白水泥生料烧成特性及其在预分解窑中的应用研究
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摘要
面对国内对高品质白水泥需求的不断增加与国内白水泥行业整体工艺技术水平落后这一矛盾,白水泥行业急需进行白水泥工艺技术的革新,将预分解窑工艺应用于白水泥生产是解决这一矛盾的关键。本文通过实验室研究和白水泥预分解窑生产线设计的结合,探讨预分解窑应用于白水泥熟料生产的适应性及工程设计优化。
通过易烧性实验和综合热分析对白水泥烧成工艺性能进行研究,研究结果处表明：①KH和SM的增加均会使白水泥生料的易烧性变差,白水泥预分解窑的KH可以控制在0.92以上,SM可以控制在5或者更高。②白水泥生料与普通水泥生料的预分解特性基本一致,二者的预分解阶段都可以分为水分的蒸发和碳酸盐的分解两个阶段,白水泥生料的分解热耗为1269kJ/kg.cl,热耗为1382kJ/kg.cl,白水泥生料和普通水泥生料中的碳酸钙分解均符合相边界反应收缩圆柱体反应机理,白水泥生料中的碳酸钙的分解活化能为219kJ/mol,普通水泥生料中的碳酸钙分解活化能为233kJ/mol。二者预分解特性基本一致,为使用预分解窑工艺生产白水泥熟料提供了理论依据。
根据成熟的普通水泥新型干法预分解窑工艺设计参数,针对白水泥预分解窑的特性,得出了HBJY白水泥预分解窑的一些优化设计措施：①直接通过窑尾热交换器预热空气作为二次风、三次风风源。②强化系统的密封,减少系统漏风,采用防积料设计,在易结皮、堵塞的部位选用抗结皮耐火材料,减少结皮、堵塞的发生几率。③增加耐火材料厚度,减少系统散热损失。
通过对HBJY白水泥预分解窑生产线试生产状况的分析,HBJY白水泥预分解窑生产线应从如下方面进行优化：①严格控制进厂原材料质量,尽量降低原料中的Fe203含量,探讨在结皮和改善易烧性二者之间平衡的碱含量范围。②强化煤质控制,除基本指标满足生产之外,煤粉的含水量控制1%以下,煤粉细度控制在4%(80μm筛余)以下,保证煤粉在分解炉内能够完全燃烧。③在稳定窑系统的前提下,慎重研究在该系统使用萤石作为矿化剂的可能性以及合适的使用量,避免使用不当造成大规模结皮、堵塞导致停窑。
正式生产后,HBJY预分解窑白水泥熟料生产线实际产量在380t/d以上,熟料烧成热耗约为5442kJ/kg.cl(1301kcal/kg.cl),白水泥熟料的白度在85度左右,都达到了设计指标。
Facing the contradiction which the domestic white cement industry technology isn't satisfied with the increasing domestic needs for high-quality white cement, the domestic white cement industry need the technology innovation urgently, it is the key for resolving the contradiction to apply the predecomposition kiln in white cement production. The adaptability and design optimization of white cement predecomposition kiln was explored by combining laboratory research and the white cement predecomposition kiln production line design in this paper.
The burnability of white cement raw material was studied by the burnability test and the comprehensive thermal analysis, the results showed that:①The increasing of KH and SM will make the white cement raw material burnability worse, the KH of white cement predecomposition kiln could be controlled over0.92, the SM of white cement predecomposition kiln could be controlled at5or higher.②The predecomposition characteristics of white cement raw material and ordinary cement raw material are basically identical, the predecomposition of them is divided into to two stages,which are water evaporation and carbonate decomposition, the white cement raw material decomposition heat consumption is1269kJ/kg.cl, the ordinary cement raw material decomposition heat consumption is1382kJ/kg.cl, the decomposition of CaCO3in the white cement raw material and the ordinary cement raw material is in according with the shrinking cylinder mechanism with surface reaction rate controlling, the activation energy of CaCO3in the white cement raw material is219kJ/mol, the activation energy of CaCO3in the ordinary cement raw material is233kJ/mol, thus, the predecomposition characteristics of them are basically identical, which is theoretical basis for applying the predecomposition kiln in white cement production.
According the mature design parameters of the ordinary cement predecomposition kiln, aiming at the features of white cement predecomposition kiln, this paper came to some optimal design measures as follows:①The white cement predecomposition kiln could get secondary air and tertiary air by adding the heat exchanger behind the kiln tail.②Through strengthening the sealing of the kiln system to reduce system air leakage, taking anti-material accumulation design, using anti-crust refractory at some parts which blocke and crust easily, the probability of block and crust will be reduced.③The white cement predecomposition kiln could reduce system heat loss by increasing the refractory thickness.
According the analysis of HBJY white cement predecomposition kiln trial production, the HBJY white cement predecomposition kiln production line should optimize it by three aspects as follows:①The raw material quality must be controlled strictly, it is the key to reduce the Fe2O3content of raw for white cement raw material quality, on the other hand, the appropriate alkali content of raw material which can reduce the probability of block and crust, improve the burnability of white cement raw material should be explored.②The coal quality control should be enhanced, except the basic indicators to meet the production, the internal water content of coal must be controlled under1%, the coal fineness must be controlled under4%(80μm sieve residue), the coal complete combustion in the calciner should be ensured.③Based on the premise which the white cement predecomposition kiln can produce stably, the possibility of using fluorite in the white cement predecomposition kiln and the appropriate added fluorite content should be studied cautiously to avoid the block and crust accident.
The actual output of HBJY predecomposition kiln white cement clinker production line is more than380t/d, the heat consumption of white cement clinker is about5442kJ/kg.cl (1301kcal/kg.cl), the whiteness of white cement clinker is about85degree, HBJY predecomposition kiln white cement clinker production line has achieved all design targets.
通过易烧性实验和综合热分析对白水泥烧成工艺性能进行研究,研究结果处表明：①KH和SM的增加均会使白水泥生料的易烧性变差,白水泥预分解窑的KH可以控制在0.92以上,SM可以控制在5或者更高。②白水泥生料与普通水泥生料的预分解特性基本一致,二者的预分解阶段都可以分为水分的蒸发和碳酸盐的分解两个阶段,白水泥生料的分解热耗为1269kJ/kg.cl,热耗为1382kJ/kg.cl,白水泥生料和普通水泥生料中的碳酸钙分解均符合相边界反应收缩圆柱体反应机理,白水泥生料中的碳酸钙的分解活化能为219kJ/mol,普通水泥生料中的碳酸钙分解活化能为233kJ/mol。二者预分解特性基本一致,为使用预分解窑工艺生产白水泥熟料提供了理论依据。
根据成熟的普通水泥新型干法预分解窑工艺设计参数,针对白水泥预分解窑的特性,得出了HBJY白水泥预分解窑的一些优化设计措施：①直接通过窑尾热交换器预热空气作为二次风、三次风风源。②强化系统的密封,减少系统漏风,采用防积料设计,在易结皮、堵塞的部位选用抗结皮耐火材料,减少结皮、堵塞的发生几率。③增加耐火材料厚度,减少系统散热损失。
通过对HBJY白水泥预分解窑生产线试生产状况的分析,HBJY白水泥预分解窑生产线应从如下方面进行优化：①严格控制进厂原材料质量,尽量降低原料中的Fe203含量,探讨在结皮和改善易烧性二者之间平衡的碱含量范围。②强化煤质控制,除基本指标满足生产之外,煤粉的含水量控制1%以下,煤粉细度控制在4%(80μm筛余)以下,保证煤粉在分解炉内能够完全燃烧。③在稳定窑系统的前提下,慎重研究在该系统使用萤石作为矿化剂的可能性以及合适的使用量,避免使用不当造成大规模结皮、堵塞导致停窑。
正式生产后,HBJY预分解窑白水泥熟料生产线实际产量在380t/d以上,熟料烧成热耗约为5442kJ/kg.cl(1301kcal/kg.cl),白水泥熟料的白度在85度左右,都达到了设计指标。
Facing the contradiction which the domestic white cement industry technology isn't satisfied with the increasing domestic needs for high-quality white cement, the domestic white cement industry need the technology innovation urgently, it is the key for resolving the contradiction to apply the predecomposition kiln in white cement production. The adaptability and design optimization of white cement predecomposition kiln was explored by combining laboratory research and the white cement predecomposition kiln production line design in this paper.
The burnability of white cement raw material was studied by the burnability test and the comprehensive thermal analysis, the results showed that:①The increasing of KH and SM will make the white cement raw material burnability worse, the KH of white cement predecomposition kiln could be controlled over0.92, the SM of white cement predecomposition kiln could be controlled at5or higher.②The predecomposition characteristics of white cement raw material and ordinary cement raw material are basically identical, the predecomposition of them is divided into to two stages,which are water evaporation and carbonate decomposition, the white cement raw material decomposition heat consumption is1269kJ/kg.cl, the ordinary cement raw material decomposition heat consumption is1382kJ/kg.cl, the decomposition of CaCO3in the white cement raw material and the ordinary cement raw material is in according with the shrinking cylinder mechanism with surface reaction rate controlling, the activation energy of CaCO3in the white cement raw material is219kJ/mol, the activation energy of CaCO3in the ordinary cement raw material is233kJ/mol, thus, the predecomposition characteristics of them are basically identical, which is theoretical basis for applying the predecomposition kiln in white cement production.
According the mature design parameters of the ordinary cement predecomposition kiln, aiming at the features of white cement predecomposition kiln, this paper came to some optimal design measures as follows:①The white cement predecomposition kiln could get secondary air and tertiary air by adding the heat exchanger behind the kiln tail.②Through strengthening the sealing of the kiln system to reduce system air leakage, taking anti-material accumulation design, using anti-crust refractory at some parts which blocke and crust easily, the probability of block and crust will be reduced.③The white cement predecomposition kiln could reduce system heat loss by increasing the refractory thickness.
According the analysis of HBJY white cement predecomposition kiln trial production, the HBJY white cement predecomposition kiln production line should optimize it by three aspects as follows:①The raw material quality must be controlled strictly, it is the key to reduce the Fe2O3content of raw for white cement raw material quality, on the other hand, the appropriate alkali content of raw material which can reduce the probability of block and crust, improve the burnability of white cement raw material should be explored.②The coal quality control should be enhanced, except the basic indicators to meet the production, the internal water content of coal must be controlled under1%, the coal fineness must be controlled under4%(80μm sieve residue), the coal complete combustion in the calciner should be ensured.③Based on the premise which the white cement predecomposition kiln can produce stably, the possibility of using fluorite in the white cement predecomposition kiln and the appropriate added fluorite content should be studied cautiously to avoid the block and crust accident.
The actual output of HBJY predecomposition kiln white cement clinker production line is more than380t/d, the heat consumption of white cement clinker is about5442kJ/kg.cl (1301kcal/kg.cl), the whiteness of white cement clinker is about85degree, HBJY predecomposition kiln white cement clinker production line has achieved all design targets.
引文
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