基于d-e-p模型的氧化铝生产过程能耗分析及节能技术研究
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摘要
随着人类社会工业化进程的加快,能源与环境问题日益成为当前全球亟待解决的问题,工业行业尤其是冶金工业能耗问题尤为突出。氧化铝工业是我国冶金工业中的重点行业,针对氧化铝生产过程展开企业能源利用状况研究,深入挖掘企业节能降耗潜力,对提高氧化铝产品国际竞争力,保持我国经济可持续发展有着重要意义。
本文在收集大量氧化铝生产过程原始数据的基础上,借用钢铁冶金行业‘e-p能耗分析法”对混联法生产氧化铝工艺过程进行能耗初步计算分析,计算结果表明蒸发工序、熟料烧成工序、焙烧工序以及管道化溶出工序是其主要能耗工序,其直接能耗与间接能耗均对企业能耗有着显著的影响。
运用(?)分析中的复杂灰箱模型建立混联法生产氧化铝工艺的(?)分析模型,对各子工序的主要耗能环节及有效利用程度进行了评价,发现熟料溶出与脱硅工序的平均(?)效率最高,达到80%以上；熟料烧成、焙烧工序的外部(?)损失较大,可回收利用空间大,具有较大的节能潜力。
在(?)分析的基础上,首次提出并建立了企业系统能耗的“d-e-p分析模型”,利用该模型对氧化铝生产过程的能耗、(?)耗以及(?)损分布进行了计算与分析,影响各工序供给(?)变化的因素主要包括两个部分：受工序能耗水平影响的直接(?)耗及受折合比变化影响的间接(?)耗；影响各工序(?)损变化的因素主要包括直接(?)损和间接(?)损两个部分。折合比对系统能耗的影响显著,有些工序虽然工序能耗与工序供给(?)降低了,但考虑折合比后,其综合能耗仍然是升高的。管道化溶出和熟料溶出及脱硅工序虽然能耗降低,但其(?)损失并没有随之降低,反而有所增加。
在d-e-p模型分析的基础上,以减少工序(?)损为目标,对石灰煅烧与熟料烧结工序进行了优化设计与技术改造,直接节能效果明显；分析了铝硅比变化对氧化铝生产能耗的影响,预测分析了当铝硅比提高到10后折合比的变化及间接节能效果。在此基础上,从宏观的角度对企业能源管理提出了建议以降低企业能耗。
从能源利用的数量以及品质两个层面对氧化铝生产过程节能技术进行全面研究,有助于全方位挖掘企业节能潜力,对工业行业的节能降耗具有重要的理论与实际意义。
As the process of industrialization of human society speeds up, energy and environmental issues are becoming more urgent to resolve for the whole world. Energy consumption of industrial sectors, especially metallurgical industry is obviously prominent. Since alumina refinery is the backbone of China's metallurgical industry, to research the energy utilization in alumina refinery process and tap the potential of energy saving for the enterprises as much as possible are of great significance to improving the products'international competitiveness and maintaining China's sustainable development in economy.
This paper presented a preliminary energy consumption analysis of an alumina refinery process with Bayer-Sinter combination method based on a large number of raw data of this process and the e-p method which has been widely used in ferrous metallurgy. The result shows that evaporation, slurry sintering, lime calcining and tube digestion are the mainly intensive-energy consumption sub processes. Their direct and indirect energy consumptions have remarkable impact on that of the enterprise.
The exergy analysis model of the Bayer-Sinter combination process was established in the form of the grey box model and subsequently the energy consumption and effective utilization degree of all sub processes were evaluated. The results show that the average exergy efficiencies of sinter digestion and desilication are the highest, which are in excess of80%. The extrinsic exergy losses in slurry sintering and lime calcining are large and can be recovered to a considerable extent. Thus the two sub processes have large energy saving potentials.
The d-e-p analysis model of an enterprise's system energy consumption was put forward and established at the first time on basis of exergy analysis theory, and then applied to calculate and analyze the energy consumption, exergy losses and their distribution in the alumina refinery process. The results indicate that there are mainly two factors influences the supply exergy of all sub processes:the direct exergy consumptions affected by the energy consumption levels of sub processes and the indirect exergy consumptions affected by alumina-process product-ratios. The factor influences the exergy losses in sub processes primarily include two items:the direct exergy losses and the indirect exergy losses. The impact of product-ratios on the comprehensive energy consumptions is significant. The energy consumptions and supply exergies of several sub processes reduced, however, the related comprehensive energy consumptions increased after taking the product-ratios into account. Although the energy consumptions of tube digestion, sinter digestion and desilication reduced, the exergy losses didn't decline accordingly but raised.
On the basis of the analysis using d-e-p model, the sub processes of lime calcining and slurry sintering were optimized and improved according to the distribution of exergy loss, which brought significant energy saving. The effect on the product ratio brought by the change of Al-Si ratio was analyzed, and the change of the product ratio and indirect energy saving were forecasted when the Al-Si ratio increased to10. Then suggestions about energy management were given in order to decrease the energy consumption.
To conduct a comprehensive study of energy saving in alumina refinery process from the quantity and quality of energy can contribute to tapping the potential of energy saving for the enterprises systematically and has important theoretical and practical significance to energy saving and consumption reducing of the alumina industry sector.
本文在收集大量氧化铝生产过程原始数据的基础上,借用钢铁冶金行业‘e-p能耗分析法”对混联法生产氧化铝工艺过程进行能耗初步计算分析,计算结果表明蒸发工序、熟料烧成工序、焙烧工序以及管道化溶出工序是其主要能耗工序,其直接能耗与间接能耗均对企业能耗有着显著的影响。
运用(?)分析中的复杂灰箱模型建立混联法生产氧化铝工艺的(?)分析模型,对各子工序的主要耗能环节及有效利用程度进行了评价,发现熟料溶出与脱硅工序的平均(?)效率最高,达到80%以上；熟料烧成、焙烧工序的外部(?)损失较大,可回收利用空间大,具有较大的节能潜力。
在(?)分析的基础上,首次提出并建立了企业系统能耗的“d-e-p分析模型”,利用该模型对氧化铝生产过程的能耗、(?)耗以及(?)损分布进行了计算与分析,影响各工序供给(?)变化的因素主要包括两个部分：受工序能耗水平影响的直接(?)耗及受折合比变化影响的间接(?)耗；影响各工序(?)损变化的因素主要包括直接(?)损和间接(?)损两个部分。折合比对系统能耗的影响显著,有些工序虽然工序能耗与工序供给(?)降低了,但考虑折合比后,其综合能耗仍然是升高的。管道化溶出和熟料溶出及脱硅工序虽然能耗降低,但其(?)损失并没有随之降低,反而有所增加。
在d-e-p模型分析的基础上,以减少工序(?)损为目标,对石灰煅烧与熟料烧结工序进行了优化设计与技术改造,直接节能效果明显；分析了铝硅比变化对氧化铝生产能耗的影响,预测分析了当铝硅比提高到10后折合比的变化及间接节能效果。在此基础上,从宏观的角度对企业能源管理提出了建议以降低企业能耗。
从能源利用的数量以及品质两个层面对氧化铝生产过程节能技术进行全面研究,有助于全方位挖掘企业节能潜力,对工业行业的节能降耗具有重要的理论与实际意义。
As the process of industrialization of human society speeds up, energy and environmental issues are becoming more urgent to resolve for the whole world. Energy consumption of industrial sectors, especially metallurgical industry is obviously prominent. Since alumina refinery is the backbone of China's metallurgical industry, to research the energy utilization in alumina refinery process and tap the potential of energy saving for the enterprises as much as possible are of great significance to improving the products'international competitiveness and maintaining China's sustainable development in economy.
This paper presented a preliminary energy consumption analysis of an alumina refinery process with Bayer-Sinter combination method based on a large number of raw data of this process and the e-p method which has been widely used in ferrous metallurgy. The result shows that evaporation, slurry sintering, lime calcining and tube digestion are the mainly intensive-energy consumption sub processes. Their direct and indirect energy consumptions have remarkable impact on that of the enterprise.
The exergy analysis model of the Bayer-Sinter combination process was established in the form of the grey box model and subsequently the energy consumption and effective utilization degree of all sub processes were evaluated. The results show that the average exergy efficiencies of sinter digestion and desilication are the highest, which are in excess of80%. The extrinsic exergy losses in slurry sintering and lime calcining are large and can be recovered to a considerable extent. Thus the two sub processes have large energy saving potentials.
The d-e-p analysis model of an enterprise's system energy consumption was put forward and established at the first time on basis of exergy analysis theory, and then applied to calculate and analyze the energy consumption, exergy losses and their distribution in the alumina refinery process. The results indicate that there are mainly two factors influences the supply exergy of all sub processes:the direct exergy consumptions affected by the energy consumption levels of sub processes and the indirect exergy consumptions affected by alumina-process product-ratios. The factor influences the exergy losses in sub processes primarily include two items:the direct exergy losses and the indirect exergy losses. The impact of product-ratios on the comprehensive energy consumptions is significant. The energy consumptions and supply exergies of several sub processes reduced, however, the related comprehensive energy consumptions increased after taking the product-ratios into account. Although the energy consumptions of tube digestion, sinter digestion and desilication reduced, the exergy losses didn't decline accordingly but raised.
On the basis of the analysis using d-e-p model, the sub processes of lime calcining and slurry sintering were optimized and improved according to the distribution of exergy loss, which brought significant energy saving. The effect on the product ratio brought by the change of Al-Si ratio was analyzed, and the change of the product ratio and indirect energy saving were forecasted when the Al-Si ratio increased to10. Then suggestions about energy management were given in order to decrease the energy consumption.
To conduct a comprehensive study of energy saving in alumina refinery process from the quantity and quality of energy can contribute to tapping the potential of energy saving for the enterprises systematically and has important theoretical and practical significance to energy saving and consumption reducing of the alumina industry sector.
引文
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