CN212357068U - System for utilize fly ash and municipal sludge preparation lightweight aggregate - Google Patents
System for utilize fly ash and municipal sludge preparation lightweight aggregate Download PDFInfo
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- CN212357068U CN212357068U CN202021662682.XU CN202021662682U CN212357068U CN 212357068 U CN212357068 U CN 212357068U CN 202021662682 U CN202021662682 U CN 202021662682U CN 212357068 U CN212357068 U CN 212357068U
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- 239000010802 sludge Substances 0.000 title claims abstract description 124
- 239000010881 fly ash Substances 0.000 title claims abstract description 65
- 238000002360 preparation method Methods 0.000 title abstract description 15
- 238000005245 sintering Methods 0.000 claims abstract description 87
- 239000000463 material Substances 0.000 claims abstract description 54
- 238000001035 drying Methods 0.000 claims abstract description 50
- 239000000203 mixture Substances 0.000 claims description 34
- 239000002918 waste heat Substances 0.000 claims description 28
- 238000002156 mixing Methods 0.000 claims description 25
- 238000011084 recovery Methods 0.000 claims description 16
- 239000000440 bentonite Substances 0.000 claims description 13
- 229910000278 bentonite Inorganic materials 0.000 claims description 13
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 claims description 13
- 239000011248 coating agent Substances 0.000 claims description 13
- 238000000576 coating method Methods 0.000 claims description 13
- 230000018044 dehydration Effects 0.000 claims description 11
- 238000006297 dehydration reaction Methods 0.000 claims description 11
- 239000007789 gas Substances 0.000 claims description 9
- 238000004140 cleaning Methods 0.000 claims description 6
- 238000001354 calcination Methods 0.000 abstract description 16
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 abstract description 9
- 229910052799 carbon Inorganic materials 0.000 abstract description 9
- 238000001816 cooling Methods 0.000 abstract description 9
- 239000002245 particle Substances 0.000 abstract description 6
- 239000004566 building material Substances 0.000 abstract description 4
- 230000007613 environmental effect Effects 0.000 abstract description 2
- 238000000034 method Methods 0.000 description 32
- 239000008188 pellet Substances 0.000 description 18
- 239000002912 waste gas Substances 0.000 description 14
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 13
- 239000000843 powder Substances 0.000 description 12
- 239000000446 fuel Substances 0.000 description 10
- 239000004568 cement Substances 0.000 description 6
- 238000005265 energy consumption Methods 0.000 description 6
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 6
- 239000010459 dolomite Substances 0.000 description 5
- 229910000514 dolomite Inorganic materials 0.000 description 5
- 235000019738 Limestone Nutrition 0.000 description 4
- 239000006028 limestone Substances 0.000 description 4
- 239000002994 raw material Substances 0.000 description 4
- 239000003345 natural gas Substances 0.000 description 3
- 238000010248 power generation Methods 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 238000002485 combustion reaction Methods 0.000 description 2
- 239000004567 concrete Substances 0.000 description 2
- 238000005034 decoration Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000007599 discharging Methods 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 238000010564 aerobic fermentation Methods 0.000 description 1
- 239000002956 ash Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000002802 bituminous coal Substances 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 238000009264 composting Methods 0.000 description 1
- 230000029087 digestion Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000003546 flue gas Substances 0.000 description 1
- 238000003837 high-temperature calcination Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000005416 organic matter Substances 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 238000000197 pyrolysis Methods 0.000 description 1
- 239000010865 sewage Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 230000007306 turnover Effects 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
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- Processing Of Solid Wastes (AREA)
- Treatment Of Sludge (AREA)
Abstract
The utility model belongs to the environmental protection field especially relates to a system for utilize fly ash and municipal sludge preparation lightweight aggregate. The utility model provides a system includes: a material mixer, a rotary sintering furnace, a green ball drying furnace, a rotary furnace and a cooler. The utility model discloses in, fly ash and municipal sludge through mix in the system, sintering, drying, calcination and cooling, finally obtained the globular lightweight aggregate of porous that can be used to the building materials field, realized fly ash and municipal sludge's resourceful treatment. Furthermore, the utility model provides a rotation type fritting furnace, green ball drying furnace and rotary furnace in the system all are the operation under certain high temperature condition, can effectively burn the carbon particle that contains in fly ash and the mud, reduce goods carbon content, consequently this system does not have strict requirement to the loss on ignition of the fly ash of handling and municipal sludge, can be used to handle the fly ash and the municipal sludge of any loss on ignition parameter, and application scope is wider.
Description
Technical Field
The utility model belongs to the environmental protection field especially relates to a system for utilize fly ash and municipal sludge preparation lightweight aggregate.
Background
The fly ash is tiny ash particles discharged in the coal burning process (particularly the burning of bituminous coal), the particle size of the fly ash is generally 1-100 mu m, and the fly ash belongs to dangerous waste. If a large amount of fly ash is not controlled or treated, the fly ash can be discharged into the air to cause atmospheric pollution, and enters water to block river channels, wherein certain chemical substances in the fly ash seriously affect human bodies and natural ecology. Coal-fired power plants generate a large amount of fly ash every year, and how to treat the fly ash in an economical and environment-friendly manner becomes a serious problem.
Municipal sludge is a semi-solid or solid precipitated substance produced in the sewage treatment process, and the water content of the municipal sludge is up to more than 99%. According to different sludge treatment modes, the sludge treatment method can be divided into primary sludge, activated sludge, humic sludge and the like. The greatest common denominator for all sludges is the high content of organic matter. At present, the main modes of sludge treatment are dehydration and incineration, anaerobic digestion or high-temperature aerobic fermentation, composting, land landfill, ocean dumping and the like. Either of which has a certain impact on the environment. Like fly ash, how to treat sludge in an economical and environmentally friendly manner has become a serious problem.
SUMMERY OF THE UTILITY MODEL
In view of this, the utility model aims at providing an utilize system of fly ash and municipal sludge preparation lightweight aggregate, the utility model provides a system can prepare into porous lightweight aggregate with fly ash and municipal sludge, realizes fly ash and municipal sludge's resourceful treatment.
The utility model provides a system for utilize fly ash and municipal sludge preparation lightweight aggregate, include:
the material mixer is provided with a dehydrated sludge inlet, a fly ash inlet and a mixture outlet;
the rotary sintering furnace is connected with the mixture outlet;
the green ball drying furnace is connected with a green ball outlet of the rotary sintering furnace;
the rotary furnace is connected with a discharge hole of the green ball drying furnace;
and the cooler is connected with the discharge hole of the rotary furnace.
Preferably, the rotary sintering furnace comprises a first rotary sintering furnace and a second rotary sintering furnace, and the second rotary sintering furnace is provided with a coating material feeding port;
the feed inlet of the first rotary sintering furnace is connected with the mixture outlet, the green ball outlet of the first rotary sintering furnace is connected with the feed inlet of the second rotary sintering furnace, and the green ball outlet of the second rotary sintering furnace is connected with the green ball drying furnace.
Preferably, the material mixing machine is also provided with a bentonite feeding port.
Preferably, the system also comprises sludge dewatering equipment, wherein an urban sludge inlet and a dewatered sludge outlet are formed in the sludge dewatering equipment;
the dehydrated sludge discharge port is connected with the dehydrated sludge inlet of the material mixing machine.
Preferably, the system also comprises a sludge crushing device arranged between the sludge dewatering device and the material mixer;
the feed inlet of the sludge crushing equipment is connected with the dehydrated sludge discharge port of the sludge dehydration equipment, and the discharge port of the sludge crushing equipment is connected with the dehydrated sludge inlet of the material mixing machine.
Preferably, the system further comprises a waste heat recovery system for recovering the waste heat discharged by the rotary kiln and the cooler.
Preferably, the system further comprises an exhaust gas cleaning treatment device for purifying the exhaust gas discharged by the waste heat recovery system.
Compared with the prior art, the utility model provides a system for utilize fly ash and municipal sludge preparation lightweight aggregate. The utility model provides a system includes: the material mixer is provided with a dehydrated sludge inlet, a fly ash inlet and a mixture outlet; the rotary sintering furnace is connected with the mixture outlet; the green ball drying furnace is connected with a green ball outlet of the rotary sintering furnace; the rotary furnace is connected with a discharge hole of the green ball drying furnace; and the cooler is connected with the discharge hole of the rotary furnace. The utility model discloses in, fly ash and municipal sludge through mix in the system, sintering, drying, calcination and cooling, finally obtained the globular lightweight aggregate of porous that can be used to the building materials field, realized fly ash and municipal sludge's resourceful treatment. Furthermore, the utility model provides a rotation type fritting furnace, green ball drying furnace and rotary furnace in the system all are the operation under certain high temperature condition, can effectively burn the carbon particle that contains in fly ash and the mud, reduce goods carbon content, consequently this system does not have strict requirement to the loss on ignition of the fly ash of handling and municipal sludge, can be used to handle the fly ash and the municipal sludge of any loss on ignition parameter, and application scope is wider. Furthermore, in the preferred scheme of the utility model, the system still is provided with waste heat recovery system to can realize retrieving the used heat that produces among the system rotary furnace and the cooler operation process, reduce entire system's operation energy consumption.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required to be used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the provided drawings without creative efforts.
FIG. 1 is a schematic view of a process flow of a lightweight aggregate preparation system according to an embodiment of the present invention;
fig. 2 is a schematic process flow diagram of a lightweight aggregate preparation system provided in embodiment 1 of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments in the present invention, all other embodiments obtained by a person skilled in the art without creative work belong to the protection scope of the present invention.
The utility model provides a system for utilize fly ash and municipal sludge preparation lightweight aggregate, include:
the material mixer is provided with a dehydrated sludge inlet, a fly ash inlet and a mixture outlet;
the rotary sintering furnace is connected with the mixture outlet;
the green ball drying furnace is connected with a green ball outlet of the rotary sintering furnace;
the rotary furnace is connected with a discharge hole of the green ball drying furnace;
and the cooler is connected with the discharge hole of the rotary furnace.
Referring to fig. 1, fig. 1 is a schematic process flow diagram of a lightweight aggregate preparation system provided by an embodiment of the present invention.
The system provided by the utility model comprises a material mixing machine, a rotary sintering furnace, a green ball drying furnace, a rotary furnace and a cooler. The material mixing machine is a mixing device of fly ash and dehydrated municipal sludge, and is provided with a dehydrated sludge inlet, a fly ash inlet and a mixture outlet. The utility model provides an embodiment, the material mixes the machine and still is provided with the bentonite charge door, the bentonite accessible the bentonite charge door adds in the material mixes the machine to increase the cohesiveness of mixture, help the formation of follow-up sintering in-process bobble. The utility model provides an embodiment, the material mixes the machine and still is provided with the filler, and water accessible the filler adds in the material mixes the machine to the moisture content of condition mixture.
The utility model provides an in the system, the rotation type fritting furnace is used for carrying out the rotary sintering to the mixture of fly ash and municipal sludge and forms green ball, is provided with feed inlet and green ball export on it, the feed inlet of rotation type fritting furnace with the mixture export that the material mixes the machine links to each other. The utility model provides an embodiment, the furnace body of rotation type fritting furnace is 45 ~ 50 with the contained angle of horizontal plane, specifically can be 45 °, 46 °, 47 °, 48 °, 49 ° or 50 °. In one embodiment provided by the utility model, the rotary sintering furnace comprises a first rotary sintering furnace and a second rotary sintering furnace, wherein the first rotary sintering furnace is used for rotary sintering the mixture of the fly ash and the municipal sludge to form green pellets, and a feed inlet and a green pellet outlet are arranged on the first rotary sintering furnace; the second rotary sintering furnace is used for sintering the green pellets again and coating the coating material, and is provided with a feed inlet, a coating material feed inlet and a green pellet outlet; the feed inlet of the first rotary sintering furnace is connected with the mixture outlet, the green ball outlet of the first rotary sintering furnace is connected with the feed inlet of the second rotary sintering furnace, and the green ball outlet of the second rotary sintering furnace is connected with the green ball drying furnace. The utility model discloses in, can effectively avoid appearing the condition of green ball adhesion in follow-up rotary furnace calcination process through wrapping up in raw ball surface and covering coating material.
The utility model provides an in the system, the green ball drying furnace is used for carrying out the drying to the green ball of fritting furnace preparation to further reduce the water content of green ball, be provided with feed inlet and discharge gate on it, the feed inlet of green ball drying furnace with the green ball export of rotation type fritting furnace links to each other.
The utility model provides an in the system, the rotary kiln is used for carrying out the high temperature calcination to the green ball after the drying, is provided with feed inlet, fuel inlet, air intlet, discharge gate and exhaust outlet on it, the feed inlet of rotary kiln with the discharge gate of green ball drying furnace links to each other. In one embodiment of the present invention, the included angle between the furnace body and the horizontal plane of the rotary furnace is 15-30 °, specifically 15 °, 17.5 °, 20 °, 22.5 °, 25 °, 27.5 ° or 30 °. When the rotary furnace is in operation, the dried green pellets are mixed with fuel and air and calcined in the rotary furnace, the green pellets are pyrolyzed and solidified in the high-temperature environment in the rotary furnace, a large amount of gas is generated, and the gas penetrates through the surfaces of the pellets to form holes, so that the hard and low-density porous spherical material, namely the lightweight aggregate, is finally obtained. The utility model discloses in, the business turn over direction of green ball, fuel and air after the drying is preferred to keep unanimous in the rotary furnace to enough greatly increased combustion efficiency, the spheroidal carbon content of furthest's elimination.
The utility model provides an in the system, the cooler is used for cooling the lightweight aggregate of preparation to the rotary kiln calcination, is provided with feed inlet and discharge gate on it, the feed inlet of cooler with the discharge gate of rotary kiln links to each other. In one embodiment of the present invention, the cooler is a water cooler or an air cooler.
In one embodiment of the present invention, the system further comprises a sludge dewatering device, on which an urban sludge inlet and a dewatered sludge outlet are disposed, the dewatered sludge outlet is connected to the dewatered sludge inlet of the material mixing machine. The utility model discloses in, sludge dewatering equipment is used for tentatively dehydrating municipal sludge to reduce municipal sludge's moisture content, make the water content of the mixture of municipal sludge and fly ash after the follow-up dehydration satisfy the sintering requirement. In one embodiment, the sludge dewatering device may specifically select a filter press or a dryer according to the water content level of the municipal sludge.
In an embodiment of the utility model, the system still includes the sludge crushing equipment, the sludge crushing equipment sets up the sludge dewatering equipment with between the material mixing machine, its feed inlet with the dehydration mud discharge gate of sludge dewatering equipment links to each other, the discharge gate with the dehydration mud entry that the material mixed the machine links to each other. The utility model discloses in, mud crushing equipment is used for carrying out the breakage to the mud after the dehydration, gets rid of the great caking that forms in dehydration process, reduces cubic volume to do benefit to its follow-up intensive mixing with fly ash.
In an embodiment of the present invention, the system further includes a waste heat recovery system, the waste heat recovery system is used for recovering the waste heat discharged from the rotary kiln and the cooler (the rotary kiln can generate high temperature waste gas during operation, and the cooler can generate hot gas or hot water according to the difference of the cooling modes), so as to recycle the waste heat energy, for example, the recovered heat energy is used as the heat source of the green ball drying furnace, the sludge dewatering equipment, or the waste heat power generation is performed.
The utility model provides an embodiment, the system still includes the clean treatment facility of waste gas, the clean treatment facility of waste gas is used for right the outer row of waste heat recovery system waste gas purifies to realize the emission to reach standard of waste gas.
The utility model provides an in the system, fly ash and municipal sludge through mix in the system, sintering, drying, calcination and cooling, finally obtained the porous globular lightweight aggregate that can be used to the building materials field, realized fly ash and municipal sludge's resourceful treatment. Furthermore, the utility model provides a rotation type fritting furnace, green ball drying furnace and rotary furnace in the system all are the operation under certain high temperature condition, can effectively burn the carbon particle that contains in fly ash and the mud, reduce goods carbon content, consequently this system does not have strict requirement to the loss on ignition of the fly ash of handling and municipal sludge, can be used to handle the fly ash and the municipal sludge of any loss on ignition parameter, and application scope is wider. Furthermore, in the preferred scheme of the utility model, through set up waste heat recovery system at the system, can realize retrieving the waste heat that produces among the system rotary furnace and the cooler operation process, reduce entire system's operation energy consumption.
The utility model also provides a method for preparing lightweight aggregate by utilizing fly ash and municipal sludge, which comprises the following steps:
a) mixing the dewatered municipal sludge and the fly ash in a material mixer to obtain a mixture;
b) sintering the mixture in a rotary sintering furnace to obtain green balls;
c) drying the green pellets in a green pellet drying furnace to obtain dried pellets;
d) and calcining the dried balls in a rotary furnace, and then cooling the calcined balls in a cooler to obtain the lightweight aggregate.
In the method provided by the utility model, firstly, the dewatered municipal sludge and the fly ash are mixed in a material mixer. The dewatered municipal sludge is preferably obtained by dewatering and crushing municipal sludge, the equipment used for dewatering is preferably the sludge dewatering equipment introduced above, and the equipment used for crushing is preferably the sludge crushing equipment introduced above, which is not described again. In the utility model discloses, the dry weight ratio of dehydration municipal sludge and fly ash is preferably (5 ~ 35): (65-95), specifically 35: 65; the material mixing machine is already described above and is not described in detail herein; in the mixing process, bentonite is preferably added to improve the subsequent sintering effect, and the addition amount of the bentonite is preferably not more than 20 wt%, more preferably 2-10 wt%, and specifically may be 2 wt%, 3 wt%, 4 wt%, 5 wt%, 6 wt%, 7 wt%, 8 wt%, 9 wt% or 10 wt% of the total dry weight of the dewatered municipal sludge and the fly ash. In one embodiment of the present invention, the total weight of the dry weight of the dewatered municipal sludge, the dry weight of the fly ash and the bentonite is 100 parts by weight, and the dry weight of the dewatered municipal sludge is 20 to 50 parts by weight, specifically 20 parts by weight, 33.6 parts by weight, 33.95 parts by weight, 34.5 parts by weight, 48 parts by weight or 48.5 parts by weight; 45-80 parts by weight of dry-weight fly ash, specifically 48 parts by weight, 48.5 parts by weight, 62.4 parts by weight, 63.05 parts by weight, 63.5 parts by weight or 77 parts by weight; the bentonite accounts for 2-5 parts by weight, and specifically can be 2 parts by weight, 3 parts by weight or 4 parts by weight. The utility model discloses in, after the material misce bene, obtain the mixture, the moisture content of mixture is preferably 5 ~ 25%, is favorable to intensive mixing and follow-up sintering, specifically can be 5%, 10%, 15%, 20% or 25%.
The utility model provides an in the method, after obtaining the mixture, will the mixture sinters in the rotation type sintering furnace, and its concrete process is preferred to include:
b1) sintering the mixture in a first rotary sintering furnace to obtain green balls to be coated;
b2) and mixing the green ball to be coated with the coating material in a second rotary sintering furnace and sintering to obtain the coated green ball.
In the above sintering process provided by the present invention, in step b1), the first rotary sintering furnace is described above and will not be described herein again; the sintering temperature is preferably 600-1100 ℃, and specifically can be 600 ℃, 650 ℃, 700 ℃, 750 ℃, 800 ℃, 850 ℃, 900 ℃, 950 ℃, 1000 ℃, 1050 ℃ or 1100 ℃; the sintering time is preferably 1.5-3 h, and specifically can be 1.5h, 2h, 2.5h or 3 h; the operating rotating speed of the first rotary sintering furnace in the sintering process is preferably 15-20 rpm, and specifically can be 15rpm, 16rpm, 17rpm, 18rpm, 19rpm or 20 rpm; the diameter of the green ball to be coated is preferably 1/8 inches to 3/4 inches, and specifically 1/8 inches, 1/4 inches, 3/8 inches, 1/2 inches, 5/8 inches or 3/4 inches.
In the above sintering process provided by the present invention, in step b2), the coating material includes, but is not limited to, one or more of dolomite powder, limestone powder and cement powder, preferably dolomite powder, limestone powder and cement powder, and the mass ratio of dolomite powder, limestone powder and cement powder is preferably 3:3: 4; the dry weight ratio of the coating material to the green ball to be coated is preferably (16.6-23): 100, specifically 17:100, 17.5:100, 18:100, 18.5:100, 19:100, 19.5:100, 20:100, 20.5:100, 21:100, 21.5:100, 22:100, 22.5:100 or 23: 100; the second rotary sintering furnace is already described above and is not described in detail herein; the sintering temperature is preferably 600-1100 ℃, and specifically can be 600 ℃, 650 ℃, 700 ℃, 750 ℃, 800 ℃, 850 ℃, 900 ℃, 950 ℃, 1000 ℃, 1050 ℃ or 1100 ℃; the sintering time is preferably 0.5-2 h, and specifically can be 0.5h, 1h, 1.5h or 2 h; the operating rotating speed of the second rotary sintering furnace in the sintering process is preferably 15-20 rpm, and specifically can be 15rpm, 16rpm, 17rpm, 18rpm, 19rpm or 20 rpm.
In the method provided by the utility model, after the green pellets are obtained, the green pellets are dried in the green pellet drying furnace. Wherein, the green ball drying furnace is already introduced above and is not described herein again; the drying temperature is preferably 150-200 ℃, and specifically can be 150 ℃, 155 ℃, 160 ℃, 165 ℃, 170 ℃, 175 ℃, 180 ℃, 185 ℃, 190 ℃, 195 ℃ or 200 ℃; the drying time is preferably 15-60 min, and specifically can be 15min, 30min, 45min or 60 min. And after drying is finished, obtaining a dried ball, wherein the water content of the dried ball is preferably less than or equal to 5%.
In the method provided by the utility model, after the drying balls are obtained, the drying balls are calcined in the rotary furnace. Wherein, the rotary furnace is already introduced above and is not described again; the calcination temperature is preferably 800-1200 ℃, and specifically can be 800 ℃, 850 ℃, 900 ℃, 950 ℃, 1000 ℃, 1050 ℃, 1100 ℃, 1150 ℃ or 1200 ℃; more specifically, the temperature of the feed inlet of the rotary furnace is preferably 820-980 ℃, specifically 823 ℃, 840 ℃, 854 ℃, 858 ℃, 880 ℃, 952 ℃, 976 ℃ or 979 ℃, and the temperature of the central region of the rotary furnace is preferably 950-1050 ℃, specifically 956 ℃, 967 ℃, 977 ℃, 982 ℃, 995 ℃, 1007 ℃, 1024 ℃ or 1034 ℃; the calcination time is preferably 30-60 min, and specifically can be 30min, 35min, 40min, 45min, 50min, 55min or 60 min; the operating rotating speed of the rotary furnace in the calcining process is preferably 2-3.9 rpm, and specifically can be 2rpm, 2.25rpm, 2.5rpm, 2.75rpm, 3rpm, 3.25rpm, 3.5rpm or 3.75 rpm. During the calcination process, the dried spheres are mixed with fuel and air in a rotary furnace for calcination, pyrolysis and solidification occur, and a large amount of gas is generated, and the gas penetrates through the surfaces of the spheres to form holes. After the calcination, send the calcination product into the cooler and cool, the cooler has been introduced above, and no longer gives details here, and after the cooling, the porous spherical material goods that obtain are the utility model discloses the lightweight aggregate of preparation.
In the method provided by the utility model, preferably, the waste heat recovery system is also used for recovering the waste heat discharged from the rotary furnace and the cooler, and the recovered heat energy is used as the heat source of the green ball drying furnace and the sludge dewatering equipment.
The method provided by the utility model finally obtains the porous spherical lightweight aggregate which can be used in the field of building materials by mixing, sintering, drying, calcining and cooling the fly ash and the municipal sludge, and realizes the resource treatment of the fly ash and the municipal sludge. Moreover, because sintering, drying and calcination are all gone on under certain high temperature condition, consequently can effectively burn the carbon particle that contains in fly ash and the mud, reduce goods carbon content, so the utility model provides a method does not have strict requirement to the loss on ignition of fly ash and the municipal sludge who handles, can be used to handle the fly ash and the municipal sludge of any loss on ignition parameter, and application scope is wider. Furthermore, in the preferred embodiment of the present invention, the waste heat generated during the operation of the rotary kiln and the cooler is recovered by using the waste heat recovery system, thereby reducing the energy consumption of the whole production process.
For the sake of clarity, the following examples are given in detail.
Example 1
A lightweight aggregate preparation system as shown in fig. 2, comprising: the device comprises sludge dewatering equipment, sludge crushing equipment, a material mixing machine, a first rotary sintering furnace, a second rotary sintering furnace, a green ball drying furnace, a rotary furnace, a cooler, a waste heat recovery system and waste gas cleaning and processing equipment.
The sludge dewatering equipment is provided with an urban sludge inlet and a dewatered sludge outlet, and specifically can select a filter press or a dryer according to the water content level of the urban sludge;
the sludge crushing equipment is provided with a feed inlet and a discharge outlet, and the feed inlet of the sludge crushing equipment is connected with the dehydrated sludge discharge outlet of the sludge dehydration equipment;
the material mixing machine is provided with a dehydrated sludge inlet, a fly ash inlet, a bentonite feeding port and a mixture outlet, and the dehydrated sludge inlet arranged on the material mixing machine is connected with a discharge port of the sludge crushing equipment;
the first rotary sintering furnace is provided with a feed inlet and a green ball outlet, the feed inlet of the first rotary sintering furnace is connected with the mixture outlet of the material mixer, the diameter of a furnace body of the first rotary sintering furnace is 100cm, the depth of the furnace body is 16.5mm, and the included angle between the gradient of the furnace body and the horizontal plane is 45 degrees;
the second rotary sintering furnace is provided with a feed inlet, a coating material feed inlet and a green ball outlet, the feed inlet of the second rotary sintering furnace is connected with the green ball outlet of the first rotary sintering furnace, the diameter of a furnace body of the second rotary sintering furnace is 100cm, the depth of the furnace body is 16.5mm, and the included angle between the gradient of the furnace body and the horizontal plane is 45 degrees;
the green ball drying furnace is provided with a feed inlet and a discharge outlet, and the feed inlet of the green ball drying furnace is connected with the green ball outlet of the second rotary sintering furnace;
the rotary furnace is provided with a feed inlet, a fuel inlet, an air inlet, a discharge port and a waste gas outlet, and the feed inlet of the rotary furnace is connected with the discharge port of the green ball drying furnace; the feed inlet, the fuel inlet and the air inlet of the rotary furnace are positioned at the same end of the rotary furnace body, and the discharge outlet and the waste gas outlet are positioned at the other end opposite to the feed inlet and the waste gas outlet, so that the inlet and outlet directions of the dried green pellets, the fuel and the air in the rotary furnace are kept consistent; the diameter of the furnace body of the rotary furnace is 65cm, the depth of the furnace body is 4m, and the included angle between the inclination of the furnace body and the horizontal plane is 22.5 degrees;
the cooler is provided with a feeding hole and a discharging hole, and the feeding hole of the cooler is connected with the discharging hole of the rotary furnace; the diameter of the cooler was 38cm and the depth was 3.6 m.
The waste heat recovery system is used for recovering the discharged waste heat of the rotary furnace and the cooler, and then the recovered heat energy is used as a heat source of the green ball drying furnace and the sludge dewatering equipment, and waste heat power generation is carried out;
the waste gas cleaning treatment equipment is used for purifying the discharged waste gas of the waste heat recovery system, so that the waste gas is discharged after reaching the standard.
Example 2
A method for preparing lightweight aggregate by using fly ash and municipal sludge is carried out in the system described in example 1, and the specific technological process is as follows:
dehydrating the municipal sludge in sludge dehydration equipment, and then crushing the dehydrated sludge in sludge crushing equipment to obtain a crushed dehydrated sludge material;
mixing the dewatered sludge crushed material and fly ash in a material mixer, adding a certain amount of bentonite (PCaS-3-5, Nanyang macrotrichite bentonite) in the mixing process, and uniformly mixing the materials to obtain a mixture with the water content of 7-14%;
sintering the mixture in a first rotary sintering furnace to obtain green balls to be coated;
mixing the green ball to be coated with the coating material in a second rotary sintering furnace and sintering to obtain a coated green ball;
drying the green pellets in a green pellet drying furnace to obtain dried pellets;
mixing and calcining the dried balls with air and natural gas in a rotary furnace, and then cooling the mixture in a cooler to obtain a porous spherical material, namely the lightweight aggregate;
in the process of preparing the lightweight aggregate, the waste heat recovery system recovers the waste heat discharged by the rotary furnace and the cooler, and the recovered heat energy is used as the heat source of the green ball drying furnace and the sludge dewatering equipment to carry out waste heat power generation; and the discharged waste gas in the waste heat recovery system is sent into waste gas cleaning treatment equipment for treatment to obtain flue gas meeting the discharge requirement, and finally discharged into the atmospheric environment through a chimney.
In this embodiment, a series of porous spherical material products with different index parameters can be obtained by adjusting the proportions of the fly ash, the sludge and the bentonite and the amount of the coating material; the coating material is a mixture of dolomite powder (CAS: 7000-29-5, Shanghai Aoke chemical Co., Ltd.), limestone powder (PS540, Dongrun chemical industry) and cement (42.5/42.5R, Xinta cement), and the mass ratio of the dolomite powder to the cement is 3:3: 4; the specific dosage proportion and the loss on ignition of the fly ash of the raw materials are shown in table 1:
TABLE 1 raw material consumption ratio and fly ash loss on ignition
In the embodiment, the rotating speed of the first rotary sintering furnace is 15-20 rpm, the sintering temperature is 900-1100 ℃, the sintering time is 1.5-2.5 h, and the diameter of the obtained green pellets is 2/8-1/2 inches; the rotating speed of the second rotary sintering furnace is 15-20 rpm, the sintering temperature is 800-1000 ℃, and the sintering time is 1 h.
In the embodiment, the drying temperature of the green ball drying furnace is 150-200 ℃, the drying time is 20-40 min, and the water content of the dried balls is less than 5%.
In the embodiment, the processing time of the drying balls in the rotary furnace is 30-60 min; corresponding to the numbers in Table 1, the operating parameters of the rotary kiln under different raw material consumption ratio conditions are shown in Table 2:
TABLE 2 Rotary kiln operating parameter table
The series of porous spherical material products (lightweight aggregates) prepared in this example were tested for wet compressive strength, dry compressive strength, bulk density, water content, dry ball loss on ignition, bulk density and packing density according to ASTM C31-2002 Standard for lightweight aggregates for concrete masonry, and the results of testing the products prepared according to the numbers in Table 1 and the ratio of the amounts of the raw materials are shown in Table 3:
TABLE 3 examination results of porous spherical material products
The heat energy consumption of this example in the course of preparing lightweight aggregate was evaluated, and the heat energy consumption of the rotary kiln was compared between the case of adding sludge and the case of not adding sludge, as shown in table 4:
TABLE 4 Heat energy consumption of rotary kiln under different process conditions
As can be seen from the data in table 4, the same unit of product is produced per hour, and the natural gas fuel required for the fly ash and sludge blend feedstock is 85% less than the natural gas fuel required for 100% fly ash feedstock. It can be seen that the addition of sludge greatly increases the combustion value of the material in the rotary kiln, while also significantly reducing the use of external fuel.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, a plurality of modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.
Claims (7)
1. A system for preparing lightweight aggregate by utilizing fly ash and municipal sludge is characterized by comprising the following components:
the material mixer is provided with a dehydrated sludge inlet, a fly ash inlet and a mixture outlet;
the rotary sintering furnace is connected with the mixture outlet;
the green ball drying furnace is connected with a green ball outlet of the rotary sintering furnace;
the rotary furnace is connected with a discharge hole of the green ball drying furnace;
and the cooler is connected with the discharge hole of the rotary furnace.
2. The system according to claim 1, wherein the rotary sintering furnace comprises a first rotary sintering furnace and a second rotary sintering furnace, the second rotary sintering furnace being provided with a coating material feed port;
the feed inlet of the first rotary sintering furnace is connected with the mixture outlet, the green ball outlet of the first rotary sintering furnace is connected with the feed inlet of the second rotary sintering furnace, and the green ball outlet of the second rotary sintering furnace is connected with the green ball drying furnace.
3. The system of claim 1, wherein the material mixer is further provided with a bentonite feed port.
4. The system of claim 1, further comprising a sludge dewatering device having a municipal sludge inlet and a dewatered sludge outlet;
the dehydrated sludge discharge port is connected with the dehydrated sludge inlet of the material mixing machine.
5. The system of claim 4, further comprising a sludge disruption device disposed between the sludge dewatering device and the material mixer;
the feed inlet of the sludge crushing equipment is connected with the dehydrated sludge discharge port of the sludge dehydration equipment, and the discharge port of the sludge crushing equipment is connected with the dehydrated sludge inlet of the material mixing machine.
6. The system of claim 1, further comprising a waste heat recovery system for recovering waste heat discharged from the rotary kiln and cooler.
7. The system of claim 6, further comprising an exhaust gas cleaning treatment device for cleaning exhaust gas discharged from the waste heat recovery system.
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