according to the respective material volumes of the 1 st section to the m th section, where n-m is 1;
the first calculating unit is used for calculating the length of the eccentric force arm of the material from the 1 st section to the m-th section;
the second calculation unit is used for calculating material eccentric torque and material eccentric resultant torque of the 1 st section to the m-th section, calculating power for overcoming the material eccentric resultant torque, and calculating friction power consumption according to the total weight of the rotary part of the rotary kiln and motion information;
and the third calculating unit is used for calculating the required power of the rotary kiln according to the power for overcoming the eccentric resultant torque of the materials and the friction power consumption.
10. A device for calculating power of a rotary kiln, comprising a memory, a processor and a computer program stored in the memory and operable on the processor, wherein the processor executes the program to perform the steps of:
obtaining a structural diagram of the rotary kiln according to structural information of the rotary kiln, and dividing material flow in the rotary kiln into n sections according to the material flow information of the rotary kiln;
respectively obtaining the mass flow and the volume density of the 1 st section to the nth section of the rotary kiln, and calculating the volume flow of the 1 st section to the nth section according to the mass flow and the volume density;
determining the material flow rate of each of the 1 st section to the nth section of the rotary kiln;
determining the material flow sectional area of each of the 1 st section to the nth section according to the volume flow and the material flow velocity of each of the 1 st section to the nth section of the rotary kiln;
determining the material flow filling rate of each of the 1 st section to the nth section according to the material flow cross section of each of the 1 st section to the nth section and the effective radius of the rotary kiln of each section;
dividing the rotary kiln into m sections according to every two adjacent sections of the n sections, determining the material volume of the material in each section from the 1 st section to the m section, and obtaining the total material volume according to the material volume of each section from the 1 st section to the m section, wherein n-m is 1;
calculating the length of the eccentric moment arm of the material from the 1 st section to the m-th section;
calculating the material eccentric moment and the material eccentric resultant moment of the 1 st section to the m th section, calculating the power for overcoming the material eccentric resultant moment, and calculating the friction power consumption according to the total weight of the rotary kiln rotating part and the motion information;
and calculating the required power of the rotary kiln according to the power for overcoming the eccentric resultant torque of the material and the friction power consumption.
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