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江苏鹏飞|水泥机械:1500t/d回转窑水泥生产线总包

1500t/d回转窑水泥生产线工艺介绍

1.生产规模、生产方法与水泥品种Production scale, production method and cement types
1.1生产方法 Production method
干法生产,设置一条φ3.5×54m带窑外分解炉五级旋风预热器回转窑生产线。
The production method is dry process. A rotary kiln(φ3.5×54m) production line with five-stage cyclone pre-heater and decomposition furnace will be adopted.
1.2生产能力及工厂规模Production scale and capacity
   烧成系统生产能力为日产熟料1500吨,掺加石膏后工厂年产硅酸盐水泥500000吨。
The production capacity is 1500t/d for clinker, while 500,000t/a for Portland cement when mixed with gypsum.
1.3 水泥品种 Cement types
本技术和设备可生产符合中国水泥标准GB175-1999中的硅酸盐水泥,其强度为32.5MP、42.5MP,可根据市场需要进行调节。
The technology and equipment adopted can produce 32.5MP and 42.5MP types of cement in accordance with Chinese Standard GB175-1999. They can be adjusted according to market demand.
 
2.原料燃料与配料
2.1.Raw materials properties chemical composition
 

Name
L.O.I
SiO2
Al2O3
Fe2O3
CaO
Mgo
K2O
Na2O
SO3
Cl-
Water
content
Density
t/m3
Limestone
39.27
7.17
2.93
1.25
46.94
1.03
0.13
0.23
 
0.009    
0.45
 
Shale
21.89
36.14
10.39
3.27
22.03
0.8
0.99
0.33
 
0.015
0.46
 
Silica
0.10
95.5
1.00
0.20
0.90
0.50
 
 
 
 
 
 
Gypsum
 
1.40
0.60
0.20
30.52
0.05
0.10
0.10
47.10
 
18.70
 
iron
11.5
30.56
22.12
26.91
1.12
 
 
 
 
 
 
 

2.2Fuel燃料
The technical property of mazut:Min. value is ≥9000 kcal/kg(37620kJ/kg)
     The S content of mazut:   2.5    %.
2.3配料计算
本生产线采用一台Ф3.5×54m五级旋风预热器带分解炉回转窑,熟料台时产量62.5t/h,熟料热耗850Kcal/kg (3552.0KJ/kg)熟料,根据所列各种原料化学成分进行配料计算。
配料计算
⑴ 熟料热耗指标:  
熟料单位热耗:850Kcal/kg.cl  熟料实物重油:960kg/t.cl
⑵ 熟料率值设计指标: KH=0.89±0.02   SM=2.6±0.1           IM=1.5±0.1
⑶ 原料配合比例:
针对业主提供的原料进行配比不能满足配料要求,需要增加铁质原料,鉴于业主没有提供相关铁质原料,配料中设定铁质原料成分进行配料。拟采用石灰石、粘土、砂、铁粉四组份配料。
According to raw material and fuel conditions, the following materials will be used for material blending: limestone, Silica, and iron powder.
 

Proportional ratio of raw material原料配比(%)
Limestone石灰石
粘土 clay
Sand砂
铁矿石iron
89.00
0
9.45
4.2

⑷ 生料、熟料化学成分

名称
LOSS
SiO2
Al2O3
Fe2O3
CaO
MgO
K2O+N2O
 SO3
Cl-
生料
35.440
14.159
3.505
2.056
41.885
0.950
0.018
0.033
0.049
熟料
 
21.311
5.225
3.196
63.041
1.430
 
 
 

⑸ 熟料矿物组成

C3S
C2S
C3A
C4AF
53.42
20.79
8.62
10.32

⑹ 熟料率值:KH=0.886   SM=2.53    IM=1.64
⑺ 熟料理论料耗:熟料理论料耗为1.556吨生料/吨熟料
⑻ 物料平衡   
物料平衡计算,根据回转窑台时产量62.50吨,年运转率82%,熟料实际料耗1.620吨生料/吨熟料,熟料烧成系统单位热耗840Kcal/kg.cl(3511.0KJ/kg),燃料热值9000 kcal/kg(37620kJ/kg)等工艺指标和配料计算中的原料配合比例进行,物料平衡计算结果列于表一:
3. 工艺设计特点Main technical characteristics
3.1 为保证系统运转率,提高产品产、质量,设计中大量选用了具有二十世纪九十年代先进水平的新设备、新工艺,以提高生产线的装备水平,确保设计指标的实现。如新型五级旋风预热预分解系统、高效空气梁篦冷机,节能型多通道喷煤管,戴维森高温风机,鲁奇最新技术生产的电收尘(BS930)等,输送设备采用了耐用、节电的板链提升机、链式输送机,将使本工程的装备在同规模生产线中处于领先水平。
This production line adopts advanced technology and equipment in 1990s to raise technical level and to ensure design indexes. New five-stage cyclone pre-heater system, high efficiency air girder grate cooler, multi-passage pulverized coal burner, Davison heat temperature fan, Luqi BS930 electrical dust collector, as well as chain-board elevator, chain conveyor adopted in this production line can ensure that the technology is advanced compared to other production lines with the same scale.
3.2 在保证生产线的完整性、生产的连续性和可靠性的前提下,力求简化生产工艺流程,以便于生产管理,减少生产事故点,降低投资。
If it has not bad influences on completeness,continuity and reliability, process procedures will be simplified to enhance production management, reduce troubles and lower investment. 
3.3 工艺布置上,简化设备厂房,减少建筑面积 Simplifying houses for equipment to decrease building area
库顶露天布置;高温风机露天布置;带式输送机通廊不设屋顶,用玻璃钢防雨罩防雨;取消提升机楼;收尘器露天放置。
Top of silos are without covers, heat temperature fan and dust collectors are open arranged and glass fiber rainproof covers instead of roofs will be set for belt conveyor passages. There will be no building for bucket elevator.
对各种原料、半成品和成品,在满足正常生产要求的前提下,合理减少储存期,并尽量采用堆棚储存。土建费用大幅度降低。
If it has not bad influences on normal production, by properly reducing storage periods for all raw materials, semi-product and finished product and adopting shed to store those materials and products, civil engineering costs will be greatly reduced.
改进窑尾工艺布置,窑尾预热器塔架设计为钢结构,既可加快施工安装进度,节省投资,又可美化建筑。
Frame for pre-heater at kiln inlet will adopt steel structure to save investment, accelerate erection speed and beautify building. 
3.4 充分考虑节能、降耗,生料入窑使用节能型的板链式提升机和空气输送斜槽,提高了系统的运行可靠性,降低了输送能耗。
Measures have been taken to save energy and reduce consumption. using chain-board elevator and air slides, reliability of the system is enhanced and conveying energy consumption is decreased.     
3.5 加强计量。除生料配料采用电子皮带秤计量外,各进厂原料、入窑生料、入窑煤粉、出窑熟料、出库熟料都设置了相应的专用计量设备,为工厂的科学管理提供了依据。
All necessary parts will adopt measuring equipment to guarantee scientific management. For example, there are measuring equipment at those parts such as raw meal blending, raw materials entering into plant, raw meal feeding to kiln, pulverized coal feeding to kiln, clinker outgoing kiln and clinker outgoing silos.  
3.6 保护环境,采取有效措施严格控制排放废气的含尘浓度在规定范围内。在生产工序中的各扬尘点,针对不同的废气特性,设置与之相应的新型高效专用收尘设备。
Effective measures have been taken to guarantee strict environment protection standards. Different efficient dust collectors are set at all dust producing points according to different characteristics of waste gas.
4.技术方案Technical plan
4.1 生产工艺Production process
4.1.1 生产规模、生产方法与产品方案Production scale, production method and product plan
本项目采用新型干法生产工艺,建设一条日产1500吨熟料的新型干法水泥生产线。采用φ3.5×54m回转窑煅烧,窑尾采用带五级旋风预热器和分解炉的预热分解系统。
A new dry process production line with capacity of 1500t clinker per day will be built. A rotary kiln(φ3.5×54m) will be used as burning equipment.  Five-stage cyclone pre-heater and decomposition furnace will be adopted at kiln inlet.
4.1.2 主机设备选型和主要生产设施配置Selection of main equipment and production facilities
4.1.2.1 石灰石破碎Limestone crushing
石灰石破碎选用单段锤式破碎机,本破碎机适用于破碎中等强度的脆性矿石,如石灰石、泥灰岩、页岩、石膏和煤等,入料粒度大,可一次将大块原矿破碎到符合入磨粒度。此外,由于本机采用顺向排料篦子,对矿石中的水分和泥土有更强的适应性。本机具有特殊的进铁保护,对混入机内不能破碎的金属异物,将反弹到给料机上,操作人员可根据异样金属声停机处理。
Single-stage hammer crusher is used for limestone crushing. This type of crusher is suitable in crushing medium strength ore such as limestone, marlite, slag, gypsum and coal. It can crush big ore to required size. Moreover, it can crush ore which has moisture and earth in it because it adopts discharging grates in the same direction. It has special iron feeding protection device, which can rebound the uncrushed metals to the feeder, so the operator can stop it if he hears peculiar sound to deal with this matter.     
本项目石灰石破碎采用TKPC16.18单段锤式破碎机,给料粒度800mm,生产能力250t/h,年利用率25.51%。
Limestone crushing will adopt TKPC16.18 single-stage hammer crusher adopted. Feeding size is 800mm, production capacity is  380t/h and annual usage rate is25.51%.
4.1.2.2 生料粉磨Raw meal grinding
对1500t/d生产线而言,生料粉磨可供选择的有HRM2800m立磨粉磨系统。
For 1500t/d cement production line, available raw mill system is HRM2800m mill system.
4.1.2.3 生料均化与储存Raw meal homogenizing and storage
本设计采用一座集生料储存、均化于一体的φ15×50mMF均化库,生料储量6500t,储存期2.86d。
φ15×50mMF silo both can homogenize and store raw meal will be adopted. Its capacity is 6500t and storage period is 2.86days.
4.1.2.3 烧成系统 Clinkering system
熟料烧成采用一套单列五级CDC预分解系统、φ3.5×54m回转窑和第三代新型空气梁篦式冷却机等设备组成的窑外分解煅烧系统。日产熟料1500t/d,熟料烧成热耗840Kcal/kg (3511.0KJ/kg),入窑生料的碳酸钙分解率大于90%。系统废气余热用于烘干原料和原煤。
A five-stage cyclone pre-heater system with CDC, φ3.5×54m rotary kiln and new air girder grate cooler, etc will be adopted for clinker preparation. The capacity is 1700t clinker per day. Clinkering heat consumption is 840Kcal/kg (3511.0KJ/kg). Decomposition degree of CaCO3 is larger than 90%. Extra heat of waste gas is used for drying raw materials and raw coal.
熟料冷却采用引进技术、中国制造的新型第三代空气梁篦冷机,篦床有效面积为61.8m2,产量62.5t/h,出冷却机的熟料温度为环境温度+65℃。
The new type air girder grate cooler manufactured in China with imported technology will be adopted for clinker cooling. Effective area of grate bed is 61.8m2. Output is 62.50t/h. Outgoing temperature of clinker is 65℃ higher than ambient temperature.
4.1.2.4水泥粉磨Cement grinding
本项目水泥粉磨选用两台φ3.5×13m管磨,配置N-1500型O-SEPA高效空气选粉机组成圈流粉磨系统,台时产量50t/h。
Twoφ3.5×13m model tube cement mills equipped with N-1500 model O-SEPA air separator will be adopted for cement grinding. Its capacity is 50t/h per set
4.1.3工艺主机设备表List of main equipment

序号
No
项目名称
Name of item
设备名称、规格及技术性能
Name, specification and performance
生产能力
(t/h.台)
Capacity
(t/h per set)
台数
Quantity (Set)
年利用率(%)
Annual running percentage rate
备注
Remarks
1
石灰石
破  碎
Limestone crushing
 
 重型板式给料机
Heavy type apron feeder
 规    格:B1250×11500mm
Specification: B1250×11500mm
 给料粒度:800mm
Feeding size: 800mm
 功    率:30kW
Power: 30kW
200~350
1
25.51
 
 单段锤式破碎机
Single-stage hammer crusher
 型    号:TKPC16.18
Model: TKPC16.18
 给料粒度:800mm
Feedingsize: 800mm
 出料粒度:≤25mm
Outgoing size: ≤25mm
 功    率:355kW
Power: 355kW
250
1
25.51
2
石灰石预均化
Limestone pre-homogenizing
混合堆取料机Stacker-Reclaimer
轨距:  24m
Distance between rails: 24m
总装机容量: 142kW
Total installed power: 142kW
堆料机Stacker
堆料方式: 连续合成式
Stacking method: continuous
堆料层数: >400层
Stacking layers: >400
取料机Reclaimer
取料形式: 全断面取料
Reclaiming method: section reclaiming
堆料能力:
Stacking capacity:
600t/h
取料能力:
Reclaiming capacity:      250t/h
1
 
 
3
生料粉磨
Raw meal grinding
立磨mill
规    格:HRM2800mm
Specification: HRM2800mm
 入磨粒度:≤40mm
Feeding size: ≤40mm
成品细度:0.080mm方孔筛筛余12%
Fineness of finished product: 12%
(remainder above 0.080mm hole screen)
 入磨水分:≤6%
Feeding moisture: ≤6%
 出磨水分:≤0.5%
Outgoing moisture: ≤0.5%
电机功率:1250 kW
Power: 1250kW
130
1
60.90
 
4
窑、磨废气处理
Treatment of waste gas of kiln inlet
and mill
 增湿塔Humidity tower
 规    格:Φ7.5×26m
Specification: Φ7.5×26m
 处理风量: 400000m3/h
Air capacity: 400000m3/h
 进口风温: 340℃
Feeding air temperature: 340℃
 出口风温: 150-220℃
Outgoing air temperature:
150-220℃
 
1
82.19
 
 高温风机High temperature fan
 流    量: 400000m3/h
Flow: 400000m3/h
 全    压: 7500Pa
Total pressure: 7500Pa
 使用温度:340℃(瞬时450℃)
Operation temperature: 340℃ (instant temperature 450℃)
 转    速: 1450r/min
Rotary speed: 1450r/min
 电机功率: 1250kW
Power: 1250kW
 
1
82.19
 
 2350DIBB24高温风机
处理风量:300000m3/h 7500 Pa
c.BS930型电收尘器:
处理烟气量:400000m3/h
入口粉尘浓度: ≤80g/Nm2
出口粉尘浓度: ≤50mg
 
1
82.19
 
 窑尾废气风机
Waste gas fan at kiln inlet
 流    量: 420000m3/h
Flow: 420000m3/h
 全    压: 1500Pa
Total pressure: 1500Pa
 使用温度:150℃
Operation temperature: 150℃
 电机功率:355kW
Power: 355kW
 
1
82.19
 
5
烧成窑尾
Kiln inlet
 五级旋风预热器及分解炉系统
Five-stage cyclone pre-heater and decomposition furnace system
 C1:2-Φ4300mm
 C2:1-Φ5600mm
 C3:1-Φ5600mm
 C4:1-Φ5900mm
 C5:1-Φ5900mm
 分解炉:Φ6300mm
decomposition furnace:
 Φ6300mm
62.50
1
82.19
 
6
窑  中
Kiln middle
 回转窑 Rotary kiln
 规    格:Φ3.5×54m
Specification: Φ4×60m
 斜    度: 4%
Inclination: 4%
 转    速: 0.4~3.96r/min
Rotary speed: 0.4~3.96r/min
 电机功率: 220kW(直流调速)
Power: 220kW (DC speed adjusting)
62.50
1
82.19
 
7
窑头熟料冷却
Kiln head clinker cooling
 空气梁篦冷机
Air girder grate cooler
 型    号:LBTF1700
Model: LBTF1700
 
62.50
1
82.19
 
8
水泥粉磨
Cement grinding
 
 管磨机 Tube mill
 规    格:Φ3.5×13m
Specification: Φ3.5×13m
 成品细度: 320m2/kg
Fineness of finished product: 320m2/kg
 主电机功率: 2000kW
Main motor power: 2000kW
50
2
58.59
 
 选粉机 Air separator
 型    号:O-Sepa1500
Model: O-Sepa2000
 风    量:1500m3/min
Air capacity: 1500m3/min
 
2
58.59
9
水泥包装
Cement packing
 八嘴回转式包装机
Eight-spout rotary packer
 计量精度:±0.25kg/包
Accuracy: ±0.25kg per bag
90
2
34.18
 

 
4.1.4 生产工艺过程Process procedures
4.1.4.1 石灰石破碎及预均化Limestone crushing and pre-homogenizing
石灰石破碎站设在厂区,采用单段破碎系统,其工艺流程为:矿区开采的石灰石由汽车运输进厂,卸入破碎站内石灰石料仓,经料仓下可调速的重型板式给料机喂入TKPC16.18锤式破碎机进行破碎,破碎机额定产量为250吨/时,破碎后的矿石(粒度≤25mm)由出料带式输送机输送入石灰石预均化堆场进行预均化和储存。预均化好后石灰石带式输送机送入配料库。
Limestone crushing workshop is set inside the plant, which adopting single-stage crushing system. Limestone exploited in mining area will be transported into plant by trucks and unloaded into hopper in the limestone crushing workshop, and then fed onto TKPC16.18 hammer crusher by speed-governable heavy apron feeder. Rated capacity of crusher is 250t/h. Crushed limestone (size:≤25mm) will be fed onto the limestone pre-homogenizing stockyard by belt conveyor. Then the limestone will be fed onto material blending bin by belt conveyor.
为避免粉尘污染,破碎车间设有气箱脉冲袋收尘器一台,抽取破碎机及带式输送机下料处的含尘气体,经收尘器净化后的气体由排风机排入大气。
To avoid dust pollution, an impulse bag filter will be used to collect dust from crusher and discharging points of belt conveyor. Purified air will be drained to the atmosphere.
4.1.4.2粘土、砂、石膏及铁粉、混合材输送 Crushing of slag, gypsum; Conveying of iron powder and admixture
由汽车运入厂区的粘土、石膏等生产辅助原料,分别卸入破碎站料仓内,经料仓下可调速的板式喂料机喂入破碎机进行破碎,破碎后的物料由出料带式输送机转运至辅助原料堆场。
clay and gypsum will be transported into plant by trucks and unloaded into different bins in the crushing station, and then fed onto crusher by speed-governable apron feeder. Crushed materials will be fed onto auxiliary materials stockyard by belt conveyor.
铁粉、混合材经破碎系统输送皮带机送入辅助原料堆场。
Iron powder and admixture will be fed onto auxiliary materials stockyard by belt conveyor.
4.1.4.3 原料配料Raw material blending
配料站内设一座φ8×14m圆仓储存石灰石;另设置三座配料仓,储存粘土、砂、铁粉,储量分别为360t和150t。参与配料的粘土、砂、铁粉和石灰石分别由库底调速链板机、电子皮带秤按设定的配比卸出,经带式输送机送至生料磨。
Four bins will be set for material blending: one for limestone (φ8×14m), one for clay(capacity: 360t)、sand (capacity: 360t) and one for iron powder (capacity: 150t). Speed-governable chain-board conveyors and electric belt balances will be used at the bottom of material blending bins. Materials with required proportion will be fed onto the raw mill by belt conveyor.
由多元素荧光分析仪和微机组成的生料质量控制系统,可自动分析出磨生料成分,并根据分析结果和设定的目标值自动调节电子皮带秤转速以控制各原料的下料量,确保出磨生料成分合格
Raw meal quality control system consists of fluorescent light analyzer and computer. It can automatically analyze raw meal composition and automatically adjust rotary speed of chain-board conveyors and electric belt balance according to analysis result and target value, so that discharging amount of each kind of material can be controlled.
 4.1.4.4生料粉磨及废气处理Raw meal grinding and treatment of waste gas
来自库底皮带输送机的配合原料,经磨头锁风装置喂入HRM2800立磨粉磨,出磨成品由旋风分离器收集经链式输送机、斗式提升机送至生料均化库,磨尾废气至窑尾电收尘器净化处理,然后排入大气。磨机生产能力:当产品细度为0.08方孔筛筛余≤12%,入磨物料粒度≤40mm。水分入磨时≤6 %,出磨时小于0.5%,台时产量为130吨,入磨气体温度控制≤350℃,热源利用废气。生料磨的年运转率为60.9%。烘干热源来自窑尾高温风机排出的部分废气。
Proportioned raw material will be fed onto the raw mill by belt conveyor. The mill is middle-discharging drying mill which can dry material and grind material. Its capacity is 150t/h. Drying heat is from waste hot gas drained by high temperature fan at kiln inlet. Gas temperature is 300℃. Drying heat is from waste hot gas drained by high temperature fan at kiln inlet.
4.1.4.5窑、磨废气处理Treatment of waste gas of kiln and mill
窑尾预热器的废气,经高温风机排出,一部分送至原料粉磨作烘干热源,其余部分经增湿塔调质后,与原料磨排出的废气汇合,进入袋收尘器净化,由排风机排入大气。当原料磨停运时,窑尾预热器排出的废气则全部进入增湿塔。废气处理系统收下的粉尘经链运机、提升机等输送设备送入生料均化库或生料称重仓;当增湿塔工作不正常,收下的窑灰水分过大时,增湿塔下面的螺旋输送机反转可将湿窑灰排出,再由人工用小车推走。
Waste gas from the pre-heater will be drained by high temperature fan. Some of it will be sent to raw material grinding section as drying heat. The other part will be adjusted by humidification tower, then mix with waste gas drained from raw mill and purified by bag filter, after that, it will be drained to the atmosphere by fan. When the raw mill is stops, all the waste gas from the pre-heater will be sent to humidity tower. Dust collected by waste gas treatment system will be fed to raw meal homogenizing silo or raw meal weighing bin by chain conveyor and elevator. When working of humidity tower is not normal and collected kiln dust has much moisture, screw conveyor under humidity tower will reverse and drain out wet kiln dust. Manual car will move away the dust.   
在系统布置上,窑、磨废气处理系统与生料磨和预热器塔架呈环状矩形布置,排废气的钢烟囱依附在预热器塔架上,不但布置紧凑、占地少,而且废气管道短,节省投资。
Waste gas treatment system, raw mill and pre-heater frame are rectangular arranged. Steel chimney is attached to pre-heater frame. The arrangement is compact and earth saving. Moreover, waste gas pipe is short, so investment can be saved.
4.1.4.6生料均化Raw meal homogenizing
设置一座储量为6500吨的φ15×50m多股流(MF)均化库储存、均化生料。从生料磨来的合格生料由提升机送至多股流(MF)生料均化库顶,经库顶生料分配器分流后呈放射状从库顶多点下料,使库内料层几乎呈水平状分层堆放,出料则由库底充气系统分区供给松动空气,竖向取料后进入库底混合室。卸料时,向两个相对的料区充气,生料受气力松动并在重力作用下在各卸料点上方形成小漏斗流,生料在自上而下的流动过程中进行重力混合的同时,各卸料孔漏入卸料槽的生料从不同的半径位置上向库中心室流动,在流动过程中进行着径向混合,各卸料槽流入中心室的生料在充气的作用下再获得一次流态化混合,进入库底混合室后,在混合室内进一步充气搅拌混合均化。出库合格生料经空气输送斜槽、斗式提升机送入设在库顶的生料喂料仓,出喂料仓的生料经计量后,用斜槽和斗式提升机直接喂入预热器系统。
A MF raw meal homogenizing silo (size:φ15×50m, storage capacity: 6500t ) is set. Qualified raw meal from raw mill will be sent to top of raw meal homogenizing silo by bucket elevator and discharged by silo top distributor. At the bottom of silo, raw meal will be loosened by aeration system and then discharged to mixing bin under silo. Raw meal will be further loosened and homogenized in the mixing bin. Qualified raw meal will be fed to raw meal weighing bin at the top of silo by air slide and bucket elevator. Weighed raw meal will be fed to pre-heater by air slide and bucket elevator.
    均化所用高压空气由库底罗茨风机提供。
High pressure air for homogenizing is supplied by Roots blower under homogenizing silo.
 4.1.4.7窑尾预分解及熟料煅烧系统Kiln inlet pre-decomposition and clinker burning system
熟料煅烧采用φ3.5×54m回转窑,窑尾设有单系列五级低压损型旋风预热器和CDC型分解炉,熟料烧成热耗850Kcal/kg.cl(3552.0KJ/kg),日产水泥熟料1500吨。
A rotary kiln (Ф3.5×54m), low-pressure-loss five-stage cyclone pre-heater and CDC decomposition furnace are adopted for clinkering. Clinker capacity is 1500t/d, clinker heat consumption: 840Kcal/kg.cl(3511.0KJ/kg). Coal usage ratio of kiln and decomposition furnace is 40:60. Apparent decomposition rate of raw meal feeding to kiln is about 90~95%.
来自均化库的合格生料计量后进入预热器,逐级预热后进入分解炉,分解后的生料再进入回转窑内煅烧。分解炉所用的三次风来自窑头罩。
Weighed raw meal will be fed to pre-heater. After heating, it will be discomposed in decomposition furnace and then fed to kiln. Third air for decomposition furnace is from kiln hood.
为防止预热器系统结皮堵塞,除在旋风筒下设有膨胀仓外,还配有独特的自动控制喷吹系统以及必要的空气炮,保证预热器系统的正常运行。
To avoid jam, expansion bin and automatic-control blowing system and necessary compressed air devices will be adopted to guarantee normal running of pre-heater.
从回转窑进入篦冷机的高温熟料,由篦板下鼓入的冷空气急速冷却,出篦冷机的熟料温度为环境温度+65℃,冷却、破碎后的熟料由链斗输送机送入熟料库。
Hot clinker feeding to great cooler will be cooled rapidly by cold air from blower under grate board. Outgoing clinker from grate cooler is 65℃ higher than ambient temperature. Then clinker will be fed to clinker silo by bucket-chain conveyor.     
出篦冷机高温废气一部分作为窑用二次空气入窑;一部分由三次风管送到分解炉作为燃烧空气;剩余废气经窑头电收尘器净化处理后排入大气。电收尘器收下的粉尘经链运机送到熟料链斗机上入熟料库。
Hot waste gas from grate cooler is divided into four parts: part of it is sent to kiln as secondary air, part of it is sent to decomposition furnace as burning air by tertiary duct, and the rest is drained to the atmosphere after purified by electric dust collector at kiln head. Dust collected by electric dust collector will fed to bucket-chain conveyor by chain conveyor. 
4.1.4.8熟料储存Clinker storage
出冷却机的熟料由链斗输送机送入两座φ18×36m熟料库中储存。总储量26000吨,储存期17天。为方便熟料外运,库侧设有熟料散装系统。
This section will adopt two silos with the size of Φ18×36m. Total capacity is 26000t and storage period is 17days. Lateral clinker bulking systems is set at the side of silos.
熟料由库底计量设备卸出后,用带式输送机送入水泥磨
Clinker will be fed to cement mill by belt conveyor after discharged by weighing machines at the bottom of silos.
4.2.5.9水泥配料及粉磨Cement blending and grinding
粉磨系统设一座石膏配料仓。配料仓由仓底微机配料秤按设定的比例搭配,熟料由库底微机配料秤按设定的比例搭配后,由带式输送机送入水泥磨内粉磨。
A gypsum bin is adopted. Computerized balance under the gypsum bin will be used for material blending. The clinker and gypsum will be fed to cement mill by belt conveyor after proportioned according to cement modulus requirements.
水泥粉磨选用两套由φ3.5×13m管磨机和N-1500型O-SEPA选粉机组成的闭路粉磨系统,台时产量50t/h。出磨后的水泥用斗式提升机和空气输送斜槽送入O-SEPA选粉机中分选,粗粉返回磨内再次粉磨;成品随气流进入气箱脉冲袋收尘器,被收集下来后由空气输送斜槽和斗式提升机送入水泥库中储存。
Twoφ3.5×13m model tube cement mills equipped with N-1500 model O-SEPA air separator will be adopted for cement grinding. Its capacity is 50t/h per set. Cement discharged from cement mill will be fed to O-SEPA air separator by bucket elevator and air slide. Coarse powder will return to mill for regrinding. Finished product will be sent to impulse bag filter. After collected by the bag filter, it will be fed to cement silo by air slide and bucket elevator.
 4.1.4.10水泥储存Cement storage
设4座φ15×41m带减压锥的水泥均化库储存出磨水泥,总储量28000t,储期15天。均化用气由库底罗茨风机供给。
Four silos (size:φ15×41m; total storage capacity: 28,000t, storage period: 15days) equipped with depressurizing cones will be used for cement storage. Air used for homogenizing is supplied by Roots blowers under cement silos.
4.2.5.11水泥包装及成品库Cement packing and finished product storehouse
水泥包装选用二台八嘴回转式包装机,每台包装能力为100t/h。
Two 8-spout packers will be used for cement packing. Packing capacity is 100t/h per set.
来自水泥库均化后的水泥由提升机送入振动筛,筛去杂物后进入衡压仓,再进入八嘴回转式包装机包装成袋装水泥,由带式输送机送至24×70m成品库内堆放。
Cement will be fed to vibrating screen by bucket elevator. Then cement will be fed to constant pressure bin. After that, it will be packed by eight-spout packer and transported to finished product storehouse by belt conveyor. 
水泥包装时,每袋重量由电子秤计量和调节。
Weight of bagged cement is weighed and adjusted by electric balance.
包装系统设有完善的除尘设施,可保证废气达标排放。
Good dust collecting system is set for cement packing to guarantee dust emission standard.
4.1.4.12 中央化验室 Central lab
厂区内设一座中央化验室,负责进出厂原料、燃料、半成品和成品的常规化学分析及物理检验,以保证全厂各生产环节的产品质量,对水泥产品质量进行调度、管理和监督。
A central lab is set in the plant to carry out normal chemical and physical tests of raw materials, fuel, semi-products and finished product, guarantee product quality in each section and adjust, manage, monitor quality of cement product.
4.1.4.13 工艺生产流程图 Process flow sheet
    本工程生产工艺流程见图。Refer to related drawing.
4.1.5 计量设施 Weighing facilities
为加强生产各个环节的管理,执行相关计量法规,掌握各个工段生产状况。本项目从原燃料进厂到水泥成品出厂的各个工段设置了计量设施,并在机构配置上设有专门计量管理人员,对计量设施进行管理、维护,使工厂达到计量合格要求。具体配置见表。
Measuring facilities and special measuring personnel are arranged at all necessary parts in the production line to guarantee good quality of product and to control production conditions.
全厂物料计量设备表List of weighing equipment            
序号
No.
计量物料名称
Material
计量设施安装位置
Position
设施形式
Name of equipment
数量
Qty.
备 注
Remark
1
进厂各原、燃料
Raw materials and fuel
进厂门口
Entrance gate of the plant
汽车衡
Platform scale
1
 
2
入生料磨石灰石
Limestone to be fed to raw mill
配料库库底
Under material blending bin
调速配料秤
Speed-governable balance
1
 
3
入生料磨砂
sand to be fed to raw mill
配料库库底
Under material blending bin
调速配料秤
Speed-governable balance
1
 
4
入生料磨铁粉
Iron powder to be fed to raw mill
配料库库底
Under material blending bin
调速配料秤
Speed-governable balance
1
 
5
入窑生料
Raw meal to be fed to kiln
窑尾喂料仓出口
Discharging point of weighing bin at kiln inlet
调速皮带秤
Speed-governable balance
1
 
6
入水泥磨熟料
Clinker to be fed to cement mill
熟料库库底
Under clinker silo
调速配料秤
Speed-governable balance
4
 
7
入水泥磨石膏
Gypsum to be fed to cement mill
磨头仓出口
Discharging point of feeding bin of mill
调速配料秤
Speed-governable balance
2
 
8
入水泥磨混合材
Admixture to be fed to cement mill
磨头仓出口
Discharging point of feeding bin of mill
调速配料秤
Speed-governable balance
2
 
9
袋装水泥
Bagged cement
包装机
Packer
电子秤
Electric balance
2
 
 
4.1.6 生产车间检修设施Maintenance facilities
   (1)对于露天布置设备的检修可由工厂自备一台吊车,或从外面租借吊车解决。既节省了一些很少使用的检修设备,又节约了土建、电气投资。
The plant can buy or rent a crane to repair open-arranged equipment. In this way, investment on equipment, electricity and civil engineering can be saved.
   (2)对于受条件限制或无法露天但平时很少检修的设备,如破碎机、风机等,在其设备厂房的上方,设检修吊钩,以备检修时临时挂葫芦使用。
For equipment which can not be open-arranged but is rarely used (such as crusher and fan), maintenance lifting hook is set on ceiling of the workshop.
 (3)对于检修时频繁使用起吊设备的地方,设置电动葫芦。如窑头、窑尾起吊耐火砖;生料磨、水泥磨装球等分别设有电动葫芦。
For equipment which is frequently used, electric hoist is set. For example, electric hoists are used to lift refractory bricks at kiln inlet and kiln head and to lift steel balls at raw meal grinding workshop and cement grinding workshop.
4.2 电气及生产过程自动化Electric and automation
4.2.1 电气Electric
4.2.1.1 供电电源Power source
主电源由公共供电网供电,供电电源为 10 kV。
Power is mainly supplied by public power supply net. Voltage is 10 KV.
4.2.1.2 电压等级Power voltage
配电电压           10kV
Distribution voltage:10kV
低压               0.4kV
Low voltage: 0.4kV
4.2.1.3 工程用电负荷及电耗 Powder demand
总装机容量          14500kW
4.2.2 生产过程自动化Processing automation
4.3.2.1 设计原则 Design principle
为满足现代化水泥生产线的工艺要求,保证工艺设备可靠运行,稳定工艺参数,保证产品质量,节约能源,提高生产线的运转率。本工程采用技术先进,性能可靠,PLC计算机控制系统,对主生产线集中监视、操作和分控制,可有效提高电控设备的可靠性和可维护性,实现控制、监视、操作的现代化。对包装车间,采用PLC现场控制站和现场操作站进行控制、监视和操作,其信号通过高速通信网与中控室操作站连接。通过中控室操作站与工厂管理计算机的网络连接,使管理人员随时掌握工厂的实际情况,实现管理现代化。
In order to reach to modern cement process requirements, guarantee reliable running of process equipment, stabilize process parameters, improve quality of product, increase running rate of production line and save investment, advanced, reliable PLC computerized control system will be used to realize centralized monitoring and separate controlling of main production line. In this way, reliability of electric control equipment is enhanced, maintenance is easier and automatic control is realized. For cement packing workshop, PLC field control station and field operation station will be adopted. Signal will send to central control room by high-speed communication net and then send to managing computer, so that management personnel can know working conditions at any time, thus management modernization can be realized.
4.3 给水排水Water supply and drainage
4.3.1
 设计原则:贯彻节约用水、充分利用水资源,节约用地、节省投资的原则。
Design principle: saving water and earth, full use of water resource and saving investment
4.3.2 用水量 Water amount
   (1)全厂生产用水量       9654m3/d
        其中:循环用水量     8665m3/d
              生产直耗水量    787m3/d(其中:中水回用414m3/d)
              辅助生产用水量  202m3/d
  Production water of the whole plant: 9654m3/d
Including: Circulation water: 8665m3/d
           Production consumption water: 787m3/d (reuse: 414m3/d)
           Auxiliary production water: 202m3/d
   (2)循环回水量           8419m3/d
       Returned circulation water: 8419m3/d 
   (3)循环补充水量          246m3/d
       Supplement circulation water: 246m3/d
   (4)循环水利用率           97.1%
       Usage rate of circulation water: 97.1%
   (5)消防补充水量          180m3/d
       Supplement fire-fighting water: 180m3/d
   (6)厂区生活用水量         80m3/d
       Living water in the plant: 80m3/d
4.3.3 供水水压pressure of supplied water
  水压 Water pressure
生产用水水压:车间管道进口压力采用0.25~0.35MPa,增湿塔回流式喷嘴进口压力采用3.3MPa。生活用水满足用水点水压要求。消防水压:室外消火栓出口压力不低于0.1MPa,室消火栓水压满足最不利点灭火要求。
Pressure of production water: 0.25~0.35MPa at inlets of workshop pipes, 3.3MPa at inlet of backflow spout of humidity tower. Pressure of living water: according to water usage points. Pressure of fire-fighting water: at outlets of outdoors fire hydrants≥0.1MPa; For indoors fire hydrants: comply with water pressure requirement of most disadvantageous points.
4.3.4 供水系统 Water supply system
   (1)生产循环供水系统Water supply system for production and circulation
为了充分利用水资源,节约用水,各车间生产设备冷却水采用密闭式回流、余压上塔循环冷却系统。本方案可节省一组上塔热水泵和热水池,减少设备和构筑物,且节约能源,减少用地,降低投资,循环水利用率高。经冷却塔(GBNL3-350型,Q=350.0m3/h,N=11kW,一座)冷却后的水自流入循环给水池,再由循环泵(2G250WFB-FD型,Q=260.0m3/h,H=55.0m,N=90kW,三台,两用一备)加压供给各生产车间设备冷却用水点。循环过程中的损失水量由生产、生活管网补给。
In order to save water, cooling water for production equipment in each workshop will adopt close backflow and spare pressure sent to tower circulation cooling system. A group of hot water pump and hot water pool can be saved. Circulation water usage factor is high and equipment, constructions, energy, earth and investment can be decreased. Water cooled by a GBNL3-350 model cooling tower (Q=350.0m3/h,N=11kW) will naturally flow to circulation water pool and will be pressurized by circulation pumps (2G250WFB-FD model, Q=260.0m3/h,H=55.0m,N=90kW, two are using and one is backup) and then sent to cooling water usage points in the plant. Water loss in circulation is supplemented by production and living piping net.
   (2)生活、消防供水系统Water supply system for fire fighting and living
本工程的车间生活用水、消防用水、辅助生产用水、窑头篦冷机喷水、部分增湿塔喷水(另外部分由中水回用供给)由该系统供给。生活水池的水经生活泵(2G80WFB-C型,Q=45m3/h,H=57m,N=22kW,二台,一用一备)加压后供给全厂使用。系统中设置了一座高位水池(V=500m3)以便水量调节,并储存消防用水量。
This system will supply living water, fire fighting water, auxiliary production water, flushing water for grate cooler and part of flushing water for humidity tower. There are two living pumps, one is using and one is backup. The pump has 2G80WFB-C model, capacity of 45m3/h, height of 57m and power of 22kW. Water in living pool will be pressurized by living pump and then sent to living water usage points in the plant. A pool (V=500m3) is set at high position to adjust water amount and to store fire fighting water.
增湿塔、篦冷机用水另设加压泵单独加压(增湿塔喷水加压泵型号为DG25-50×9型,Q=25m3/h,H=450m,N=75kW,二台,一用一备;窑头篦冷机喷水加压泵为D12-50×3型,Q=9m3/h,H=165m,N=15kW,二台,一用一备)。
Pressure pumps are adopted for water supply of humidity tower and grate cooler. There are two pressure pumps for humidity tower, one is using and one is backup. The pump has DG25-50×9 model, capacity of 25m3/h, height of 450m and power of 75kW. There are two pressure pumps for grate cooler, one is using and one is backup. The pump ha, s D12-50×3 model, capacity of 9m3/h, height of 165m and power of 15kW.
4.4 建筑结构Building and structure
4.4.1 建筑Building
4.5.1.1 设计原则 Design principle
根据全厂平面布局,工艺生产流程以及生产设备确定建筑, 物的开间、跨度和空间。由于水泥厂生产车间各建筑物、构筑物形式各不相同,所以将运用, , 建筑手段来统一建筑形式,并遵守技术先进、经济合理、安全适用、确保质量的设计原则。
Areas, positions and spans should be decided according to general layout, process flow and equip, , ment. The design chooses security, economic and reasona, ble building plan should be chosen.
4.4.2 结构 Structure
4.4.2.1 结构设计原则 Design principle
在满足工艺和使用要求的前提下,选择合理的结构方案和结构形式,做到安全、经济、适用。
Reasonable, safe, economica, l an, d practical structure plan and structure, , types s, houl,, , , , , , d be chosen to comply with process, , requirements and usage requirements.
4.4.2.2 结构设计Structure design
   (1)结构选型Selection of structure
水泥厂工艺流程复杂,设备多,荷重大,各楼层孔洞仓斗繁多,其位置和形状均无规则,为满足设备布置要求,柱网尺寸一般较大,为保证建构筑物的整体性并满足工艺生产要求,主要厂房一般采用现浇钢筋混凝土结构方案,次要建筑及部分辅助车间可采用砌体结构。
Cement plant has the following characteristics: complex process, many machines, big load, many holes, hoppers and bins and irregular forms. In order to comply with equipment arrangement requirements, size of pillar net is usually big. Main workshops usually use site-casting reinforced concrete structure and minor buildings and auxiliary workshops can use step structure.
多层厂房:如窑头、磨房、破碎车间、煤粉制备和水泥包装等,采用现浇钢筋混凝土框架结构,基础采用钢筋混凝土独立基础或桩基础。
Multi-layer workshop such as kiln head, grinding, crushing, pulverized coal preparation and cement packing workshops: adopting site-casting reinforced concrete frame; foundation will use reinforced concrete separate foundation or pile foundation.
窑尾预热器塔架:窑尾烟室平台以下部分采用现浇钢筋混凝土框架,以上部分采用钢结构。窑尾烟囱采用薄壁钢结构,以窑尾塔架作其支撑。基础采用钢筋混凝土弹性地基梁或桩基础。
Frame of pre-heater: the part under platform of smoke chamber will use site-casting reinforced concrete frame while the upper part use steel structure. Chimney at kiln inlet will use thin-wall steel structure with kiln inlet frame as support. Foundation of pre-heater frame will use reinforced concrete elasticity foundation beam or pile foundation.
辅助原料联合预均化堆场,采用钢筋混凝土柱,屋盖采用网架结构,屋面及墙面采用彩色压型钢板,基础采用钢筋混凝土独立基础。
Pre-homogenizing stockyard for auxiliary materials: adopting reinforced concrete pillar; room lid will use net structure; roof and wall will use profiling steel plate; foundation will use reinforced concrete separate foundation.
中、小跨度的单层厂房:采用轻钢门式刚架,屋面及墙面采用彩色压型钢板,基础采用钢筋混凝土独立基础。
Single-layer workshop with medium or small span: adopting light steel portal frame; roof and wall will use profiling steel plate; foundation will use reinforced concrete separate foundation.
圆筒仓:熟料库、水泥库和生料均化库等采用现浇钢筋混凝土结构,基础采用钢筋混凝土环形、圆板形基础或桩基础。
Silo: clinker silo, cement silo and raw meal homogenizing silo, etc will adopt site-casting reinforced concrete structure; foundation will adopt ring-type reinforced concrete foundation, round-plate-type reinforced concrete foundation or pile foundation.
大型设备基础:如窑基础一般采用钢筋混凝土墙式基础,磨机基础及破碎机基础一般采用大块式钢筋混凝土基础。
Foundation of large equipment: for kiln, reinforced concrete wall-type foundation is usually used; for mill and crusher, reinforced concrete block foundation is usually used.
输送天桥:架空皮带廊除工艺要求采用封闭的外,其余尽量采用开敞式结构,仅设镀铝锌彩色压型钢板皮带机罩。支柱采用钢管承重结构,基础采用钢筋混凝土独立基础或桩基础。
Conveying over-bridge: if not required by process specialty, open structure with galvanized profiling steel plate belt covers will be adopted for belt conveyor passages; pillar will use steel tube structure; foundation will use reinforced concrete separate foundation or pile foundation.
adopted.
4.5 环境保护 Environment protection
4.5.1 主要污染源及污染物 Main pollution sources and pollutants
4.5.1.1 烟尘和粉尘Mist and dust
水泥厂对环境空气质量产生影响的主要污染物是烟尘和粉尘,主要产生于物料破碎、输送、煅烧、粉磨、储存、包装等生产环节。最大的烟尘排放源是窑尾排气筒。
Dust is the main pollutants of cement plant. It is generated in material crushing, transporting, burning, grinding, storage and packing, etc. Mist is mainly generated from gas pump at kiln inlet.
4.5.1.2 废气 Waste gas
在窑尾排放的废气中除烟尘外,还含有NOx和SO2等有害气体。
Of the waste gas emitted at kiln inlet, Nitrogen oxides (NOx), Sulphur dioxide (SO2), etc are poisonous gases which have bad influences on environment.
4.5.1.3 废水 Waste water
排放的废水包括生产废水和生活污水。排放的生产废水主要是设备冷却水循环系统的排污水;生活污水主要是食堂、办公楼等排放的生活洗涤水及粪便污水。本工程生产废水和生活污水经过处理净化后回收利用。
Drained sewage includes production sewage and living sewage. Production sewage is mainly cooling water of equipment; living sewage is mainly washing water and other organic sewage from canteen and office building. Production sewage and living sewage will be purified and reused.
4.5.1.4 噪声 Noise
强噪声源主要有破碎机、磨机、空压机及风机等,其声源强值一般为80~115dB(A)。
Noise sources are crushers, mills, air compressors and fans. Their decibels are between 80 and115dB (A).  
4.5.2防治污染的方案 Pollution treatment measures
4.5.2.1 粉尘和烟尘的防治措施 Treatment measures for mist and dust
为了有效地控制粉尘和烟尘的排放,以减轻其对周围环境的影响,本工程设计采取以防为主的方针,从工艺流程上尽量减少扬尘环节;选择扬尘少的设备;粉状物料输送采用密闭式输送设备;物料转运尽量降低排料落差,以减少粉尘飞扬;粉状物料储存采用密闭圆库。
To control emission of mist and dust and to reduce bad influences on environment, several measures are taken. For example, choose equipment which generates less dust; adopt close type conveying equipment for powder; adopt close round silo for powder material storage and decrease dropping distance of material transferring. 
本工程在所有的烟粉尘排放点均设置了技术可靠、效率高的收尘器。窑尾废气量大、含尘浓度高,是本工程最大的烟尘排放源,设计选用高效的电收尘器,经除尘净化后,窑尾烟尘排放浓度≤50mg/Nm3,经85m高的排气筒排放。
Reliable and high-efficiency dust collectors are adopted at all dust generated points. Dust amount and dust concentration is the most at kiln inlet in this project, so high-efficiency electric dust collector is selected. After purifying, dust emission at kiln inlet is no more than 50mg/Nm3. it is drained by drainage pipe with height of 85m.
4.5.2.2 废气排放 Treatment measures for waste gas
 SO2的排放 SO2 (Sulphur dioxide)
烧成系统窑尾排放的SO2主要是由水泥原料和燃料中的单质硫和硫化物氧化或分解产生的,由于在窑中大部分SO2被物料中的氧化钙和其它碱性氧化物吸收形成硫酸钙及亚硫酸钙等物质进入熟料,所以窑尾SO2的实际排放量很少。窑外分解窑的吸硫率可达98%。本工程计算排放浓度约为12mg/Nm3,低于本工程所执行的标准,可直接排放。
In reaction, Sulphur in raw materials and fuel will form into Sulphur dioxide (SO2), which will emitted at kiln inlet. Sulphur dioxide (SO2) emission is little because it will react with Calcium oxide or other Basic oxide to produce Calcium sulfate or Calcium sulfite and will leave in clinker. Sulphur absorption rate can reach to 98% if adopting new technology of pre-discomposing kiln. According to preliminary calculation, Sulphur dioxide discharge in this plan is about 12mg/Nm3. It complies with discharging standard and can be discharged directly.
4.5.2.3噪声控制 Noise control
水泥厂生产中噪声大的设备较多,为了控制噪声污染,设计时从降低声源源强值及传播途径上加以控制,尽量选用噪声低的设备;在罗茨风机和空压机进、出口处加设消声器,以降低这些设备的噪声;在总图布置上尽量将强噪声源布置在远离厂界处,并尽可能利用建构筑物来阻隔声波的传播;对有强噪声源的车间采用封闭式或半密闭式厂房;同时在车间外尽可能搞好绿化,以其屏蔽作用使噪声受到一定程度的阻隔,以减轻对周围环境的影响。
There are many noise sources. In order to control noise pollution, low noise equipment should be chosen as possible. Mufflers are adopted at both inlets and outlets of Roots blower and air compressors. High noise resources are set far from boundary plant. High noise resources are set in close or semi-close rooms. Buildings and structures are used for noise preventing. By planting trees and bushes at spare area can absorb some noise.
4.5.3 环境绿化 Greening
搞好绿化,既可美化环境,还可以在一定程度上起到吸尘隔尘、净化空气、降低噪声影响的作用。绿化以厂内道路两侧条带地段及场地边坡绿化为主,车间四周空地绿化为辅。对有大量粉尘产生的堆场四周种植一些阔叶、抗尘吸尘树种作为防护带,尽量减少粉尘的扩散。对行政管理及辅助生产设施区域给予重点绿化以美化环境。
Greening is very useful in beautifying environment, absorbing dust and noise and purifying air. Greening at both sides of road and in sloping fields will be main greening measures, while greening in spare area around workshops is auxiliary. Around stockyard which can generate much dust, planting broadleaf trees and dust absorbing trees can form the dust protective belt. Area around management buildings and auxiliary production rooms is key greening place.  
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